Manual de Entrenamiento PS5

PLC-5r and
RSLogixt 5
Maintenance and
Troubleshooting
Student Manual
Important User Information

This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation) is intended for
use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware.
The Documentation should only be used as a learning tool by qualified professionals.
The variety of uses for the hardware, software and firmware (hereinafter Products) described in this Documentation,
mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary
steps have been taken to ensure that each application and actual use meets all performance and safety requirements,
including any applicable laws, regulations, codes and standards in addition to any applicable technical documents.
In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell
Automation) be responsible or liable for any indirect or consequential damages resulting from the use or application of
the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for
damages of any kind based on the alleged use of, or reliance on, this Documentation.
No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or
software described in the Documentation.
Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for:
properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell
Automation or third--party provided instructions, warnings, recommendations and documentation;
ensuring that only properly trained personnel use, operate and maintain the Products at all times;
staying informed of all Product updates and alerts and implementing all updates and fixes; and
all other factors affecting the Products that are outside of the direct control of Rockwell Automation.
Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell
Automation is prohibited.
Throughout this manual we use the following notes to make you aware of safety considerations:
Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property
damage, or economic loss.
Identifies information that is critical for successful

application and understanding of the product.
Identifies information about practices or circumstances

that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
identify a hazard
avoid a hazard
recognize the consequence
Important User Information

Labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
Labels may be located on or inside the drive to alert

people that surfaces may be dangerous temperatures.
Pub# GMST10-PP287A-EN-E
Optional
Understand
Maintain
4 Days
CCP412
Understand
www.rockwellautomation.com/services/training
Instructor-Led Training
4 Days
PLC-5 and RSLogix 5

Maintenance
and Troubleshooting
CCP410
2 Days
PLC-5/SLC 500
and RSLogix
Fundamentals
CCP122
Program and Design
PLC-5 and RSLogix 5

Programming
PLC-5/RSLogix 5 Curriculum Map
Maintain
CCPS65
1 Day
SLC 500 and PLC-5

Communications
Program and Design
4.5 Days
CCP409
Computer-Based
Training
4 Days
PLC-5 and RSLogix 5

Advanced
Maintenance and
Troubleshooting
CCP411
PLC-5 and RSLogix 5

Advanced
Programming
2 Days
RSTrainer
Enterprise Edition
PLC Fundamentals
9393-RSTLINX
(9393-RSTLINXENF)
RSTrainer for
RSLinx Software
2006 Rockwell Automation, Inc. All rights reserved.
Web-Based Training
Available on Rockwell Automation University Online
9393-RSTLX5
(9393-RSTLX5ENF)
RSTrainer for
RSLogix 5 Software
Related e-Learning Products
CCP710
PLC-5 to ControlLogix
Transitioning
Comment Form
Email: ratps@ra.rockwell.com
or Fax:
440.646.4425
Page 1 of
Date:
Contact Information:
Name:
Company and Location:
Phone:
Email:
Comments (include lesson title, if applicable):

Course or Product Name (Important):
Page 2
Table of Contents
Introduction
Course Overview
Course Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should Attend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Agenda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meeting Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Student Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hands On Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I
I
I
II
III
III
IV
Lessons
Identifying PLC-5 System Components
What You Will Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Why These Skills Are Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC-5 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Power-Supply Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Power-Supply Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Enhanced PLC-5/40 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Discrete Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal Flow through a PLC-5 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributed I/O and Network Communications Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extended Local I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Extended Local I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS-232 Serial Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: RS-232 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Remote I/O Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Universal Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DH+ Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DeviceNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: DeviceNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1--1
1--1
1--2
1--2
1--2
1--3
1--3
1--4
1--5
1--7
1--9
1--9
1--10
1--10
1--13
1--13
1--14
1--14
1--15
1--15
1--16
1--17
1--17
1--18
1--18
1--18
ii
Table of Contents
Example: EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--19
1--19
1--20
1--21
Exercise: Identifying PLC-5 System Components

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--23
1--26
1--28
Getting Started with RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RSLogix 5 Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RSLogix 5 Software Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RSLogix 5 Help Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Project Storage Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--1
2--1
2--1
2--2
2--2
2--6
2--6
2--7
2--7
2--9
Exercise: Getting Started with RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--11
2--13
2--14
Communicating with a PLC-5 Processor Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Going Online to a Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration for DH+ Network Communications Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel Configuration for DH+ Network Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--1
3--1
3--1
3--3
3--4
3--7
3--8
3--9
Exercise: Communicating with a PLC-5 Processor Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--11
3--12
3--14
Table of Contents
iii
Identifying Memory Layout in an RSLogix 5 Project

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC-5 Processor Data Storage Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC-5 Logical Address Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC-5 I/O Address Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Group Addressing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Two-Slot Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: One-Slot Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Half-Slot Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Image Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Input Image Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Output Image Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O Address Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: I/O Module Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: DIP Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4--1
4--1
4--2
4--3
4--4
4--4
4--5
4--6
4--6
4--7
4--8
4--9
4--9
4--9
4--10
4--10
4--11
4--12
4--12
4--12
Exercise: Identifying Memory Layout in an RSLogix 5 Project

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--19
4--19
4--20
4--20
4--21
4--27
4--28
4--28
4--28
4--28
Monitoring and Entering Data Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data File Monitoring or Entering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CDM (Custom Data Monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5--1
5--1
5--2
5--3
5--4
5--6
5--7
iv
Table of Contents
Exercise: Monitoring and Entering Data Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--11
5--12
5--14
Interpreting Bit Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rungs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Last Rung Wins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Last Rung Wins Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Output States as Input Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Branches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Start/Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logic Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditional Input Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Retentive Output Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retentive Output Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6--1
6--1
6--2
6--2
6--3
6--3
6--4
6--4
6--4
6--5
6--5
6--6
6--6
6--6
6--6
6--7
Exercise: Interpreting Bit Instructions Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--11
6--12
6--12
6--13
6--14
6--14
6--14
Editing Ladder Logic Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Online Editing Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edit Zone Markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--1
7--1
7--1
7--1
7--2
7--2
7--3
7--3
Table of Contents
Exercise: Editing Ladder Logic Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7--5
7--5
7--6
Documenting an RSLogix 5 Project

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address/Symbol Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8--1
8--1
8--1
8--2
8--2
8--3
Exercise: Documenting an RSLogix 5 Project

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8--5
8--6
8--8
Searching Ladder Logic Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Find Search Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Search Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advanced Diagnostics Search Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Go To Search Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-Reference Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tracing Shortcut Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9--1
9--1
9--1
9--2
9--3
9--4
9--6
9--7
9--8
9--10
Exercise: Searching Ladder Logic Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9--11
9--13
9--14
Interpreting and Editing Counter Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTU Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTD Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter Instructions Used with RES Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10--1
10--1
10--1
10--3
10--4
10--5
10--5
vi
Table of Contents
Exercise: Interpreting and Editing Counter Instructions Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10--9
10--10
10--11
10--11
10--12
10--12
10--12
Interpreting and Editing Timer Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TON Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOF Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTO Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timer Instructions Used with RES Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11--1
11--1
11--1
11--3
11--4
11--5
11--6
11--6
11--7
Exercise: Interpreting and Editing Timer Instructions Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11--11
11--13
11--13
11--13
11--14
11--14
11--14
Integrated Practice: Searching and Interpreting Basic Ladder Logic Using RSLogix 5
Software
12--1
12--1
Exercise: Integrated Practice: Searching and Interpreting Basic Ladder Logic Using
RSLogix 5 Software
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12--3
12--3
12--4
Interpreting and Editing Compare Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13--1
13--1
13--1
Table of Contents
CMP Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQU Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEQ Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LES Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEQ Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRT Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEQ Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEQ Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIM Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
13--2
13--2
13--3
13--3
13--4
13--4
13--5
13--5
13--6
13--7
Exercise: Interpreting and Editing Compare Instructions Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13--13
13--14
13--14
13--14
13--16
13--16
13--16
Interpreting and Editing Data Manipulation Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRD Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BTD Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOV Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MVM Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COP Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Tips for FAL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14--1
14--1
14--1
14--2
14--2
14--3
14--4
14--5
14--6
14--7
14--8
14--8
14--9
Exercise: Interpreting and Editing Data Manipulation Instructions Using RSLogix 5

Software
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14--13
14--15
14--16
14--16
14--18
14--18
14--19
viii
Table of Contents
Interpreting and Editing Program Control Instructions Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor Operating Cycle and Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . .
Common Program Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JMP and LBL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JSR, SBR, and RET Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MCR Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temporary End (TND) Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFI Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15--1
15--1
15--1
15--1
15--2
15--2
15--3
15--5
15--6
15--6
15--7
Exercise: Interpreting and Editing Program Control Instructions Using RSLogix 5

Software
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15--11
15--15
15--16
15--17
15--18
15--18
15--19
Forcing Inputs and Outputs Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for Forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Force Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relationship between Forcing Inputs and Input Image Tables . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relationship between Forcing Outputs and Output Image Tables . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16--1
16--1
16--1
16--2
16--2
16--3
16--4
16--5
16--5
Exercise: Forcing Inputs and Outputs Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16--7
16--8
16--10
Configuring and Previewing a Project Report Using RSLogix 5 Software

17--1
17--1
Table of Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Report Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
17--1
17--1
17--2
Exercise: Configuring and Previewing a Project Report Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17--3
17--3
17--4
Creating a Histogram Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18--1
18--1
18--1
18--2
Exercise: Creating a Histogram Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18--3
18--4
18--6
Creating a Trend Chart Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trend Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19--1
19--1
19--1
19--2
19--3
Exercise: Creating a Trend Chart Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19--5
19--5
19--6
Troubleshooting Noise-Related Problems Using RSLogix 5 Software

Why These Skills are Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Troubleshooting Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise-Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Grounding Configuration for Remote I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Grounding Configuration for Extended Local I/O Systems . . . . . . . . . . . . . . . . . . . .
Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20--1
20--1
20--1
20--1
20--2
20--2
20--2
20--3
20--4
20--4
20--4
Table of Contents
Example: Remote I/O Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input and Output Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20--5
20--5
20--5
20--6
20--6
Exercise: Troubleshooting Noise-Related Problems Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20--7
20--8
20--10
Troubleshooting Discrete I/O Problems Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Discrete Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: Discrete Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Discrete I/O Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21--1
21--1
21--1
21--2
21--3
21--4
21--5
21--5
Exercise: Troubleshooting Discrete I/O Problems Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21--7
21--7
21--8
21--15
21--16
21--16
21--16
Troubleshooting Analog I/O Problems Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interpreting Block Transfer Status Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example: BTR and BTW Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Transfer Instruction Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog I/O Diagnosis and Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Input Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Output Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22--1
22--1
22--1
22--4
22--5
22--6
22--7
22--7
22--8
22--9
22--9
Table of Contents
xi
Exercise: Troubleshooting Analog I/O Problems Using RSLogix 5 Software

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22--11
22--15
22--16
Troubleshooting I/O Channel and Chassis Problems Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel Configuration Screen Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O and Extended Local I/O Adapter Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O Adapter Normal Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O Adapter Channel Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O Adapter Chassis Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23--1
23--1
23--1
23--3
23--4
23--4
23--4
23--5
23--5
Exercise: Troubleshooting I/O Channel and Chassis Problems Using RSLogix 5 Software
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23--7
23--11
23--12
Troubleshooting Processor and Power Supply Problems Using RSLogix 5 Software

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Force LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communications LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processor and Power Supply Diagnosis and Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heres How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24--1
24--1
24--1
24--2
24--2
24--3
24--3
24--3
24--4
24--4
24--5
24--5
Exercise: Troubleshooting Processor and Power Supply Problems Using RSLogix 5

Software
Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24--7
24--9
24--10
Integrated Practice: Maintaining and Troubleshooting a PLC-5 System

25--1
25--1
xii
Table of Contents
Exercise: Integrated Practice: Maintaining and Troubleshooting a PLC-5 System

Exercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Did You Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25--3
25--4
25--6
Appendices
Application Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A- 1
Cable Selection for PLC-5 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B- 1
Block Transfer Error Codes for Enhanced PLC-5 Processors . . . . . . . . . . . . . . . . . C- 1
Course Overview
Opening Comments:
Course Overview
Welcome students.
Give administrative details:
1. Class hours
2. Break times
3. Cafeteria information
4. Telephones
5. Restroom locations
Ask each student to share:
1. Name and title
2. Company and location
3. How they use the PLC-5 systems on
the job
4. Experience with controllers and
programming languages
Course Purpose
Stress that this course covers basic
maintenance and troubleshooting skills.
Advanced troubleshooting skills are not
covered in this course.
This skill-building course provides you with the knowledge and

practice needed to interpret, isolate, and diagnose common hardware
problems related to noise, power, and discrete and analog I/O. In
troubleshooting scenarios, you will be introduced to basic ladder
logic interpretation, which is applied to diagnostic tasks. you will
practice these diagnostic skills by tracing through ladder logic
instructions in an RSLogix 5 project. An integrated practice of
multiple troubleshooting skills completes the training.
Who Should Attend
Individuals who are responsible for troubleshooting and maintaining

PLC-5r systems using RSLogix 5 software should attend this course.
Prerequisites
To complete this course successfully, the following prerequisites are

required:
Experience maintaining electrically controlled systems
Poll the class at this time to determine

the students experience with
maintaining and troubleshooting PLC-5
processors. If the class has a significant
amount of maintenance and
troubleshooting experience with PLC-5
processors, the exercises in the course
may take less time than indicated.
Rev. February 2007
Working knowledge of programmable controllers or completion

of the PLC-5/SLC 500 and RSLogix Fundamentals
(Course No. CCP122)
Experience operating a personal computer within a Microsoftr
Windowsr environment
E 2007 Rockwell Automation, Inc. All rights reserved.

OVRsb85r
II
Course Overview
Agenda
This course consists of the following lessons:

Day 1
30 minutes
60 minutes
95 minutes
80 minutes
90 minutes
Course Overview
Identifying PLC--5 System Components
Communicating with a PLC--5 Processor
Day 2
70 minutes
55 minutes
45 minutes
55 minutes
60 minutes
55 minutes
60 minutes
Monitoring and Entering Data

Interpreting Bit Instructions
Editing Ladder Logic
Searching Ladder Logic
Interpreting and Editing Counter Instructions
Interpreting and Editing Timer Instructions
Day 3
45 minutes
Integrated Practice: Searching and Interpreting Basic ladder
65 minutes
Logic
Interpreting and Editing Compare Instructions
Interpreting and Editing Data Manipulation Instructions
80 minutes
Interpreting and Editing Program Control Instructions
40 minutes
Forcing Inputs and Outputs

Configuring and Previewing a Project Report
Creating a Histogram
60 minutes
20 minutes
50 minutes
Day 4
40 minutes
55 minutes
90 minutes
90 minutes
90 minutes
90 minutes
65 minutes
Creating a Trend Chart

Troubleshooting Noise--Related Problems
Troubleshooting Discrete I/O Problems
Troubleshooting Analog I/O Problems
Troubleshooting I/O Channel and Chassis Problems
Troubleshooting Processor and Power Supply Problems
Integrated Practice: Maintaining and Troubleshooting a PLC--5
System
Rev. February 2007

OVRsb85r
Course Overview
Meeting Course Objectives
III
The following course structure is generally used to help you

understand the content and activities:
One lesson is devoted to each task.
Typical lesson includes most or all of these sections:

-- What You Will Learn -- lesson objectives
-- Before You Begin -- preparatory material
-- Heres How -- demonstration of procedures
-- Exercise -- opportunity to perform new skills, often in a
hands-on lab environment
-- How Did You Do? -- where to go for feedback on

performance
-- Answers -- answers to exercises

Integrated practices provide an opportunity to perform tasks using
the skills obtained during the training.
Student Materials
Show and briefly review the course
materials.
Hold up the Procedures Guide. Show

the Table of Contents, one or two
procedures, and the Glossary. Note that
this guide will be a good reference when
students are completing tasks back on
the job.
Hold up the Troubleshooting Guide.
Show that this publication is a flowchart
that leads the troubleshooter to solutions
to common maintenance problems. Turn
to a section in the guide and point out a
portion of the flow chart.
Rev. February 2007
To enhance and facilitate your learning experience, the following

materials are provided as part of the course package:
Student Manual, which contains the key concepts, definitions,
and examples presented in the course and includes the hands-on
exercises.
RSLogix 5 and PLC-5 Procedures Guide, which provides all the
steps required to complete common tasks using RSLogix 5 and
RSLinxt software, including the tasks in the exercises. By
following the procedures in this job aid, you can immediately
apply what is learned in the course to your own job.
PLC-5 and RSLogix 5 Troubleshooting Guide, which contains
diagnostic algorithms that lead to possible maintenance and

troubleshooting solutions.
The PLC-5 Documentation Reference Guide, which contains
several relevant technical publications. This searchable, electronic
resource contains the most frequently referenced programming
information and is a quick and efficient on-the-job resource.
1785 PLC-5 Programmable Controllers Quick Reference, which
provides a wide-range of maintenance information about the
PLC-5 processors.

OVRsb85r
IV
Course Overview
Hands On Exercises
Explain how the application will be used
in the course. Mention that this section
can be used as a reference for the
application during the exercises.
Many of the hands-on exercises in this course are based on a

fictitious scenario in which you work for a company that
manufactures paint products. During this course, you will be asked to
interpret and modify a PLC-5 project for the paint mixing process.
The paint factory operates one facility that mixes paint, fills
containers, and packages those containers. The entire operation relies
on PLC-5 processors and RSLogix 5 software for its automation
requirements. The facility contains a number of paint mixing lines
surrounded by four support areas: ingredients storage, container
filling, maintenance, and administrative.
Demonstrate the context-based

application by opening the
CCP412_1785r_App.exe file.
The paint factory uses a patented mixing process that begins with
pumping the primary colors into a mixing tank. The ingredients are
then thoroughly mixed. After mixing, the paint is loaded into
3.78-liter (1-gallon) cans, 4 or 6 cans per case, and shipped to the
retail locations for sale to customers.
A PLC-5 project file contains the ladder logic for the entire
manufacturing process, which includes sections of the paint
processing line. The paint mixing, filling, and packaging process is
shown in the following graphic:
Mixing Tank
Filling Station
Lid Installation
Inspection
Packaging Station
Palletizing Station
Rev. February 2007

OVRsb85r
Lesson
Identifying PLC-5 System

Components
What You Will Learn
After completing this lesson, you should be able to identify PLC-5

system components by performing the following tasks:
Identify the main components of a PLC-5 system
Define the functions of PLC-5 system components
Describe the signal flow through a PLC-5 system

Identify distributed I/O configurations
Why These Skills Are Important
Maintenance and troubleshooting efficiency is improved when
system components and signal flow are properly identified. If system
components and their functions are misidentified, basic system
problems may be improperly recognized.
Before You Begin

Highlight some of the benefits of the
PLC-5 processor with the students
real-world job applications.
PLC-5 System Overview

A PLC-5 control system, at minimum, consists of a PLC-5 processor
and I/O modules in a single 1771 chassis with a power supply. A
PLC-5 system provides proven equipment for industrial control with
the following benefits:
Requires minimal space
Provides maximum flexibility in system configuration
Withstands harsh industrial environments

Provides fast delivery of messages between networks, between
Briefly mention the differences between
the PLC-5 processor family and the SLC
500 processor family, with which
students may be familiar.
Rev. February 2007
links within networks, and between modules across the backplane

RH1sb85r
1--2
PLC-5 System Components

Point out these basic hardware
components, with the understanding that
the features of each component will be
covered in detail throughout the lesson.
PLC-5 system components include a power supply, processor,

chassis, and I/O modules, as shown in the following graphic:
I/O Modules
Power Supply
PLC-5 Processor
Chassis
Power Supply
Refer students to power supply
specifications found in either the 1785
PLC-5 Programmable Controllers Quick
Reference or the PLC-5 Processors
Troubleshooting Guide (page 1-11).
Tip "
Explain that two power supplies can be
used in the same chassis to produce
more power by connecting them with a
power-supply paralleling cable
(1771-CT) via the parallel connector. If
one power supply has to shut down, the
second supply will continue to operate
until its DC output limits are exceeded.
Power Supply: A component that provides system power

requirements for the processor and the I/O modules.
All power supplies contain an LED (light-emitting diode) that
indicates proper power supply voltage is present. PLC-5 power
supplies can be either internal or external with respect to the chassis.
A jumper, located on the chassis backplane, is used to indicate the
use of either an internal or external power supply
Internal Power-Supply Modules
An internal power-supply module provides 8 A output current at 5 V
DC power directly to the chassis backplane. Each internal
power-supply module occupies one slot in the chassis. An example
of a single 1771-P4S internal power-supply module is shown in the
following graphic:
One internal power-supply module
uses one slot in the chassis.
Power Indicator
Parallel Connector for
Communication Between
a Second Power Supply
Power Switch
Fuse
Power Connection
Rev. February 2007

RH1sb85r
1--3
Redundant Power-Supply Modules

Mention that each redundant power
supply equally shares the load, thereby
reducing operating temperatures,
increasing reliability, and extending the
life of each redundant power-supply
module.
Redundant power-supply modules can be used to reduce downtime

by protecting the system from a power-supply failure or
power-source failure. An example of two, 120 V AC, 1771-P4R
power-supply modules is shown in the following graphic:
Redundancy Cable
Connections for
Load-Sharing
Information
Power Source 1
Power Source 2
Relay Contacts
Fuse
Because a redundant power supply can incur

unacceptable chassis temperatures, observe
specific debating guidelines based on the given
application.
If an external power supply is available,

point out the front panel indicators and
terminals.
Explain that an external power supply
frees up space in the chassis for I/O.
Rev. February 2007
External Power Supply

External power supplies are mounted on the side plate of a 1771 I/O
chassis or up to 5 cable-feet from the I/O chassis. External power
supplies fill a variety of application requirements by operating on
120/220 V AC. An example of a 1771-P1 external power supply is
shown the following graphic:

RH1sb85r
1--4
Power Connection
Power Switch
Fuse
Voltage Selector Switch
Power Indicator
Processor
Processor: A component that controls a process or machine by
following a set of logical instructions based on information received
by its I/O system.
Mention that PLC-5 processors are
designed for large sequential and
regulatory control applications.
Point out that, unless otherwise
specified, enhanced PLC-5 processors
include Ethernet, ControlNet, protected,
and VME PLC-5 processors.
Briefly review the PLC-5 processor

comparison charts listed in the 1785
PLC-5 Programmable Controllers
Quick Reference (page 1-6).
Tip "
PLC-5 processors are designed for high-speed information

processing and offer a wide range of choices in memory, I/O
capacity, instruction set, and communications ports. The following
table lists the PLC-5 naming conventions:
Naming Convention
Processor Representation
Standard (Classic)
PLC-5/10t PLC-5/12t PLC-5/15t

PLC-5/25t
Enhanced

PLC-5/40Lt PLC-5/60Lt
Ethernetr
PLC-5/20Et PLC-5/40Et PLC-5/80Et
ControlNett
PLC-5/20C25t PLC-5/40C25t
PLC-5/60C25t PLC-5/80C25t
The following features are specific based on each processor type:

Memory capacity
I/O capacity
Communications options
Refer to the 1785 PLC-5 Programmable Controllers Quick
Reference Guide for a comparison chart of PLC-5 processors.
Rev. February 2007

RH1sb85r
Mention that the left-most slot of the

chassis is known as the utility slot.
Briefly describe the functionality of the

following major front panel components:
status indicators, keyswitch,
communication connectors, and battery
holder. Point out that channel 1A
defaults to Data Highway Plus (DH+)
For an example of a standard PLC-5
processor front panel, refer students to
the Hardware Components tab of the
1785 PLC-5 Programmable Controllers
Quick Reference.
1--5
The PLC-5 processor in the left-most slot of the

chassis is called the resident processor.
Example: Enhanced PLC-5/40 Processor

PLC-5/40 series processors have a maximum user memory of
48 K words. The PLC-5/40 processor has 4 channels and one
serial port, and the PLC-5/40L processor has 2 channels, one
serial port, and one extended-local I/O scanner. Front views of
enhanced PLC-5/40 and PLC-5/40L processors are shown in the
following graphic:
Indicators
Keyswitch
Channel 2 (A/B)
Status Indicators
Channel 2 Extended-Local
I/O Communication Port
Channel 2
Status
Indicator
Channel 2A
Channel 2A
Communication
Port
Channel 0
On-Board
Serial Port
Channel 2B
Communication
Port
Channel 1B (A/B)
Status Indicators
Channel 1A
(DH+ Default)
Channel 1B (A/B)
Communication
Ports
Battery Holder
PLC-5/40
Processor Module
Rev. February 2007
PLC-5/40L
Processor Module

RH1sb85r
1--6
Mention that standard PLC-5 processors

have DIP switch assemblies that differ
slightly from the enhanced processor
module shown here.
Top of Processor
Processor Switch Assemblies: Dual inline package (DIP) switches

on PLC-5 processors that are used to set the DH+ station number,
DH+ baud rate, and serial port configuration.
The following graphic shows the position of DIP switch assembly 1
on a PLC-5/40 processor:
Back View of PLC-5/40 Processor Module
DIP Switch Assembly 1
For examples of either standard or

enhanced processor switch assemblies,
refer students to the Switch Settings tab
of the 1785 PLC-5 Programmable
Controllers Quick Reference.
The following graphic shows the position of DIP switch assembly 2

on a PLC-5/40 processor:
Bottom View of PLC-5/40 Processor Module
Battery Holder
(Front of Processor)
DIP Switch Assembly 2
When replacing a module, always make note of

the current DIP switch settings. This will allow
you to set the switches on the new module to
match the settings of the old module.
Point out where the EEPROM module

would be located on a PLC-5 processor.
Memory Module: A module that is inserted into a PLC-5 processor

to store processor memory in the event of memory corruption or
extended power loss.
Rev. February 2007

RH1sb85r
Mention that 16,000 to 100,000 words of

memory can be stored, depending on
the EEPROM module.
1--7
An example of an EEPROM (electrically erasable programmable

read only memory) module is shown in the following graphic:
EEPROM Module
Memory Module
Installation Slot
Chassis
Explain the basic source and destination
functions of a 1770 I/O chassis without
covering addressing in detail.
Addressing will be covered in the
Identifying Memory Layout lesson.
Chassis: The physical structure that houses a processor or adapter

module, a power supply, and I/O modules.
Slot: The physical section of the chassis where a processor or
adapter module, a power supply, or I/O module can reside.
The 1770 I/O chassis provides the following functions:
Power distribution
Containment of I/O modules

Communication path between I/O modules and processor
I/O chassis are manufactured in four different sizes as shown in the
following graphic:
Slots
Card
Guides
4-Slot
Chassis
8-Slot
Chassis
12-Slot
Chassis
16-Slot
Chassis
The left-most slot of each chassis accepts either a processor module

or an I/O adapter module. The other slots in the chassis accept
communications modules, I/O modules, and power-supply modules.
Rev. February 2007

RH1sb85r
1--8
Point out that instructions for these

switches can be found in the 1785
Reference (page 4-1). Mention that the
application of these switches to
addressing will be covered in detail in
the Identifying Memory Layout lesson.
The chassis that contains the PLC-5 processor is

the resident chassis.
When a PLC-5 processor is installed in the left-most slot of a

chassis, the chassis backplane DIP switches are identified as follows:
4-Slot
Chassis
Last State of Outputs
Addressing Mode
Chassis
Backplane
Switches
EEPROM Transfer to Processor

Processor Memory Protection
Describe the location of the chassis

backplane jumper and mention the
importance of the setting in regard to
internal and external power supplies.
The chassis backplane jumper is used to configure the system for the
type of power supply being used (internal or external). The
backplane jumper setting for an internal power supply is shown in
the following graphic:
Chassis
Backplane
Jumper
Point out that information regarding this

jumper setting can be found in the 1785
Reference (page 4-3).
Tip "
Mention that the 1771-A3B

(12-slot) chassis has the same jumper
located at the top of the backplane
between slots four and five.
Jumper setting for power supply

module residing in the chassis.
Refer to the 1785 PLC-5 Programmable Controllers Quick

Reference Guide for additional information regarding this jumper.
Rev. February 2007

RH1sb85r
1--9
I/O Modules
I/O Modules: Electronic plug-in units used to interface with the
input and output devices in the machine or process being controlled:
Input modules receive data from input devices and send it to the
processor.
Output modules receive data from the processor and send it to
output devices.
Briefly describe the discrete I/O
modules, highlighting the number of I/O
points, indicators, and swing arms.
The type of I/O module used will vary depending on the application,
as shown in the following table:
Type of I/O Module
Emphasize that 1771 I/O modules are

removable and that different types of
modules can be inserted as dictated by
the application. At your discretion,
remove and insert a module to show
students how easy it is to do.
Mention that more than 100 different I/O
modules comprise the 1771 I/O product
line. See the PLC-5 Processors
Troubleshooting Guide for a complete
listing.
Point out that the LED indicators show

input/output status and will assist with
troubleshooting.
Function
Examples of Devices That

Connect to Module
Digital/discrete
Sends and receives on/off

signals
Pushbuttons, indicators,
photo eyes, starters
Analog
Sends and receives

variable input or output
signals
Temperature, voltage,
speed current devices
Process
Provides process control
Temperature, weighing
devices
Servo positioning
Provides positioning control
Hydraulic rams, encoders
Specialized
Provides specific functions
Flowmeters, clutch/brake
systems
Example: Discrete Input Module

The LED indicators light when their corresponding inputs are
energized. An example of a 16-point discrete input module
(1771-IAD) is shown in the following graphic:
1771-IAD Input Module (120 V) AC/DC
Not Used
Not Used
Not Used
Not Used
Input 00
Input 01
Input 02
Input 03
Input 04
Input 05
Input 06
Input 07
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
Input 17
L2
Rev. February 2007
A
B
C
D
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
E
Terminals A through D
are not used.
L1
Module Active
Indicator
(Green)
00 to 17 Status
Indicators (Red)
Status Indicator Lights
L2 (Common)
AC/DC Low
Actual wiring runs in this direction.
(Field Wiring Arm, 1771-WH)
RH1sb85r
1--10
Use the I/O shown in the graphic to

demonstrate signal flow through the
system.
Signal Flow through a PLC-5 System

The following graphic outlines the sequence of events from the
activation of machine or process inputs to the energizing of machine

Emphasize the concept that the PLC-5
processor holds the memory for the data
or process output devices:
and program files, and that a computer
is not required for the PLC-5
Input
Output
processor to operate.
Modules
Modules
Processor Memory
Input Devices
Input
Image Table
I:000/06
Output Devices
Data Files
Output
Image Table
I:000/06
O:003/07
I:001/04
O:004/05
O:003/07
Program Files
I:000/06
O:003/07
][
I:001/04
( )
I:001/04
O:004/05
]/[
( )
O:004/05
Computer
Explain that details of I/O addressing will

be covered in the Identifying Memory
Layout lesson.
Distributed I/O and Network Communications Options

A PLC-5 processor can control and monitor I/O in remote locations
through distributed I/O configurations or on a variety of
communications platforms.
Rev. February 2007

RH1sb85r
Mention that DH+ is considered a legacy

network while DeviceNet, ControlNet,
and Ethernet/IP are regarded as open
networks.
1--11
The following communications options are available, depending on

the communications channels available for specific PLC-5
processors:
If the Communications Function Is To Be:
Then Use This

Communication Option:
Connection between local processor and I/O adapters
Extended local I/O
Connection of ASCII terminals and modems
RS-232 serial connection
Connection between processors and I/O adapters
Universal Remote I/O link
Data sharing with program maintenance, plant-wide and

cell-level
DH+t network
Connection of low-level devices directly to the plant floor

controllers without interfacing them through I/O modules
DeviceNett network
Support of time-critical data between processors and I/O

devices
ControlNet network
Plant management tie-in, configuration, data collection,

and control on a single high-speed network; time-critical
applications with no established schedule
EtherNet/IPt network
Briefly explain the network options and

configurations available for PLC-5
processors.
The following terms are associated with distributed I/O and network
communications:
Network: A series of stations (nodes) physically connected
together.
? Ask students how their systems are
Node: A device on a network capable of sending or receiving
configured in the workplace (networks,

peripheral devices, etc.).
information.
Link: The path or physical means established for transmitting
data between two or more locations.
Modem: A device that connects data terminal equipment to a
communication line (modulator/demodulator).
Baud: A unit of signaling speed, across a communications link,

Mention that where one bit is encoded
on each signaling event, the baud is the
same as the number of bits
Tip "
per second.
Tip "
Rev. February 2007
equal to the number of signal events per second (bits per second).
All devices on a link or network must be configured to communicate

at the same transmission rate.
For information on network cable selection, refer to the Cable
Selection for PLC-5 Processors appendix.

RH1sb85r
1--12
Explain that adapter modules and

remote I/O configurations are used to
allow a processor to control I/O that is
not within the processors resident
chassis.
Adapter Modules: A communication interface between a resident

PLC-5 processor in one chassis and the I/O modules of another
individual chassis.
Because adapter modules are less expensive than PLC-5 processors,
it is cost-effective to use adapter modules when additional I/O
modules are required. The following graphic shows a remote I/O
adapter module and an extended local I/O adapter module:
Status Indicators
Field Wiring Arm
1771-ASB Remote
I/O Adapter Module
Cable Connector
1771- ALX Extended

Local I/O Adapter
Module
When an adapter module is installed in the left-most slot of the

chassis, the switch assembly settings for the I/O chassis backplane
serve different functions.
Tip "
See the Switch Settings tab of the 1785 PLC-5 Programmable

Controllers Quick Reference for the functions of these switches.
Rev. February 2007

RH1sb85r
1--13
Extended Local I/O Configuration

An extended local I/O configuration is used when the following
conditions exist:
All of the I/O devices controlled by a PLC-5 processor cannot be
connected to the I/O modules contained in the processors
resident chassis.
Speed is critical.
Point out the necessity of a local I/O

adapter for the extended local I/O
configuration. If available, pass a local
I/O adapter module around to the
students.
An extended local I/O configuration has the following

characteristics:
The resident PLC-5 processor is connected to one or more
extended local I/O adapter module in a separate chassis via a
parallel link. (Only the L-type enhanced PLC-5 processors have
extended local I/O capability.)
The maximum distance between a local I/O adapter module and a
processor is 30 m (100 ft).
Example: Extended Local I/O Configuration
The following graphic shows a PLC-5/40L processor in an
extended local I/O configuration:
Local I/O
PLC-5/40L
Processor
Extended Local I/O

1771-ALX
Extended
Local I/O
Adapter
Module
Extended Local I/O
1771-ALX
Extended
Local I/O
Adapter
Module
Resident I/O Chassis
Parallel Link (Round Cable)

30 m (100 ft) Maximum
Rev. February 2007

RH1sb85r
1--14
RS-232 Serial Connection
Mention that a serial connection is a

direct link between two devices and not
part of a network.
Each PLC-5 processor has a built-in serial port that can be

configured for either RS-232, RS-422A or RS-423 serial
communications. The RS-232 communications format has the
following characteristics:
Uses baud rates from 1,200 to 19,200 bit/s
Explain that the serial connection is

used to connect to devices that
communicate using the DF1 protocol,
such as modems, and those that send
and receive ASCII characters, such as
bar-code readers and printers.
Requires physical connection to the processor to which you want

to go online
Has maximum cable length of 15 m (50 ft)
Tip "
Telephone and radio modems can be integrated into the RS-232

interface, thereby allowing communications over long distances.
Example: RS-232 Connection
Emphasize that this is a point-to-point

connection and no communication card
is required in the computer.
Example: Printers commonly connect to
computers using direct serial
connections.
The simplest way to physically connect a PLC-5 processor to a

computer is to use a direct serial connection. This involves
connecting a serial cable between the serial port of the computer
and the serial port (channel 0) of the PLC-5 processor.
Computer
RS-232 Serial Port
Null Modem (1784-CP10)

Serial Cable
Rev. February 2007

RH1sb85r
1--15
Universal Remote I/O Network
Note that there are over 100 devices

available that can communicate on a
Universal Remote I/O link.
Mention that Universal Remote I/O is an

advanced technique for linking I/O
modules in separate rooms or buildings.
Like the extended local I/O, Universal
Remote I/O provides an economical
means of distributing I/O modules.
The Universal Remote I/O network connects PLC-5 processors to

remote I/O chassis and intelligent devices, such as operator
interfaces and drives. The Universal Remote I/O network has the
Uses 1771-ASB adapter modules
Uses baud rates up to 230.4 kbit/s

Uses a daisy-chain connection with a maximum length of
3,048 m (10,000 ft) at 57.6 kbit/s
The Universal Remote I/O network is based on a master-slave model

in which the PLC-5 processors scanner is the master and the adapter
modules are slaves.
Example: Universal Remote I/O
An example of a PLC-5/40 processor (master station) and remote
I/O (slave) on a Universal Remote I/O network is shown in the
following graphic:
ControlNet, Ethernet, or DH+ Network
Computer
PLC-5/40 Processor
Master Station
Universal Remote I/O Link
1771-ASB
Remote I/O
Adapter
Explain that applications for Universal

Remote I/O include the following:
S
Making connections between

processors and I/O adapters
Establishing distributed processors

so that each has its own I/O but
communicates with a master
processor
Rev. February 2007
PanelViewt
Terminal
1794-ADN Flex I/Ot Adapter

Module and I/O Modules
Remote I/O
The maximum cable length for Universal Remote I/O network

depends on the selected transmission rate. The following
transmission rates determine cable length within a single Universal
Remote I/O network:
Data Transmission Rate
Maximum Cable Length
57.6 kbit/s
3,048 m (10,000 ft)
115.2 kbit/s
1,524 m (5000 ft)
230.4 kbit/s
762 m (2500 ft)

RH1sb85r
1--16
DH+ Network
Mention that a DH+ network can be
used for data transfer to other PLC-5
processors or high-level computers and
as a link for programming multiple
PLC-5 processors.
The Data Highway Plust (DH+) network is a local area network

designed to support remote programming for plant floor applications.
A DH+ network has the following characteristics:
Uses baud rates up to 230.4 kbit/s
Allows a maximum of 64 (0 to 77 octal) nodes per link

Allows a maximum network length of 3,048 m (10,000 ft)
at 57.6 kbit/s
Explain that a DH+ network supports

trunk line and daisy-chain
configurations; however, the two types of
connections cannot be mixed in within
one DH+ link.
Example: DH+ Network

DH+ network is the default configuration for the channel 1A
communications port of a PLC-5/40 processor. An example of
PLC-5 processors on a DH+ network is shown in the following
graphic:
Computer with 1784-KTXD
Computer with 1784-KTX
Node 76
Node 77
PLC-5/40
Processor
Node 5
SLC 5/04 Processor

Node 13
Point out that 15 or fewer nodes are

recommended per link.
SLC 5/04t Processor

Node 31
SLC 5/04 Processor

Node 15
PLC-5/20 Processor Logix5000t Chassis with

1756-DHRIO Module
Node 23
Node 25
The number of supported devices on a DH+ network and the length

of the cable depend on the selected data transmission rate. The
following transmission rates determine cable length within a single
DH+ network:
57.6 kbit/s
3,048 m (10,000 ft)
115.2 kbit/s
1,524 m (5,000 ft)
230.4 kbit/s
762 m (2,500 ft)
Rev. February 2007

RH1sb85r
1--17
DeviceNet Network
Mention that a DeviceNet network is a
flexible, open network that works with
devices from multiple vendors.
A DeviceNet network connects low-level devices directly to

plant-floor controllers over an open network without the need to
interface them through I/O modules. A DeviceNet network has the
Uses baud rates up to 500 kbit/s
Allows up to 64 nodes
Has a maximum cable trunk length of 500 m (1,640 ft)
at 125 kbit/s
Point out that devices can be removed

and replaced without shutting down
other devices and without programming
tools. This can lead to a reduction in
maintenance costs.
Example: DeviceNet Network

An example of an PLC-5/40 processor with a 1771-SDN/B
scanner module on a DeviceNet network is shown in the
following graphic:
PLC-5/40 Processor
ArmorBlockt MaXum I/O
1771-SDN/B
Scanner
Module
DeviceNet Network
1794-ADN Flex I/O Adapter

Module and I/O Modules
RediSTATIONt
Operator Interface
Bulletin 160 Drive
Photoelectric Sensors
RS- 232
Cable
Host Computer with RSNetWorxt for

DeviceNet Software
1770- KFD Module
The maximum cable length for a DeviceNet network depends on the

selected transmission rate. The following transmission rates
determine cable length within a DeviceNet network:
Rev. February 2007
125 kbit/s
500 m (1,640 ft)
250 kbit/s
250 m (820 ft)
500 kbit/s
100 m (328 ft)

RH1sb85r
1--18
ControlNet Network
Point out that a ControlNet network is
well-suited for applications that include
high-speed digital I/O and/or remote
analog I/O.
A ControlNet network combines the functionality of Universal

Remote I/O and Data Highway Plus networks. A ControlNet
network, available for PLC-5/20C15, PLC-5/40C15, and
PLC-5/80C15processors, has the following characteristics:
Uses baud rates up to 5 Mbit/s
Allows up to 99 nodes
Allows data transfer distances of up to 30 km (18.6 miles) using
fiber optic media
Note that although a ControlNet network

is based on a bus topology, the use of
repeaters allows you to implement tree
and star topologies.
Example: ControlNet Network

PLC-5/80C15 and PLC-5/40C15 processors on a segment of a
ControlNet network are shown in the following graphic:
PLC-5/80C15 Processor
PanelView
Terminal
1336 PLUS II
AC Drive
ControlNet
Network
Segment
1786-RG6
Cable
1747-ACN15 ControlNet
1746 I/O Adapter
PLC-5/40C15 Processor
EtherNet/IP Network
Note that EtherNet/IP is an open
industrial network that emerged due to
the high demand for using the Ethernet
for control applications.
An EtherNet/IP network is a local area network that provides

communications between various devices at 10 Mbit/s. The
EtherNet/IP network is available for PLC-5/20E, PLC-5/40E, and
PLC-5/80E processors. An EtherNet/IP network has the following
characteristics:
Requires RJ45 connectors on both ends of a 10BaseT cable
Requires a PC Ethernet communications card

Uses baud rates up to 10 Mbit/s
Allows unlimited nodes on the network
Allows connections to the Internet via a 32-bit IP address
Rev. February 2007

RH1sb85r
Highlight that only the messaging portion

of EtherNet/IP is supported by the
PLC-5 processor and not I/O control.
Firewall / Router
1--19
Example: EtherNet/IP Network

A PLC-5/40E processor on an EtherNet/IP connection is shown
in the following graphic:
Logix5000 Chassis with
1756-ENET Module
Computer with
RSLinxt Software
EtherNet/IP
Network
10BaseT Cable
Ethernet
Switch
RJ45 Connector
PanelView Terminal
To Next
Ethernet
Switch
Heres How
Review the main components and
functions of the PLC-5 system.
Demonstrate how to remove modules
from the chassis.
Use the graphic or a workstation to
demonstrate signal flow through the
system.
PLC-5/40E Processor
To identify PLC-5 system components by performing the following

tasks:
Identify the main components of a PLC-5 system
Define the functions of PLC-5 system components
Describe the signal flow through a PLC-5 system
Identify distributed I/O configurations

As your instructor demonstrates these procedures, follow along in
the associated job aid(s).
Rev. February 2007

RH1sb85r
1--20
Example
Describe the Signal Flow through a PLC-5 System
Highlight how information from an input

device can be traced through the PLC-5
system to an output device.
Use the graphic to reinforce the

functions and functional relationships of
the principal components.
The following graphic shows an example of a basic PLC-5 system.

In the example, note the following relationships:
Each time an input device sends information, it is received by an
input module.
When information from an input module is received by a
PLC-5 processor, the information is processed through the
instruction set in the program files. Based on the instruction set,
the processed information is stored or sent to the appropriate
output module.
Each time data is received by an output module, the data is sent to

the appropriate output device.
Computer
PLC-5
Processor
Communications
System
Power Supply
Input Module
Output Module
Information to Output Devices

(e.g., Compressor)
Data from Input Devices
(e.g., Thermostat)
Rev. February 2007

RH1sb85r
Example
1--21
Identify Distributed I/O Configurations
Emphasize that there are two remote I/O

links in the example. Explain that link #1
is made up of processors 1, 2, and 3.
Link #2 is made up of processor #3 and
the remote I/O adapter module.
The following graphic shows an example of three PLC-5 processors

connected together in a remote I/O configuration. In the example,
note the following:
Processor 1 acts as the master station to processors 2 and 3.
Processor 3 has one channel configured as a remote I/O adapter
and one channel configured as a remote I/O scanner.
PLC-5
Processor 1
Channel
Configured
as Remote I/O
Scanner
Slave to Processor 1
Slave to Processor 1
Channel
Configured as
Remote I/O
Adapter
Channel
Configured
as Remote I/O
Scanner
Channel
Configured as
Remote I/O
Adapter
PLC-5 Processor 3
Secondary Chassis to
Processor 3
PLC-5 Processor 2
Remote I/O
Adapter
Module
Rev. February 2007

RH1sb85r
1--22
Rev. February 2007

RH1sb85r
1--23
Exercise: Identifying PLC-5 System

Components
Exercise A
In this exercise, you will practice identifying PLC-5 system

components.
Context:
As the maintenance technician for a paint factory, you need to be
familiar with the PLC-5 system components being used in the paint
mixing application. In order to troubleshoot future problems in the
paint mixing application, you need to perform a quick inspection of
the system components.
For help performing steps in this exercise, see the associated job
aid(s).
Directions:
1. Remove power from the chassis.
Remove power from the 1771-I/O chassis
backplane and wiring arm before accessing the
processor or other components. Failure to remove
power from the backplane or wiring arm could
cause damage to hardware or personal injury, and
could also cause injury or equipment damage due to
unexpected machine operation.
2. Raise the latch holding the PLC-5 processor in the chassis and
slide the processor out of its slot.
3. Write down the processor type (e.g., PLC-5/40E):
4. Locate the configuration DIP switches on the processor.

5. Write down the number of slots in the chassis (e.g., 12-slot):
6. Locate the chassis backplane jumper.

7. Locate the chassis backplane DIP switches.
8. Lower a wiring swing arm from any input or output module, then
remove that module from the chassis.
Rev. February 2007

RH1e85r
1--24
9. Record the number of discrete and analog I/O modules:
10. Replace all components that you have removed and reapply
power.
11. Define the function(s) for each component:
A. Power supply:
B. Processor:
C. Chassis:
D. I/O modules:
12. Describe signal flow through the system using the the following
graphic and the corresponding letters:
A. Place the letters in sequential order to represent the sequence
of signal flow if input A is a pushbutton that, when pressed,
controls output device H.
B. Using your answer above, what would happen to the signal

flow if the programming system and the communications
system were removed?
Rev. February 2007

RH1e85r
Programming System
G
C
Communications
System
1--25
Power Supply
Processor
Data from Input Devices
Input Module
Output Module
Information to
Output Devices
13. On the following graphic, label each of the chassis as either

resident or remote and label the I/O configurations as either local
or remote:
PLC-5 Processor
Chassis
Remote I/O
Adapter Module
I/O
I/O
I/O
I/O
Remote I/O
Adapter Module
Remote I/O
Adapter Module
Chassis
Chassis
Chassis
Serial Link
14. In the spaces that follow, write the name of the network that is
best suited to meet the application requirements described:
A. The application requires the connection of low-level devices
directly to plant-floor controllers over an open network
without the need to interface them through I/O modules.
B. The application requires a local area network that provides

communications between various devices at 10 Mbit/s.
Rev. February 2007

RH1e85r
1--26
How Did You Do?
Turn to the Answers section.
Rev. February 2007

RH1e85r
Rev. February 2007
1--27

RH1e85r
1--28
Answers
Exercise A
11.
A. The power supply provides power to the chassis and the I/O
modules.
B. The processor acts as the brain of the system and provides
memory capacity for the data and program files.
C. The 1771 chassis houses the processor, the power supply, and
I/O modules
D. Input modules receive data from input devices and send that
data to the processor. Output modules receive data from the
processor and send it to output devices.
12.
A. The signal flow starts when the pushbutton (A) is pressed.
Then the signal continues to input module (B), to the PLC-5
processor (C), to the output module (F) and finally to the
output device (H).
B. Nothing would happen, as the computer and communications
system have nothing to do with the signal flow between the
processor and the I/O components.
13. The PLC-5 system configuration is labeled as follows:
Local
PLC-5 Processor
Resident I/O
Remote
I/O
Chassis
Remote
I/O
Remote I/O
Adapter Module
I/O
Remote I/O
Adapter Module
Remote I/O
Chassis
Remote I/O
Chassis
Remote
Remote I/O
Adapter Module
I/O
Remote I/O Chassis
14.
A. A DeviceNet network provides the connection of low-level
devices directly to plant-floor controllers over an open
network without the need to interface them through I/O
modules.
B. An EtherNet/IP network provides a local area network for
communications between devices at 10 Mbit/s.
Rev. February 2007

RH1e85r
Lesson
Getting Started with RSLogix 5

Software
What You Will Learn
Poll the students to determine how many
have Windows and/or RSLogix 5
experience.
Based on the responses, pace the
lesson accordingly.
After completing this lesson, you should be able to get started with
RSLogix 5 software by performing the following tasks:
Open an RSLogix 5 project
Navigate through the RSLogix 5 software
Configure the display

Identify the components of an RSLogix 5 project
Display RSLogix 5 Help options
View a project revision history
Generate and restore an auto-backup file
Back up a project with secondary save enabled and restore a
backup file

A proper understanding of the software used to run ladder logic is
necessary for efficient troubleshooting of application problems.
When basic software components are not recognized, investigation
and analysis of problems with the ladder logic is difficult.
Before You Begin

Add that, although the software is
versatile, the basic concepts are
covered in this lesson as a starting point
and general overview for the students.
RSLogix 5 Software Overview

The RSLogix 5 software package is a 32-bit Windowsr ladder logic
programming tool for PLC-5 processors. RSLogix 5 software can be
used to perform the following tasks:
Create and modify ladder logic
Configure chassis and I/O modules

Establish communications with PLC-5 processors
Monitor and display process data
Rev. February 2007

GS1sb85r
2--2
RSLogix 5 Project
RSLogix 5 Project: The complete set of files associated with ladder
logic for the purpose of controlling a machine or process.
Stress that detailed information
concerning program files, data table
files, and database files will be covered
in later lessons.
An RSLogix 5 project contains two basic types of files:

Processor Files: Files that can be modified or monitored from the
computer while they are being used by the PLC-5 processor.
Database Files: Files that contain descriptions, symbols, and
other information not used by the processor and stored in only
computer memory.
RSLogix 5 Software Navigation

Mention that the RSLogix 5 main
window is pictured in the glossary of the
Procedures Guide.
The RSLogix 5 main window includes the following elements:

Standard toolbar
Online toolbar (Program/Processor Status toolbar)
PLC-5 Instruction toolbar

Project window
Project tree
Ladder window
The following graphic shows a RSLogix 5 main window:

Standard Toolbar
Online Toolbar
PLC-5
Instruction
Toolbar
Project Window
Project Tree
Ladder Window
Rev. February 2007

GS1sb85r
2--3
Standard Toolbar: The toolbar that contains icons for the functions
used repeatedly in developing and testing ladder logic.
The following graphic shows a standard toolbar:
Mention that the Online toolbar can also

be used to upload and download a
project. If teaching the standard course,
point out that this topic will be discussed
in the next lesson.
Online Toolbar: The toolbar used to view the state of the

application program.
The following graphic shows an online toolbar:
Node Number of
the Processor
Active Network
The Online toolbar indicates the following information:

Operational state of the processor
Status of edits in the online ladder logic program
Mention that forces are a
troubleshooting tool and will be
discussed in the Forcing Inputs and
Outputs lesson.
Existence of forces in the ladder logic program

Status of forces in the ladder logic program (i.e., enabled or
disabled)
Current driver information
Node number of processor

If students have limited Windows
experience, explain or demonstrate how
to use tabbed categories in the
Instruction toolbar.
PLC-5 Instruction Toolbar: The toolbar that displays instruction

mnemonics in tabbed categories. Each tabbed category (e.g.,
Compare) contains a set of PLC-5 instructions assigned to that
category.
The following graphic shows a PLC-5 instruction toolbar:
Instruction Mnemonics
Instruction Category
Rev. February 2007

GS1sb85r
2--4
Project Window: A window within the RSLogix 5 main window in

which the project is displayed.
Project Tree: A graphical outline of all the folders and files
contained in a single project.
In the project tree graphic, point out the

expanded and closed folders.
The following graphic shows a project window with an expanded

project tree, showing processor files and database files:
Name of PLC-5 Project
Processor Files
Database Files
The project tree functions like Windows Explorer:

As with other Windows programs, a folder with a plus (+) sign
can be expanded to show its contents.
A folder with a minus (--) sign can be collapsed to hide its
contents.
Using the project tree, you can perform the following actions:
Create files
Delete files
Copy files
Open files
Rename files
Tip "
Many of these functions are available through the right-click menu.
Rev. February 2007

GS1sb85r
2--5
Ladder Window: The window that contains any open program files.
Program files contain the following information:
User-defined ladder logic
Mention that documenting a project will
be discussed in detail in the
lesson.
Ladder
Window
Any occurrences of documentation

The following example shows the Ladder window and its main
components:
Documentation
Ladder
Logic
Rung
Open
Program
File
Tip "
Rev. February 2007
Two sections of a program file or two different programs can be

viewed simultaneously by splitting the Ladder window.

GS1sb85r
2--6
Display Configuration
Indicate to the students that some color
selections, such as white text against a
white background, should be avoided.
One or more program files can be configured and displayed in a split

Ladder window. Display configuration also allows you to set the
following operator preferences:
Select colors used in the display
Select size and style (font) of documentation
Select address presentation used in the display

Hide or show documentation
Assign a key to a specific instruction
The following example shows the View Properties dialog box where
the display preferences are set:
Option Tabs
Selection Boxes
RSLogix 5 Help Options

Mention that the Help system is the
online user manual.
Tell the students that a quick way to
access help is to press [F1] after
selecting the instruction or dialog box.
RSLogix 5 software provides the following online Help options:

Status bar messages for menu selections
Tooltips for button selections

A Help menu that includes the following information:
-- Programming procedures and reference information
-- Instruction set reference
-- Help search function
Rev. February 2007

GS1sb85r
2--7
Revision Notes
Point out that revision notes can be a
valuable tool when troubleshooting a
project.
The Revision History/Editor can be used to identify changes that

were made to a project since the last time it was saved:
Example: A revision note that was

created by a programmer indicates that
an input device was removed from the
system. A troubleshooter can be alerted
to such a change via the revision note.
Mention that the Revision History/Editor
is accessed from the Edit menu.
Revision Note
Project Storage Functions

RSLogix 5 software offers two project storage functions:
Auto-backup files
Secondary save option
Compressed backup files

Auto-Save
Settings
Program Backup
Settings
Enable
Secondary
Save Option
Secondary
Save Path
Mention that a project file must be saved

or closed at least one time for the
auto-save process to work.
Rev. February 2007
Auto-Backup File: A file that is created automatically as a backup

each time the project is saved or closed.
GS1sb85r
2--8
Point out that a user can specify the

number of backups to be contained in
the project folder and how frequently
backups should be performed. Also, a
secondary save path can be specified.
To modify settings, from the Tools
menu, select Options to access the
System Preferences dialog box.
An auto-backup file is identified with a name such as

NEW_BAK032.RSP:
BAK indicates that this is an auto-backup file.
Explain that the time interval can be

changed by the user.
RSLogix software, by default, auto-saves the project every 10

minutes. If a system or power interruption occurs, two file recovery
options are available:
Open and save the last auto-backup version of the file
Open and save the last auto-saved version of the file
Point out that file extensions for all types

of files can be viewed by setting the files
of type drop-down list to All Files in
Explorer or an Open dialog box.
The number (000 to 999) indicates the archive order, with a

higher number being a more recent backup.
RSP is the extension for an auto-backup file.
Secondary Save Option: Enable this checkbox to have the file also
saved to a secondary location specified in the Secondary Save Path
field each time you save the file.
Mention that a compressed backup file
includes the .RSP and all database files
for a particular project.
Compressed Backup File: A file generated for archiving or sending

to another user. This file is indicated with a .RP1 extension.
Point out a compressed (.RP1) and an

auto-backup (.RSP) file.
The following dialog box shows auto-backup and compressed file

extensions:
Compressed
Backup File
Auto-Backup
Files
File Type
Rev. February 2007

GS1sb85r
Heres How
Demonstrate each of these tasks offline
with the CCP412_1785r_DEM1.rsp
project:
1. Point out the processor and
database files in the project tree.
2. Open multiple program files.
" To open a program file in a separate
window, in the project tree, right-click
the file and select New Window.
3. Maximize, restore, and size
windows, and then return windows
to the default size and orientation.
" To return the windows to the default
settings, from the Windows menu,
select Arrange...
2--9
To get started with RSLogix 5 software by performing the following

tasks:
Open an RSLogix 5 project
Navigate through the RSLogix 5 software

Configure the display
Display RSLogix 5 Help options
View a project revision history
Generate and restore an auto-backup file
Back up a project with secondary save enabled and restore a
backup file

4. Configure the display, including

splitting the Ladder window using
the split bar, selecting address,
comment format, colors and fonts.
5. Save a project and enter a revision
note.
6. View a project revision history.
7. Back up a project and restore a
project file.
8. Generate and restore an
auto-backup file.
Rev. February 2007

GS1sb85r
2--10
Rev. February 2007

GS1sb85r
2--11
Exercise: Getting Started with

RSLogix 5 Software
Exercise A
In this exercise, you will practice getting started with RSLogix 5

software.
Context:
You have been asked to review a new process line for a paint mixing
application on a PLC-5 system with RSLogix 5 software. Before
beginning to troubleshoot the project, you first need to become
familiar with the RSLogix 5 software.
Tip "
For information on the context-based application for this lesson,

refer to the Application Overview appendix.
aid(s).
Directions:
1. Open the GS1_1785r_A1.rsp project.
2. Locate the elements of the RSLogix 5 main window called out in
the glossary of the Procedures Guide.
3. Maximize and arrange the Project window to the default setting.
4. Increase the size of the Ladder window so that it partially covers
the Project window, and then return the windows to the default
setting.
5. Open LAD 3 in the existing Ladder window and then use the
Split Bar to view LAD 2 in the upper window and LAD 3 in the
lower window.
6. Display several tool tips (e.g., Copy, Zoom In).
7. In the ladder logic, select the first instruction symbol from rung 0
and display the help regarding that instruction. Repeat this step
for a different instruction.
Rev. February 2007

GS1e85r
2--12
8. Display the View Properties dialog box, then use the Comments
Display tab to set the following options:
9. Select the Address Display tab of the View Properties dialog box
to set the following options:
10. Change the text and background colors for several ladder logic
elements and then return the display to the default colors.
11. In the System Options dialog box, perform the following actions:
A. Verify that the prompt for revision note option is selected.
Rev. February 2007

GS1e85r
2--13
B. In the Number of Backups box, increase the existing number

by two.
C. Enable the secondary save option and enter a secondary save
path.
12. Save the project and enter a revision note.
13. View the project revision history.
14. Close the project.
15. Open the most recent auto-backup file of the project.
16. Backup (compress) the project and store it in the folder that you
opened in Step 1.
17. Close the project.
How Did You Do?
Rev. February 2007

GS1e85r
2--14
Answers
Exercise A
5. The split bar can be accessed as shown in the following
graphic:
7. To display the help regarding the instruction, highlight the

instruction and hit the F1 key.
11. The system options dialog box should look similar to the
following graphic:
Step A
Step C
Step B
Your
number
of
backups
may be
different
than
shown
here.
Rev. February 2007

GS1e85r
Lesson
Communicating with a PLC-5

Processor Using RSLogix 5
Software
What You Will Learn
Poll the students to determine their level
of experience in going online with an
PLC-5 processor.
After completing this lesson, you should be able to communicate

with a PLC-5 processor using RSLogix 5 software by performing the
following tasks:
Download a project
Upload a project
Go online to a PLC-5 processor
Configure a DH+ communications driver in RSLinxt software
Configure a channel for DH+ communications

Select and change the processor operating mode
Communicating with the correct PLC-5 processor is critical to the
safety of the equipment and of the personnel working with the
equipment controlled by the processors. Downloading to the wrong
PLC-5 processor can result in substantial damage to equipment
and/or personal injury.
Before You Begin
Data Transfer Options

Data must be exchanged between a computer and a processor in
order for the data to be monitored or modified. The following
communication states describe the data transfer process:
? Are any of these terms used
differently in your work environment?
Offline: Viewing or working with a project that resides only on the

hard disk of a computer.
Online: Using a computer to view or work with a project that is
loaded in a PLC-5 processor. The computer must be in continuous
communication with the processor, so that the following actions can
be performed:
Monitor or modify a project loaded on a processor
Monitor data while it is being collected
Modify data stored in a processor
Rev. February 2007

GOOsb85r
3--2
The following graphic represents the offline and online

communications states:
Offline
Computer
Online
Computer
PLC-5 Processor
Download: Transfers a copy of a project from a computer to a

processor.
Downloading overwrites the current project in the
processor.
Contrast volatile memory (a memory that

loses its information if the power is
removed) with non-volatile memory (a
memory that is designed to retain its
data while its power supply is turned off).
Upload: Writes a copy of a project to the volatile memory of a

computer. When power is removed from a computer, projects in
volatile memory are erased.
The following graphic represents the download and upload
communications states:
Upload
Download
Computer
Tip "
PLC-5 Processor
Because uploading allows the operator to view the project that is on

the processor, it is commonly used by maintenance personnel to
troubleshoot and monitor a project.
Rev. February 2007

GOOsb85r
3--3
Going Online to a Processor

Mention that database files and
documentation will be discussed in more
detail in the Documenting an RSLogix 5
Project lesson.
When a project is downloaded to a PLC-5 processor, all information,

except database files, is loaded into the processors memory, as
RSLogix 5 Project
Stored in Computer
Memory Only
Database Files
Mention that RSLogix 5 software

searches for the matching offline file in
the default directory only. The default
directory can be specified in the
Systems Options dialog box.
Transferred between Computer

and PLC-5 Processor
Processor Files
When going online or uploading a project, the computer will search

for an offline project that matches the project in the processor. The
following options may be available in the Going to Online
Programming State dialog box:
Upload Logic, Merge with Existing Files Comment/Symbol
DB: RSLogix 5 software will merge the documentation in the
selected file with the information from the processor.
Browse: RSLogix 5 software will search the user-specified
directory for a matching file and, if a match is found, the upload

will occur automatically and the computer will be online with the
processor.
Create New File: RSLogix 5 software will apply only default
documentation to the online ladder file.
Rev. February 2007

GOOsb85r
3--4
Configuration for DH+ Network Communications Driver

Note that there are actually four
communications packages to choose
from: RSLinx, RSLinx Lite, WINtelligent
LINX, and WINtelligent LINX Lite; but,
they function the same.
A computer running RSLogix 5 software communicates with a DH+

network through a communication software package known as
RSLinxt software. RSLinx software automatically opens when you
activate any of the communications options in the RSLogix 5
software.
Communications Driver: An independent application that enables a
software application to communicate with a specific external device,
such as a computer.
Communication Interface Card: An interface device that allows a
computer to connect to a network and communicate with other
devices on the network.
Note that RSLinx software is available in

several packages with varying degrees
of functionality.
RSLinx software can be used to accomplish the following actions:

Add, configure, and modify communications drivers
Perform communications tasks through RSLogix 5 software, such
as uploading, downloading, going online, and sending messages
View active networks and active nodes for those networks

Point out the active DH+ network from
the project tree and the available nodes.
RSWho is the network browser interface for RSLinx software that

allows users to view all the active network connections from a single
screen:
Active DH+
Network
Previously
Recognized
Devices
PLC-5 Processor Currently Active at

Node 50 on the DH+ Network
Rev. February 2007

GOOsb85r
3--5
Configuring a computer for DH+ communications involves selecting

an appropriate driver type:
Drop-Down Menu
A PLC-5 Processor
Currently Connected
to the DH+ Network
(Node 50)
Driver Types that

Can Be Added
Suggest that students reboot or

refresh when problems with
communications exist.
Rev. February 2007
Tip "
When configuring drivers, make certain that no other application is

running.

GOOsb85r
3--6
Point out the common properties

specifications errors, such as a
baud-rate mismatch between the
existing network
and the new
driver.
Properties associated with the selected device are specified as

follows:
Driver To Be
Added
Display of
Drivers
Currently
Configured
for Use with
RSLinx and
the Status of
Each
Property
Specifications
Refer to the
notes section
for information
on each
property.
Select a
property and
edit it in the
value list.
Rev. February 2007

GOOsb85r
3--7
Channel Configuration for DH+ Network Communications

Mention that it is advisable to use the
channel 1A default configuration so as to
avoid the potential loss of the DH+
connection while configuring another
channel.
Tip "
In order for a PLC-5 processor to communicate using a DH+

network, a channel must be configured specifically for
DH+ communications.
Most PLC-5 processors designate channel 1A for DH+
communications.
Channel configuration is done in the Edit Channel Properties
window:
DH+ Selection
Rev. February 2007

GOOsb85r
3--8
Point out that the front panel keyswitch

positions are presented in the 1785
Programmable Controllers Quick
Reference
Processor Modes
The extent and type of communications that can occur between a
computer and a PLC-5 are dependent on the mode of the processor.
PLC-5 processors have three basic modes:
Run
Program
Remote
Review where the keyswitch is on the
processor using a workstation, then
demonstrate changing the processor
mode using the keyswitch.
Point out the processor LED, which
gives a quick visual indication of the
processor mode.
Point out that in Remote mode,
processor modes can be switched using
RSLogix 5 software.
The keyswitch on a PLC-5 processor controls which mode the

processor is in. The functions of the processor modes are outlined in
the following table:
Processor Mode
Run
Program
Function
Run mode is used to run a project to
control a process or machine.
Run mode should only be

used when conditions are
safe.
Program mode is used to modify the

project on a processor, create a new
data table address, or create a new
program file online.
When the processor is

switched to Program
mode, the manufacturing
process stops. Do not use
Program mode instead of
an E-stop. Program mode
is not a safety device.
Remote mode is used to control the

processors operations mode from a
computer connected to the processor.
RSLogix 5 software specifies three
Remote mode choices: Remote Run,
Remote Program, and Remote Test.
Remote
Remote Run and Remote Program

mode are identical to Run and
Program mode with the exception that
you can edit the program in Remote
Run mode.
Remote Test mode allows you to run a
program but disables its outputs. It is
commonly used for troubleshooting
and diagnostics.
WARNING!
Personnel can modify a

program in Remote Run
mode. Be sure to control
outputs with care to avoid
injury to personnel and
damage to equipment.
" Make sure your
organization allows
editing in the Remote
Run mode.
Rev. February 2007

GOOsb85r
Heres How
Demonstrate the following tasks:
1. Upload the
CCP412_1785r_DEM1.rsp project
and go online.
2. Configure a DH+ communications
driver in RSLinx software.
3. Go offline, make a few edits and
then download the program.
4. Change the processor operating
mode.
5. Save the project.
Rev. February 2007
3--9
To communicate with a PLC-5 processor by performing these

actions:
Download a project
Upload a project
Go online to a PLC-5 processor
Configure a DH+t communications driver in RSLinxt software
Configure a channel for DH+ communications
Select and change the processor operating mode
As your instructor demosntrates these procedures, follow along in


GOOsb85r
3--10
Rev. February 2007

GOOsb85r
3--11
Exercise: Communicating with a

PLC-5 Processor Using RSLogix 5
Software
Exercise A
In this exercise, you will practice communicating with a PLC-5

processor.
Context:
You have been assigned to configure the communications setup of a
PLC--5 processor that was recently taken offline. To accomplish this
task, you will need to configure a DH+ communications driver,
configure a channel for DH+ communications, and select and change
the processor operating mode. You are now ready to communicate
with a PLC-5 processor.
aid(s).
Directions:
1. Make sure the keyswitch on your workstations PLC-5 processor
is positioned to REM (remote).
2. Connect the 1784 communications card of the computer to the
PLC-5 processor.
3. Configure the appropriate communication driver for your setup
using RSLinx software.
4. Open the project GOO_1785r_A1.rsp and assign a node address
(If you are on a DH+ network, assign the node addresses of the
workstations in sequential order. e.g. 10, 20, 30...).
5. Configure a channel for DH+ communications, if needed.
6. Download the project to your workstations PLC-5 processor and
go online.
7. In the Online toolbar, verify the processor node number (just
below the animated graphic).
8. Verify that the project was downloaded properly:
A. Change the processor to Run mode by turning the keyswitch
on front of the processor to the RUN position.
B. Press pushbutton 8 (Input tied to I:002/10) and verify that the
lights on the display panel begin blinking.
Rev. February 2007

GOOe85r
3--12
C. Return the processor to Program mode by turning the

keyswitch on the front of the processor to the PROG
position.
9. Save the project, enter a revision note and go offline.
10. Upload the project from the PLC-5 processor in your workstation
and go online.
11. When you have verified that your computer is online, go offline.
12. (Optional) If your workstation is attached to a network, go online
to a different PLC-5 processor at a different node.
13. (Optional) When you have verified that your computer is online,
go offline.
How Did You Do?
Rev. February 2007

GOOe85r
Rev. February 2007
3--13

GOOe85r
3--14
Answers
Exercise A
2. Use the following guidelines to determine if you connected
your system correctly:
-- If you are using an RS-232 serial port, use cat. no. 1784-CP10
-- Otherwise, use the following table to select an appropriate
cable:
If you have
this processor . . .
And you have this

communication card . . .
PLC-5/10t, -5/12t,
-5/15t, -5/25t
1784-KT, -KT2, -KL, -KLB

1784-KTK1
1784-KTX, -KTXD
1784-KT, -KT2, -KL, KL/B
PLC-5/11t, -5/20t,
-5/26t, -5/30t, -5/40t,
-5/46t, -5/40Lt, -5/60t,
-5/60Lt, -5/80t, -5/86t
1784-KTK1
1784-PCMK
1784-KTX, -KTXD
PLC-5/20Ct, -40Ct,
-80Ct
1784-KTC, -KTCX
Then use this cable . . .

1784-CP
1785-CP5
1784-CP12
1784-CP6 or 1784-CP with
1784-CP7 adapter
1784-CP5 with 1784-CP7
adapter
1784-PCM6 or 1784-PCM5
with 1784-CP7 adapter
1784-CP12 with 1784-CP7
adapter or 1784-CP13
1786-RG6 or 1786-CP
3. Configure the appropriate 1784 driver in RSLinx if you are

using DH+ or RS-232 DF--1 driver if you are using a serial port.
7. The node number of the PLC-5 is displayed just below the
animated graphic:
Rev. February 2007

GOOe85r
Lesson
Identifying Memory Layout in an

RSLogix 5 Project
What You Will Learn
After completing this lesson, you should be able to identify memory

layout by performing the following tasks:
Identify processor data file types
Identify PLC-5 logical address format
Determine I/O addresses assigned to I/O modules and devices

Mention that understanding a PLC-5
processors memory system will aid the
student in understanding how the
processor operates and interacts with
I/O interfaces.
Before You Begin

Note that memory capacity can vary
based upon the type of PLC-5 processor
being used in an application.
Identifying the source of a problem through the inspection of

processor files and I/O addresses is one of the initial steps in
troubleshooting. A proper understanding of PLC-5 addressing will
aid I/O troubleshooting efforts.
Processor Memory Division

A PLC-5 processors memory is divided into two storage areas. Like
two drawers in a filing cabinet, one area is for program files and the
other is for data files:
Memory
...
...
...
...
999
Program
Files
999
Data
Files
Rev. February 2007

AD1sb85r
4--2
Program Files
Mention that some PLC-5 processors,
such as series E, allow up to 2000
program files.
Program files contain processor information, the main ladder logic

program, and other ladder logic files. A PLC-5 processor can contain
up to 999 program files. Program files are located in the Program
Files folder of the RSLogix 5 project tree, as shown in the following
graphic:
Explain that program files contain the

instructions to examine inputs and
outputs and return results to the user.
Program Files
Point out that file 0 contains information

such as processor type, I/O
configuration, processor file name, and
passwords.
Program files are assigned as follows:

File 0 always contains system information.
File 1 is the SFC (sequential function chart) file or is undefined.
File 2 contains the main ladder logic file.
Files 3 to 999 contain other ladder files (routines).
Rev. February 2007

AD1sb85r
4--3
Data Files
Explain that all of the data a PLC-5
processor examines or changes is
stored in the data files.
Data files contain the status information associated with I/O and all
other instructions used in the main and subroutine ladder logic
program files. Data files are located in the Data Files folder of the
RSLogix 5 project tree, as shown in the following graphic:
Data Files
Data files are assigned as follows:

File O0 stores the state of output terminals.
File I1 stores the state of input terminals.
File S2 stores processor operation data.
Mention that although files 3 through 8
are default, they can be changed to
another data file type.
File B3 stores data for internal relay logic (binary).

File T4 stores the timer accumulator values, timer preset values,
and status bits.
File C5 stores the counter accumulator values, counter preset
values, and status bits.
File R6 stores the length, pointer position, and status bits for
Provide an example of user-defined data

that would be found typically in files 9
through 999.
Example: In a food or chemical
processing plant, different recipes can
be stored in different data files (3-999).
Rev. February 2007
specific instructions such as shift registers.

File N7 stores whole number values, both negative and positive,
or bit-level information.
File F8 stores positive and negative numbers that include a
decimal point.
Files 3 through 999 store user-defined data.

AD1sb85r
4--4
PLC-5 Processor Data Storage Units

Briefly discuss the following terms as
they relate to data storage in a PLC-5
processor.
PLC-5 processors store data in the following units of memory:

Bit: A digit in the binary radix (0 or 1). A bit may represent the state,
on or off, of a discrete I/O device.
Word: In a PLC-5 system, 16 bits in sequence. For example, the 16
bits representing the 16 points of an I/O module comprise one word.
Element: A word or collection of words that work together as a unit.
For example, a 32-point I/O module uses two words of memory.
Those words work together as one element.
File: A consecutive group of words (an array) addressable as a unit.
Type: Group of words or elements with a common usage (e.g.,
timers, counters, control, etc.).
PLC-5 Logical Address Characteristics

Emphasize that although logical or
internal storage addresses are viewable
through RSLogix 5 software, they reside
in the PLC-5 processor.
PLC-5 logical addresses (internal storage addresses) are used for

processor and program control. A logical address is a value stored
within a processors data file that is not directly connected to
real-world inputs or outputs.
The following PLC-5 logical address format is used for bits stored in
status, binary, timer, counter, control, and integer data files:
File Number
Element Number (0-999)
File Type
Bit Number (0-15)
N 9 : 2/5
Give some examples of the mnemonics
used in counter and control files (e.g.,
.PRE, .ACC, .POS, etc.).
The following PLC-5 logical address format is used for word

addresses stored in timer, counter, and control files:
File Number
Element Number
(0- 999)
Word
Address
File Type
T 14 : 2 . PRE
Rev. February 2007

AD1sb85r
4--5
PLC-5 I/O Address Characteristics

Briefly discuss the terms associated with
I/O image addressing.
Mention that the modules density
determines the formation of I/O groups.
The address for a real-world device (input or output) is directly

determined by hardware components and their representation in
processor memory:
I/O Rack: Processor memory equivalent to a maximum of 8 I/O
groups, or 128 input bits and 128 output bits, or 8 input words
and 8 output words.
I/O Group: A group of 16 input and 16 output terminals, where
16 bits represent 1 word in processor memory (hence, 1 I/O group
represents 2 words in the data table).
Terminal: A connection point for an I/O device, where each

terminal represents one bit in processor memory.
Ensure that the students know the

difference between a chassis and an I/O
rack.
Tip "
Point out that PLC-5 processors adopt

an octal numbering system, contrasted
with SLC 500 processors that use
decimal numbering in all of their data
files.
In a PLC-5 system, rack is a software term and

should not be confused with the physical
chassis.
Each PLC-5 processor has a finite amount of I/O racks it can
support. For more information, refer to 1785 PLC-5 Programmable
An I/O address contains the following information:
The module type, either an input (I) or an output (O) module
The rack number (must be two digits, numbered in octal)
I/O group number (0--7)
The terminal number (numbered in octal)

An example of a PLC-5 I/O address is shown in the following
graphic:
I/O Group Number (0- 7)
Two-Digit I/O Rack Number (0- 278)

Module Type
(I for Input;
O for Output)
Rev. February 2007
Terminal (Bit) Number (00-078, 10-178)
I : 0 1 4 / 12

AD1sb85r
4--6
I/O Group Addressing Mode

I/O group addressing mode is used in system planning to make
efficient use of processor memory and I/O module density.
Introduce the concept of I/O module

density and how I/O module density
should be considered when choosing an
addressing mode.
There are three I/O group addressing modes:

Two-slot addressing (2 I/O slots equal 1 I/O group)
One-slot addressing (1 I/O slot equals 1 I/O group)
? Which I/O group addressing mode is
Half-slot addressing (1/2 of an I/O slot equals 1 I/O group)
used at your work location?
The addressing mode for each I/O chassis is defined by setting the
chassis backplane DIP (dual inline package) switch assembly.
Tip "
For more information, refer to either of these publications: PLC-5

Processors Troubleshooting Guide or 1785 PLC-5 Programmable
Example: Two-Slot Addressing
Two-slot addressing is used when two chassis slots equal one I/O
group. Two-slot addressing is usually used with 8-point I/O
modules, and 32-point I/O modules cannot be used with two-slot
addressing. In the following example of two-slot addressing, note
the I/O module density for a complementary chassis:
I/O Rack 2
I/O Groups
2 Slots = 1 I/O Group
8 Bits
Input
8 Bits
Output
R2
G 0G G 0 G
16 Slots = 8 I/O Groups = 1 I/O Rack
An I/O Module Label for Two-Slot Addressing

(from I/O Rack 2, I/O Group 0) when 8-Point I/O
Modules Are Used
Rev. February 2007

AD1sb85r
4--7
Example: One-Slot Addressing

One-slot addressing is used when one chassis slot equals one I/O
group. One-slot addressing is usually used with 16-point I/O
modules. In the following example of one-slot addressing, note
Point out that one-slot addressing has

double the density of two-slot
addressing.
I/O Rack 2
I/O Groups 0
I/O Rack 3
5
1 Slot = 1 I/O Group
16 Bits Input and

16 Bits Output
R2
G 0G
G 1G
An I/O Module Label for One-Slot Addressing

(from I/O Rack 2, I/O Groups 0 and 1) when
16-Point I/O Modules Are Used
If a chassis has more than eight I/O groups (as in the above example)
and therefore more than one I/O rack, then the following actions
should be taken:
1. Increment the I/O rack number.
2. Reset the I/O group number to 0 (zero).
3. Continue numbering with the new I/O rack number.
Rev. February 2007

AD1sb85r
4--8
Example: Half-Slot Addressing

Mention that half-slot addressing has the
limiting factors of power and heat.
Half-slot addressing is used when half a chassis slot equals one

I/O group. Half-slot addressing is usually used with 32-point I/O
modules. In the following example of half-slot addressing, note
I/O Rack 2
I/O Groups
I/O Rack 3
I/O Rack 4
I/O Rack 5
0/1 2/3 4/5 6/7 0/1 2/3 4/5 6/7 0/1 2/3 4/5 6/7 0/1 2/3 4/5 6/7
1/2 Slot = 1 I/O Group
16 Bits Input and

16 Bits Output
R2
G 0G 1 G 2G 3
An I/O Module Label for Half-Slot Addressing

(from I/O Rack 2, I/O Groups 0 through 3) when
16-Point I/O Modules Are Used
If a chassis has more than eight I/O groups (as in the above example)
and therefore more than one I/O rack, then the following actions
should be taken:
1. Increment the I/O rack number.
2. Reset the I/O group number to 0 (zero).
3. Continue numbering with the new I/O rack number.
Rev. February 2007

AD1sb85r
4--9
I/O Image Tables

I/O addressing is a means of connecting the physical location of an
I/O module terminal to a bit location in the processor memory. I/O
addresses are stored in the input image table and the output image
table of the processor memory.
Explain that the I/O image tables are

important for identifying and
troubleshooting problems associated
with I/O function.
Example: Input Image Table

The input image table reflects the state of the on or off condition
of an input device. An example of an input device with
corresponding I/O address displayed in the input image table is
Trace the address from the hardware

device to the input module and then to
the input image table.
Input Module
I/O Rack 1
I/O Group 4
Input Image Table

Bit Corresponding
to Input Terminal
Input Device
Word in Input
Image Table
12
I:014/12
Note that the I/O address is displayed on

the I/O image tables.
Trace the address from the hardware
device to the output module and then to
the output image table.
Example: Output Image Table

The output image table reflects the state of the on or off condition
of an output device. An example of an output device with
corresponding I/O image address displayed in the output image
table is shown in the following graphic:
Output Module
I/O Rack 1
I/O Group 5
Output Image Table

Bit Corresponding
to Output Terminal
Output
Device
Word in Output
Image Table
Rev. February 2007
7
O:015/7

AD1sb85r
4--10
I/O Address Identification
? How many of these methods of I/O

address identification are used at your
work location?
Tip "
An unknown I/O address can be determined by inspecting any of the

following:
Wire numbers
Device tags
Electrical drawings
I/O module labels
DIP switch settings
When determining I/O addressing from DIP switch settings, refer to
either of these publications: PLC-5 Processors Troubleshooting
Guide for Use with RSLogix 5t Software or 1785 PLC-5
Programmable Controllers Quick Reference.
Example: I/O Module Labels
Point out the information on an I/O

module label that contributes to the I/O
address.
An example of an I/O module label is shown in the following

graphic:
I/O Rack Number
Written Here
G G
I/O Group
Number
Written Here
G G
Solenoid
A
0
1
2
3
4
5
6
7
B
A
10
11
12
13
14
15
16
17
B
R5
G 2G
G 2G
Color in Square
Indicates Terminal
Numbers Used
Label with I/O Rack, I/O Group,
and Terminals Identified
From inspecting the module and module label, the I/O address is
O:052/10.
Rev. February 2007

AD1sb85r
Point out the areas that contribute to the

I/O address; namely the chassis
backplane DIP switch, switch 1 of the
1771-ASB module, the I/O group
location, and the terminal number.
4--11
Example: DIP Switch Setting

An example of an I/O address using system DIP switches is
Chassis Backplane DIP Switch
Pressed in at Top:
Closed (on)
Module
Type
Pressed in at Bottom:
Open (off)
Input
T erminals
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
Input
T erminals
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
1771- ASB Module SW-1
Module Location in Chassis
One-slot addressing is indicated from the chassis backplane

switch. The 1771-ASB module switch indicates that the I/O rack
is 13 and the starting I/O group number is 0. From inspecting the
module, the I/O group number is 1. The I/O address is I:141/11.
Rev. February 2007

AD1sb85r
4--12
Heres How
From the project tree, review the
processor memory division.
Refer students to the Addressing tab of
the 1785 PLC-5 Programmable
To identify processor data file types.

As your instructor demonstrates this procedure, follow along in the
associated job aid(s).
Review the file identifier and purpose of

each of the various data table file types.
Focus on the first eight default files and
their functions.
Heres How
Review the functional differences

between logical (software) and I/O
(hardware) addresses.
Example
For the PLC-5 logical address,
demonstrate how the address can be
written, given the necessary information.
Point out the delimiters and the
sequence of the address.
To identify PLC-5 logical address format.

As your instructor demonstrates this procedure, refer to the following
example:
Identifying PLC-5 Logical Address Format

The following graphic shows a PLC-5 logical address for bit 2 in
element 3 in binary file 15. In the example, note the position and
order of the file type, file number, element, and bit number:
File Number Element Number (0- 999)
File Type
Bit Number
(0- 15)
B 15 : 3 / 2
Rev. February 2007

AD1sb85r
Heres How
4--13
To determine I/O addresses assigned to I/O modules and devices:
Use the examples on the next pages to

demonstrate how to use the
Troubleshooting Guide or the 1785
Reference to determine an address,
given the information available.
Example
? What would be the address in this

example?
Answer: O:013/11
As your instructor demonstrates this procedure, follow along with

the following examples in the associated job aid(s).
Determining I/O Addresses

From inspecting the module and module label, the following
information is evident:
The I/O rack number is 1.
The I/O group number is 3.
The output terminal point is 11.

The complete address is O:013/11.
A
0
1
2
3
4
5
6
7
B
Rev. February 2007
A
10
11
12
13
14
15
16
17
B
Solenoid

AD1sb85r
4--14
Example

example?
Answer: I:054/13

The input terminal point is 13.

The complete address is I:054/13.
Rev. February 2007

AD1sb85r
Example

example?
Answer: I:054/17
4--15

The input terminal point is 18 but functions as input 17.

Use the following examples to

demonstrate determining an I/O address
using the DIP switches.
Rev. February 2007

AD1sb85r
4--16
Example
From inspecting the module and chassis and from determining the
DIP switch settings, the following information is obtained:
The first I/O group number is 0, so the I/O group number is 5.
example?
Answer: I:145/15

Pressed in at Top:
Closed (on)
Open (off)
Input Terminals
Input Terminals
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
Rev. February 2007

AD1sb85r
Example
4--17

example?
Answer: I:061/17
From inspecting the module and chassis and from determining the
DIP switch settings, the following information is obtained:

Pressed in at Top:
Closed (on)
Open (off)
A
0
1
2
3
4
5
6
7
B
Rev. February 2007
A
0
1
2
3
4
5
6
7
B

AD1sb85r
4--18
Rev. February 2007

AD1sb85r
4--19
Exercise: Identifying Memory

Layout in an RSLogix 5 Project
Exercise A
In this exercise, you will practice identifying processor data file

types.
aid(s).
Directions:
Match the following data file types in the left column with their
usage in the right column by placing the appropriate letter on the
blank next to the data file type.
Tip "
Data File Type
_______ 1. C -- Counter
There may be more than one data file usage for each data file type.
Data File Usage

A. Math instructions that require fractional accuracy
B. A place to store internal coils or relays
_______ 2. N -- Integer
C. Math instructions that will only be working with whole

numbers
_______ 3. B -- Binary
D. A location where the current number of cans in a case

would be found
_______ 4. F -- Floating Point
E. A location where bits can be shifted through a register
_______ 5. T -- Timer
F. Instruction addresses that cause something to happen

based on a duration
G. A data file to store precise temperature values ranging
from --40.0 to +500.0
H. A data file that will display how long parts have been
in a furnace
I. Instruction addresses that keep track of a quantity of
something
J. Data file that can be addressed anywhere from file 3 to
999
How Did You Do?
Rev. February 2007

AD1e85r
4--20
Exercise B
In this exercise, you will identify PLC-5 logical address formats.

aid(s).
Directions:
Write the logical addresses for the following descriptions:
Tip "
For reference, refer to the 1785 PLC-5 Programmable Controllers

Quick Reference.
1. Write the logical address of bit number 5 in word 2 in binary file
3:
2. Write the logical address of bit number 9 in word 4 in integer file

7:
3. Write the logical address of word 2 in integer file 9:
4. What is the file type and file number of F8:20?
5. What is the file type and file number of T4:7.DN?
How Did You Do?
Rev. February 2007

AD1e85r
Exercise C
4--21
In this exercise, you will determine I/O addresses assigned to I/O

modules and devices.
Context:
You have been asked to verify the I/O addresses assigned to some
field devices that have had a history of failure.
aid(s).
Directions:
Determine the I/O address for each of the following examples using
the PLC-5 Troubleshooting Guide.
1. Address = ____________________
R7
G4 G
A
0
1
2
3
4
5
6
7
B
Rev. February 2007
A
0
1
2
3
4
5
6
7
B
G4 G
Motor

AD1e85r
4--22
2. Address = ____________________
R 11
G2 G
A
B
C
D
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
E
A
B
C
D
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
E
G3 G
Solenoid
Rev. February 2007

AD1e85r
4--23
3. Address = ____________________
Pressed in at Top:
Closed (on)
Open (off)
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
Rev. February 2007
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17

AD1e85r
4--24
4. Address = ____________________
Addressing Mode
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
Pilot Light
Rev. February 2007

AD1e85r
4--25
5. Address = ____________________
Pressed in at Top:
Closed (on)
Open (off)
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
Solenoid
Rev. February 2007

AD1e85r
4--26
6. Address = ____________________
Pressed in at Top:
Closed (on)
Pressed in at Bottom
Open (off)
A
0
1
2
3
4
5
6
7
B
A
0
1
2
3
4
5
6
7
B
Rev. February 2007

AD1e85r
4--27
7. Address = ____________________
Pressed in at Top:
Closed (on)
Open (off)
How Did You Do?
Rev. February 2007

AD1e85r
4--28
Answers
Exercise A
1. D, I, J
2. C, J
3. B, E, J
4. A, G, J
5. F, H, J
Exercise B
1. B3:2/5
2. N7:4/9
3. N9:2
4. The file type is floating point and the file number is 8.
5. The file type is timer and the file number is 4.
Exercise C
1. O:074/15 or O:74/15. The output is wired to terminal 15 of an
output module in I/O group number 4 of I/O rack 7.
2. O:112/07 or O:112/7. The output is wired to terminal 7 of an
output module in I/O group number 2 of I/O rack 11.
3. I:133/01 or I:133/1. One-slot addressing is indicated from the
chassis backplane switch. The 1771-ASB module switch
indicates that the I/O rack is 13 and the starting I/O group
number is 0.
4. O:013/12 or O:13/12. One-slot addressing is indicated from the
Status file; therefore, the I/O rack is 1 and the I/O group for the
output module is 3.
5. O:045/15 or O:45/15. One-slot addressing is indicated from the
number is 4.
6. I:062/03 or I:62/3. Two-slot addressing is indicated from the
number is 0.
7. I:164/17. Half-slot addressing is indicated from the chassis
backplane switch. The 1771-ASB module switch indicates that
the I/O rack is 16 and the starting I/O group number is 0. The
module label indicates that terminal 18 functions as input 17.
Rev. February 2007

AD1e85r
Lesson
Monitoring and Entering Data

Using RSLogix 5 Software
What You Will Learn
? What situations at your workplace
require you to monitor or change data?

What methods do you typically use?
Given a computer configured for communications and RSLogix 5

projects on a network, you should be able to monitor and enter data
by performing these actions:
Determine processor status
Monitor data or enter data into a data file
Create and edit a CDM (custom data monitor) file

Monitor an I/O module and enter data
In order to troubleshoot a PLC-5 system, you need to be able to
quickly identify and reference data from data files. Referencing the
wrong data can result in increased downtime.
Before You Begin

Because this information was
introduced, in part, in the previous
lesson, offer a brief review of the types
of data files.
Briefly review the various data table file
types.
Review of Data File Types

Data files store the status information associated with I/O and all
instructions used in the main program and subroutine files. The
following data file types are available for a PLC-5 processor:
File Type
File Number
(Reserved)
Data Stored
O--Output
State of output terminals
I--Input
State of input terminals
S--Status
Controller operation information
B--Binary
Internal relay logic
T--Timer
Timer accumulator, preset, and status values
C--Counter
Counter accumulator, preset, and status

values
R--Control
Length, position, and status of application

specific instructions
N--Integer
Positive or negative whole numbers
F--Floating Point*
Positive or negative numbers that include the

decimal point
A--ASCII*
ST--ASCII Strings*
D--BCD*
None
Alphanumeric characters
Binary coded decimal
*PLC-5 enhanced processors only.
Rev. February 2007

MONsb85r
5--2
Processor Status
Point out that the type of processor used
in your application will affect what can be
viewed and written to in the Processor
Status file.
The Processor Status file monitors the operating system and allows
for new status parameters to be entered. The Processor Status file can
be used to accomplish the following actions:
Monitor communications channels
Control loading memory from memory modules
Enter new status parameters

Monitor hardware and software faults
Monitor scan times
Note that fields shown in white are
read/write and fields grayed out cannot
be written to.
The Processor Status file is shown in the following graphic:
Read/Write Field
I/O Status
From the Main status tab, information can be gathered on how the
operating system works. An I/O status file can be used to store the
reset and fault bits for each remote I/O rack.
Interrogate the Errors tab of the status file when the processor faults
to determine the cause of the error:
Errors Tab
Watchdog Timer
Error Code
Information
Button to Clear Error
Rev. February 2007

MONsb85r
5--3
Data File Monitoring or Entering

Although troubleshooting circumstances
will vary widely, underscore the
importance of seeking information from
the data files during troubleshooting.
Examples:
Bar codes are typically in the binary
radix.
We usually count in the decimal system.
Computer memory addresses use
hexadecimal.
Depending on operator preference, data in a data file can be

monitored or entered through different number systems.
Radix: A fundamental (base) number of any system.
The radix refers to the data display available for each digit of a
number in a numbering system. For example, in the decimal
(base 10) system, 10 characters, 0 to 9, are available for each digit.
The following table compares different radices:
Radix
Available Characters
Example
Binary
0 or 1
0000 0011 1101 1101
Octal
0 to 7
1735
Decimal
0 to 9
989
Hexadecimal
0 to F
3DD
Binary Coded Decimal
0 to 9
8739
ASCII
256 character set
\03\DD
The following graphic shows a bit file with a binary radix:
Radix
The same bit file is shown with hexadecimal radix:
Radix
Rev. February 2007

MONsb85r
5--4
Monitoring an I/O Module

Point out the importance of this feature
as a troubleshooting procedure, in that
valuable diagnostic information can be
easily gained.
Monitoring I/O modules is accomplished through viewing dialog

boxes that are initiated from the Controller folder of the project tree.
Information, such as chassis type, I/O addressing, and descriptions
for each module, can be obtained by selecting the appropriate dialog
box.
Monitoring an I/O module is possible only if the
relevant I/O module is already documented. It is
typically the programmers responsibility to
document I/O modules.
Rev. February 2007

MONsb85r
Inform students that pressing [F1] on the

keyboard will display online Help
information about any task that is being
attempted while using RSLogix 5
software.
5--5
Examples of I/O monitor dialog boxes are shown in the following

graphic:
Addressing Information
Descriptive Information
for Specific I/O Module
Rev. February 2007

MONsb85r
5--6
CDM (Custom Data Monitor)

Point out that a CDM list can be very
useful in monitoring a specific segment
of a process.
A CDM is a list of bit and word addresses within a project. The list
can be used as a central reference for values and descriptions of the
entered addresses.
The following specifications apply to a CDM:
CDM lists can contain bit addresses, element addresses, and
sub-element addresses.
CDM lists can contain ASCII comments to help clarify bit
listings. (ASCII comments are shown in yellow in the CDM list.)
Each project can have up to 256 (CDM) lists per project
(0 to 255), with the default being 0.

Addresses can be moved (clicked and dragged) from the data
tables or the ladder logic to the CDM.
An example of a CDM is shown in the following graphic:
ASCII Comment
Rev. February 2007

MONsb85r
Heres How
Demonstrate the following actions:
1. Open the Processor Status file (Data
File S2 -- STATUS).
5--7
To determine the processor status.

As your instructor demonstrates, follow along in the associated job
aid(s).
2. In the Processor Status file, review

the tabs that typically determine the
processor status.
3. Click the Errors tab to show where
information can be located when
troubleshooting a fault.
Heres How
Demonstrate the following procedures:
1. Go online to the
CCP412_1785r_DEM1.rsp project.
To monitor data or enter data into a data file.

As your instructor demonstrates, refer to the associated job aid(s) for
the following examples.
2. To activate program file 3, in N10:0,

enter a 3.
" The project contains a CDM for easy
access to N10:0.
3. Display program file 3.
Example
1. Display the Input image file and the
Output image file dialog boxes.
2. Turn on pushbutton 16, which
latches on light 17, and correlate the
change in data values in the image
files.
3. Turn on pushbutton 17, which
unlatches light 17, and correlate the
change in data values in the image
files.
Monitoring Discrete Input and Output Data

The following graphic shows an example of discrete input and output
data in the input and output data tables. In the example, note the
following relationships:
When switch I:002/16 is closed, a value of 1 is entered into the
input data table.
When switch I:002/16 is opened, a value of 0 is entered into the
input data table.
When pushbutton I:002/17 is pressed, light O:003/17 is
illuminated and a value of 1 is placed in the output data table.
4. To display which bits are used in the

project, in the image file dialog box,
click the Usage button.
5. Turn off pushbuttons 16 and 17.
6. Toggle on and toggle off any bit.
Rev. February 2007

MONsb85r
5--8
Example
1. Determine the address of analog
input 1.
2. In RSLogix 5 software, display the
Input data file in the decimal radix.
3. Turn the input and point out the
change in data.
4. Repeat for analog output 1. The
output can be varied using analog
input 1.
Monitoring Analog Input and Output Data

The following graphic shows an example of analog input and output
data in the input and output data tables. In the example, note the
following relationships:
The input device, a potentiometer, controls the output device, a
meter.
The data table address for the potentiometer is N24:4; the data
table address for the meter is N26:6.

When the potentiometer is turned, the values in N24:4 and N26:6
change.
5. In RSLogix 5 software, display the

N24 data file in the decimal radix.
6. Vary analog input and point out the
change in N24:4 and N26:6.
7. Be aware that the block transfer
supplied here is configured for 2-slot
addressing.
Rev. February 2007

MONsb85r
Rev. February 2007
5--9

MONsb85r
5--10
Heres How
To create and edit a CDM file.

aid(s).
1. In the project tree, right-click on the

open the CDM folder and create a
new CDM file.
2. Give the CDM file a title.
3. Add addresses and descriptions to
the newly created CDM to show
editing options
Heres How
To demonstrate:
1. Explain that this procedure will work
only if the programmer of the project
has documented the relevant I/O
module.
To monitor an I/O module and enter data.

aid(s).
Note: This procedure is not as

intuitive as others. It is fully
documented, however, in the
Procedures Guide.
2. Access the adjacent 1771--OBD
dialog box.
3. In the Value column, enter a 0 or 1 in
the Value column to turn a light off or
on.
Rev. February 2007

MONsb85r
5--11
Exercise: Monitoring and Entering

Data Using RSLogix 5 Software
Exercise A
In this exercise, you will practice monitoring and entering data using
RSLogix 5 software.
Context:
A PLC-5 processor is showing a fault at powerup. You have the
responsibility to determine the processor status and to clear the error.
In addition, you must change the presets on some timers and
counters and create a CDM that will provide easy monitoring of the
data.
Finally, you have noticed an I/O point that you suspect is faulty. You
feel that, while the system is down, this is a good time to verify that
the signal from the device is being detected by the processor.
aid(s).
Directions:
1. Open the MON_1785r_A1.rsp project.
2. Download the project to the PLC-5 processor
3. Go online to the PLC-5 processor, and set the PLC-5 processor in
Run mode.
4. Examine the processor status file:
A. Which tab of the processor status file presents information
about DH+ Station number and addressing mode?
B. Which tab presents information about faults and major

errors?
C. Under the Errors tab, what value is given for the watchdog
set point?
Rev. February 2007

MONe85r
5--12
5. Within the appropriate data files, change the following timer and
counter presets to the values specified in the table:
Timer/Counter
Preset
T4:0
200
T4:2
400
T4:4
200
C5:3
300
6. Close the data files and verify that any two of the changes you
made appear in the instructions of the ladder logic program.
7. Create a CDM named Timer/Counter Edits that includes all of the
timer and counter addresses that appear in the above table.
Tip "
To view the complete address structure of a timer or counter, click

next to the base address (e.g., C5:3) within the CDM.
8. Start the project by completing the following steps:
A. Enter 1888 at the thumbwheel (digital input 1).
B. Press I:002/4 to start the paint line.
C. Press I:002/5 to enter the paint order.
D. Press I:002/0 to load the recipe.
E. Press I:002/1 to load the colors and initiate the operation.
9. Monitor the dynamic values of T4:4 in the CDM.
10. Use the CDM to change the value of T4:4.PRE to 500.
11. Enter a description for the changed T4:4 value and observe that
the description takes effect in the ladder logic.
12. Monitor the I/O module in I/O group number 2 of your chassis,
the input module for the pushbutton switches.
13. Turn the switches on and off and observe how the changes in
state (on or off) are reflected in the monitor window values
(1 or 0).
14. Monitor the I/O module in I/O group number 3 of your chassis,
the output module for the lights.
15. Verify the correlation between the state of each light (on or off)
and the value in the monitor window (1 or 0).
16. Close the file without saving it.
How Did You Do?

Rev. February 2007

MONe85r
Rev. February 2007
5--13

MONe85r
5--14
Answers
Exercise A
4. After examining the processor status file, you should see the
following results:
A. The Switches tab of the processor status file presents
information about DH+ Station number and addressing
mode.
B. The Errors tab presents information about faults and major
errors.
C. The watchdog set point is set at 500 ms.
11. After entering a description in the CDM, you should notice the
change in the ladder logic:
Rev. February 2007

MONe85r
Lesson
Interpreting Bit Instructions Using

RSLogix 5 Software
What You Will Learn
After completing this lesson, you should be able to interpret bit

instructions by performing the following tasks:
Determine logic continuity
Interpret bit instructions

To troubleshoot the state of input devices, such as pushbuttons and
limit switches, and to control machine/process output devices, such
as motor starters and valves, you have to be able to interpret bit
instructions and understand rung continuity.
Before You Begin
Processor Operating Cycle

The processor operating cycle, or program scan, determines the order
in which the elements of ladder logic are processed. The following
graphic shows main elements of the processor operating cycle:
Mention that during the input scan, the

on/off status and signal levels of
input devices are read from the
Processor Housekeeping:
input modules and are written into
the input image table.
Status file update is
performed.
Note that internal housekeeping
also includes updating the
Communications:
timebase and performing
Communication
with
the program pre-scan.
other devices is
performed.
Input Scan:
Input modules are read.
Logic Scan:
Program file 2 is executed.
Output Scan:
Output data is sent to
output modules.
Rev. February 2007

BI1sb85r
6--2
Data concerning outputs is written only to the data

table during the program scan. Physical outputs
are not actually updated until the output scan.
Mention that in PLC-5 processors, basic

housekeeping takes 3.5 ms. If it takes
the processor 21.8 ms to execute a
ladder logic program, the overall
program scan time is 25.3 ms. Any
increase in housekeeping affects the
program scan.
If no change in input status occurs and the processor continues to

execute the same ladder logic instructions, the processor operating
cycle is consistent. Under true operating conditions the processor
operating cycle fluctuates due to the following factors:
False logic executes faster than true logic.
Different instructions execute at different rates.

Different input states cause different sections of ladder logic to be
Mention that this is not an inclusive list
and that there are many variables for
each section of the program scan.
executed.
Editing programs while online affects housekeeping times.
Rung size and the number of branches also can cause scan time to
fluctuate.
Ladder Logic
? When is ladder logic evaluated?
Answer: During the program scan,

which falls between the actual reading of
inputs and the change in outputs.
The programming language used to create programs to control

PLC-5 systems is known as ladder logic. There are three basic
organizational elements associated with ladder logic:
Rungs
Instructions
Branches
Rungs
Point out that although ladder logic looks
like an electrical diagram, it depicts the
flow of logic not electricity.
Ladder logic instructions are written on rungs. During the program

scan, the processor scans each rung from left to right, one rung after
the other, as shown in the following graphic:
0000
0001
0002
Rev. February 2007

BI1sb85r
6--3
When interpreting rungs, keep these key points in mind:

Rungs are scanned from zero to the highest number (top to
bottom).
Rungs are read from left to right.

A new rung is automatically numbered according to where it is
placed in the ladder logic file.

The last rung in a ladder logic file automatically contains an END
instruction.
Instructions
Explain that as each conditional
instruction is executed, the addressed
bit is examined to see if it matches a
certain condition (on or off). If a
complete path of true conditions
examined are found, the rung is set to
true. The rung must contain a
continuous path of true instructions from
the start of the rung to the output for the
output to be enabled.
A ladder logic rung is divided into two parts:

Input instructions:
-- Displayed on the left side of the rung

-- Check, compare, or examine specific conditions
Output instructions:
-- Displayed on the right side of the rung
-- Take some action
An example of a ladder logic rung, with input instructions and output
instructions, is shown in the following graphic:
Input Instructions
Output Instructions
Mention some of the categories of

instructions including, bit, timer, counter,
math, data handling, and comparison.
When interpreting instructions, keep these points in mind:

Input instructions are displayed on the left side of the rung while
output instructions are always displayed on the right side of the
rung.
A rung does not need to contain any input instructions, but it must
contain at least one output instruction.
Input instructions examine the state of data in the data files.
Because of this, it is possible to use the same piece of data
multiple times in one program. Thus, the state of one input device
may affect several outputs.
Review the differences between

hardware relay and ladder logic.
Mention that this is referred

to as the true-rung rule.
Tip "
If there is a path of true input instructions, the rung is true and the
output occurs.
Last Rung Wins
Mention that when troubleshooting a

project, if an output is not turning on (or
off) as expected, one of the first things to
consider is the Last Rung Wins rule.
Rev. February 2007
If two or more output instructions reference the same bit or word in

the data table, the action of the last output instruction is the one seen
by the corresponding output module. This fact is commonly referred
to as the Last Rung Wins rule.
BI1sb85r
6--4
Example: Last Rung Wins Rule

Suppose in a given program scan an output instruction in rung 5
sets O:003/2 to 1. Suppose in the same program scan an output
instruction in rung 23 sets O:003/2 to 0. At the end of the
program scan, O:003/2 is 0.
The state of an output can be examined as an input condition for a
rung by having an input instruction reference an outputs address.
Example: Output States as Input Conditions
The following graphic shows an example of a rung of ladder logic
that uses the state of another rungs output as an input condition.
1
( )
] [
] [
Tip "
] [
] [
( )
AND logic is used when all conditions that make the rung true are on
the same level in a side-by-side series.
Branches
Explain that a branch creates an

alternate route for the processor. If one
instruction is false the processor can
bypass the instruction.
Branches are used in ladder logic to create different paths that direct
the reading of the conditional inputs and outputs, as shown in the
following graphic:
Branch
Parallel Branch
] [
] [
] [
] [
] [
] [
] [
Mention that OR logic is used when
more than one condition can make a
rung true.
Nested Branch
] [
] [
] [
] [
When interpreting branches, keep these points in mind:

Branches are read from left to right, top to bottom.
A branch can be used to create a different path for reading inputs
or programming multiple outputs.
A parallel branch has the same start and same end point as the
branch it is below.
A nested branch starts and ends inside the same branch
(maximum of 4 nested branches).
Tip "
OR logic is used when any one of the conditions that may make the
rung true are on separate branches of a rung.
Rev. February 2007
BI1sb85r
Example: If a piece of equipment, such

as a conveyor, experiences a power loss
and you do not want the conveyor to
automatically restart when power is
restored, you could use seal-in logic to
prevent this from happening.
6--5
Example: Start/Stop Circuit

The following graphic shows an common example of branching,
where seal-in logic is used to start or stop a motor or process or to
enable or disable some function:
1
] [
] [
( )
] [
Tip "
Seal-in logic is often used to prevent an automatic restart after power

loss.
Logic Continuity
As the processor scans a rung, it looks at each input instruction to
determine which are true and which are false:
If there is . . .
Then the rung is said to be . . .
A path of true input instructions
True or have logic continuity.
Not a path of true input instructions
False or have no logic continuity.
Mention that if a rung is true, an output

instruction on the rung might specify that
a motor be started. If the rung is false,
the same instruction might specify that
the motor be turned off.
The logic continuity of a rung is used to determine the states of the

output instruction(s) on the rung.
Mention that most output instructions are

active when the rung they are on is true
and no other rungs of ladder logic in the
project inhibit them.
The following graphic shows examples of rungs with and without

logic continuity:
Whether a given input instruction is true or false

depends on its rules for interpreting the status of
the bit or word that the instruction corresponds to
in the processors memory.
Logic Continuity
No Logic Continuity
Rev. February 2007

BI1sb85r
6--6
Bit Instructions
Point out that the address of an output

instruction can be used as a conditional
instruction.
Mention that bit instructions are also
referred to as relay instructions.
Bit instructions are ladder logic instructions that examine or change a

single bit of data in the data files. There are three types of bit
instructions:
Conditional input instructions
Non-retentive output instruction
Retentive output instructions

Conditional Input Instructions
These instructions are used to examine specific conditions:
Instruction
ONS Example: When a user presses a

pushbutton, that input will be closed for
several program scans. To limit the input
to one scan, an ONS is used.
Depending on students interest,

highlight the difference between an OSR
and OSF instruction:
An OSR instruction is used when an
event must start based on the change of
state of the rung from false to true.
An OSF instruction is used when an
event must start based on the change of
state from true to false.
Note that OSR and OSF instructions
only are available for enhanced PLC-5
processors.
Function
Name
Mnemonic
Symbol
Examine If Closed
XIC
] [
Examines a bit for an on (1)

condition. If the bit is on, the
instruction is true.
Examine If Open
XIO
]/[
Examines a bit for an off (0)

condition. If the bit is off, the
instruction is true.
One-Shot
ONS
[ONS]
When the conditions preceding the

instruction are true, makes the
rung true for one program scan.
Non-Retentive Output Instruction

This instruction produces a specific output if the rung is true:
Instruction
Name
Output Energize
Mnemonic
Symbol
OTE
( )
Function
If the rung is true, turns on a bit.
When the rung goes false or a
power cycle occurs, the bit turns
off.
Retentive Output Instructions

These instructions change the value of the bits they correspond to
when the rung they are on is true:
Instruction
Name
OTL Example: A cooling pump might be

latched on so that it automatically
restarts after a power failure.
Note that OTL and OTU instructions
maintain their state even when the rung
goes false or a power cycle occurs.
Output Latch
Output Unlatch
Mnemonic
OTL
OTU
Symbol
Function
(L)
If the rung is true, turns on a bit.

When the rung goes false, it does
nothing; therefore, the output
remains as is.
(U)
If the rung is true, turns off a bit.

When the rung goes false, it does
nothing; therefore, the output
remains as is.
Rev. February 2007

BI1sb85r
Heres How
1. Go online to the
enter a 3.
6--7
To interpret bit instructions by performing the following tasks:

Determine logic continuity

As your instructor demonstrates these procedures, refer to the
following examples:

access to N10:0.
4. Toggle inputs on and off and point
out the changes in continuity.
" Display the input and output data
files as you toggle switches on and
off and correlate data values to the
true/false states of instructions.
" Point out that the XIC and XIO
instructions examine the existing
state of a device, regardless of
whether it is normally open or
normally closed.
Example
Go online with the
CCP412_1785r_DEM1.rsp, project, and
display rung 0. Discuss the behavior of
the two instructions.
Example
In the CCP412_1785r_DEM1.rsp
project display rung 1. Discuss the
behavior of the two instructions.
? Why is the XIO instruction

highlighted?
Answer: I:002/0 has a value of 0.
Rev. February 2007
Interpreting XIC and OTE Instructions

The following graphic shows an example of an XIC instruction
paired with an OTE instruction. In this example, note the following
conditions:
When I:002/0 has a value of 1, rung 0 is true. When I:002/0 has a
value of 0, rung 0 is false.
When rung 0 is true, the OTE instruction sets O:003/0 to 1. When
rung 0 is false, the OTE instruction sets O:003/0 to 0.
Interpreting XIO and OTE Instructions

The following graphic shows an example of an XIO instruction
paired with an OTE instruction. In this example, note the following
conditions:
When I:002/0 has a value of 1, rung 1 is false. When I:002/0 has
a value of 0, rung 1 is true.

BI1sb85r
6--8
Example
Display rung 2 and discuss logical
continuity in regard to an OTE on a rung
by itself.
Interpreting OTE Instructions

The following graphic shows an example of an OTE instruction on a
rung by itself. In the example, note the following conditions:
As long as the processor is in Run mode, rung 2 is true.
When the project is not being scanned the rung is false.
Example
Add an ONS instruction to a rung.
Discuss the effect this has on the rung.
Make the XIC instruction in the rung a
pushbutton to show a common
application.
Example
Go to rungs 3 and 4 and review the OTL
and OTU instructions.
Point out that OTL and OTU instructions
typically do not control real-world
devices.
Interpreting ONS Instructions

The following graphic shows an example of an ONS instruction. In
the example, note the following conditions:
When I:002/14 transitions from 0 to 1, rung 5 goes true for one
program scan.
Because of the ONS instruction, rung 5 can only be true for one
program scan following a 0 to 1 transition of I:002/14.
Interpreting OTL and OTU Instructions

The following graphic shows an example of the OTL and OTU
instructions. In this example, note the following conditions:
When I:002/1 transitions from 0 to 1, rung 3 goes true and the
OTL instruction sets O:003/3 to 1.
When I:002/1 transitions from 1 to 0, rung 3 goes false; however,
this has no effect on the OTL instruction and thus no effect on
O:003/3.
When I:002/4 transitions from 0 to 1, rung 4 goes true and the
OTU instruction sets O:003/3 to 0.
Because of the Last Rung Wins rule, if both I:002/1 and I:002/4
are 1, O:003/3 is 0.
Rev. February 2007

BI1sb85r
Example
Go to rung 7 and review the seal-in
logic.
Point out that OR logic is used when

more than one condition can make a
rung true.
Example
In the CCP412_1785r_DEM1.rsp
project, go to rung 8 and review the
branching, the AND and OR logic, and
the different instructions.
6--9
Interpreting Start/Stop Circuit

The following graphic shows an example of bit instructions used in
combination to seal-in the output. In this example, note the
following conditions:
Both an input instruction and an output instruction use O:003/5.
Once rung 7 goes true, the only way it can go false is for I:002/2
to transition from 1 to 0.
Interpreting Branching
The following graphic shows an example of how branching can be
used. In this example, note the following conditions:
When rung 8 is true, O:003/15, and O:003/7 are set to 1.
In order for rung 8 to be true, I:002/0 and I:002/12 must be true,
and either I:002/1, I:002/2, I:002/3, I:002/10, or I:002/11 must be

true.
Rev. February 2007

BI1sb85r
6--10
Rev. February 2007

BI1sb85r
6--11
Exercise: Interpreting Bit

Instructions Using RSLogix 5
Software
Exercise A
In this exercise, you will practice determining logic continuity.

aid(s).
Directions:
Review the following ladder logic and answer the questions in the
spaces provided:
1. When will the output on rung 0 be on?
2. Can the output on rung 0 and on rung 1 be on at the same time?

Why or why not.
Rev. February 2007

BI1e85r
6--12
3. Explain the purpose of using O:003/12 on the input side of

rung 2.
How Did You Do?
Exercise B
In this exercise, you will practice interpreting bit instructions using

RSLogix 5 software.
Context:
You need to interpret the start-stop section and the status information
on the programming terminal to determine if the paint mixing line is
functioning properly.
Tip "

Directions:
Open the BI1_1785r_B1.rsp project and answer the following
questions:
1. What condition or conditions must be met before the output on
rung 1 can go true?
2. If rung 1 goes true, what will happen to the output B3:0/0 when
input I:002/04 is allowed to go false and all other conditions
remain true?
3. Input B3:0/0 is being used as what common purpose?
4. The ONS using B3:0/1 on rung 4 requires what conditions to

occur before the outputs will energize?
Rev. February 2007

BI1e85r
6--13
5. What must happen for the outputs on rung 4 to energize a second

time?
6. Will outputs O:003/06 and O:003/07 on rungs 31 and 32 be true

at the same time?
Why or why not?
How Did You Do?
Rev. February 2007

BI1e85r
6--14
Answers
Exercise A
1. O:003/10 will be true (on) when I:002/11 is on and I:002/00 is
off.
2. No. I:002/00 is off for O:003/10 and I:002/00 is on for
O:003/12.
3. Using O:003/12 on the input side of rung 2 demonstrates the
ability to examine the output of one rung in order to control
another rung of logic.
Tip "
You can check your answers by running program

BI1_1785r_A1.rsp.
Exercise B
1. Rung 1 -- output B3/0 will be true (on) when I:002/04 and
I:002/07 are on and O:003/16 is off.
2. Output B3/0 will remain on.
3. Input instruction B3/0 is being used as a holding (seal-in)
contact.
4. MACHINE_RUN must be off and MANUAL_LOAD must be
closed.
5. Either MACHINE_RUN has to turn on and then off, or
MANUAL_LOAD must open and then close.
6. No, input I:002/10 is examined off for rung 31 and examined on
for rung 32.
Rev. February 2007

BI1e85r
Lesson
Editing Ladder Logic Using

RSLogix 5 Software
What You Will Learn
? At your company, who determines
when a project requires editing? Who

writes the edits? Who makes the actual
edits to the project?
Before You Begin
? How are you notified of changes to a

project?
After completing this lesson, you should be able to edit ladder logic
by performing the following tasks:
Enter and edit ladder logic instructions
Verify ladder logic

RSLogix 5 software has many features that can make entering,
editing, and verifying ladder logic very easy. Being able to take
advantage of the edit features can save time and effort when editing
is required.
Offline vs. Online Editing

Ladder logic may be entered, edited, and verified while either online
or offline. Online editing allows you to monitor and correct a ladder
logic program when a programming terminal is connected to a
PLC-5 processor. Because of the editing restrictions and safety
precautions associated with online editing, editing offline is safer,
easier, and faster to perform.
Online Editing Restrictions
The following options are available when making online edits, if the
PLC--5 processor is in Program or Remote Program mode:
Create, resize, or delete data files
Create or delete program files
Rev. February 2007

EL1sb85r
7--2
Safety Precaution
Entering and editing ladder logic while online can cause dangerous
situations:
Use extreme caution when entering or editing
ladder logic or data, forcing I/O bits, toggling I/O
bits, or making other changes online that will affect
the control of devices. Mistakes can cause
unintended machine motion or loss of process
control, injuring personnel and damaging
equipment. Before performing procedures online,
complete these safety precautions:
Determine if the changes must be made online.
Verify that your company permits online entering
and editing.
Assess how machinery will respond to changes.
Check the proposed changes for accuracy.
Notify all personnel of the changes.
Verify that you are online to the correct processor.
Edit Zone Markers

Emphasize that lowercase edit zone
markers indicate that edits exist only in
computer memory, while uppercase edit
zone markers indicate that edits exist in
processor memory.
Tip "
RSLogix 5 software places zone markers in the margin to the left of

the left power rail to signify edit zones. The following table outlines
the zone markers used by the RSLogix 5 software:
This marker . . .
Marks a rung that you are . . .
Entering or editing
Inserting into the project
Replacing by marking the preceding rung with an i or e
Deleting from the project
Upper-case edit zone markers apply only to online editing in the

Remote Run mode. When edits are accepted, lower-case i and r
markers change to upper-case markers.
Rev. February 2007

EL1sb85r
7--3
Verifying Ladder Logic

Note that RSLogix 5 software offers
several options for verifying a project.
After ladder logic has been entered or edited, the edits can be
validated using the verification process in RSLogix 5 software. In
this process, RSLogix 5 software identifies any of the following
entry errors:
Improper instruction placement
Improper or incomplete addressing
Empty rungs
Shorted branches
Parsed symbols
A program that contains errors will not download.
The verification process requires different steps in different modes.

The following table compares the sequence of actions you must
perform when in the different processor modes:
After Editing . . .
Heres How
You must perform the following actions . . .
Offline
Make edits
Verify
Save
Online in the Remote Program mode
Right-click the rung number to be edited:

From Edit menu, select Start rung edits
Edit the rung to be modified.
Select Verify/Accept from the Edit menu
Online in the Remote Run mode
Right-click the rung number to be edited:

From Edit menu, select Start Rung Edits
Edit the rung to be modified
From Edit menu, select Accept Rung Edits
From Edit menu, select Test Rung Edits
From Edit menu, select Assemble Rung Edits
To edit ladder logic by performing these actions:

Enter and edit ladder logic instructions
1. Open CCP412_1785r_DEM1.rsp
project offline.
Verify ladder logic
2. Using your own examples, enter and

edit ladder logic.

3. Download the project and go online.

edit ladder logic.
?What are the differences between

offline and online editing?
? If you edit a project online, what do

you have to do to update the offline
project?
Rev. February 2007

EL1sb85r
7--4
Rev. February 2007

EL1sb85r
7--5
Exercise: Editing Ladder Logic

Exercise A
In this exercise, you will practice editing ladder logic.

Context:
You have been asked to enter the edits in a program using a printed
markup of the ladder logic changes to the program. Once you have
completed the edits, you need to download the project and verify that
it operates correctly.
aid(s).
Directions:
1. Open the EL1_1785r_A1.rsp project.
2. While offline, use the instruction palette and instruction toolbar to
make the following edits to program file 2:
3. Verify the edits.

4. Save the changes you have just made and add a revision note .
How Did You Do?

Rev. February 2007

EL1e85r
7--6
Answers
Exercise A
After completing the edits, the ladder logic should appear as shown
in the following graphic:
Rev. February 2007

EL1e85r
Lesson

What You Will Learn
After completing this lesson, you should be able to document an

RSLogix 5 project by performing the following tasks:
Enter and edit a page title or rung comment
Document an address
Create, assign, and edit addresses and symbols using
the Address/Symbol Editor
? Who documents your projects?
When is the documentation added?
Documenting a project with clear descriptions and comments will

help the troubleshooter quickly identify relevant sections of the
ladder logic.
When elements of the ladder logic are poorly documented, downtime
will increase during troubleshooting.
Before You Begin
Documentation Options
Mention that project documentation is a

large part of any ladder logic project.
Project documentation provides a quick description of a group of

rungs, a single rung, or an address.
An RSLogix 5 ladder logic project can contain the following
documentation:
Page Title
Rung Comment
Address
Description or
Instruction
Comment Area
Symbol
(Address Symbol)
Rev. February 2007

DC1sb85r
8--2
? How can page titles be used?

Example: In a certain packaging line,
the product is flipped over as it moves
along the conveyor system. If the
flipping operation malfunctions, page
titles help the troubleshooter quickly
identify the relevant section of ladder
logic.
Mention that any symbol or

description associated with an
I/O bit address can be changed
from the data file.
The following documentation can be added to an RSLogix 5 project:

To . . .
Then enter a . . .
Label and separate the function of a group of

rungs
Page title
Describe the function of a specific rung or group

of rungs
Rung comment
Describe the function of an address regardless of

the instruction with which it is used
Address description
Describe the function of a specific address and

instruction combination
Instruction comment
Use a string of alphanumeric characters to label

an address
Symbol
Tip "
A single address can have both an address description and an

instruction comment assigned to it; however, instruction comments
take precedence over address descriptions.
Tip "
All documentation is stored in computer memory and is not

downloaded to the PLC 5r processor.
The View Properties dialog box controls how
documentation is displayed. The display can be
configured to show or hide documentation.
Example: Symbol
In the following example, an instruction is labeled with an
address and a symbol of not more than 20 characters:
Mention that symbol names are
determined subjectively. There are no
right or wrong choices.
Symbol
PUSH_BUTTON_5
I:003/3
] [
Point out that symbols, such as

MOTOR_1 or ZONE_3 fan, are typically
easier to remember and identify than the
actual addresses.
Address
( )
Address/Symbol Editor
Addresses and symbols can be created, assigned, and edited by using
the Address/Symbol Editor dialog box located in the Database folder
of the Project tree.
Mention that you can select addresses

and symbols from the database and
drag them to the instructions you
program in the ladder logic.
Address/Symbol Editor: A database that keeps records of addresses

and symbols.
Rev. February 2007

DC1sb85r
8--3
The following examples show symbols and addresses assigned in the

Address/Symbol Editor:
Point out the addresses and symbols,
reinforcing the idea that symbols are
easy to identify.
Tip "
Heres How
Note that the Address/Symbol database (as with other databases) is

not stored in the processor. It resides in computer memory only. If
you upload a project to a new computer, it will have no symbols.
2. Point out an example of each type of

documentation.
To document an RSLogix 5 project by performing these actions:

Enter and edit a page title or rung comment
Document an address
Create, assign, and edit addresses and symbols using
the Address/Symbol Editor
3. Show how to turn on and off the

display of documentation.


1. Open the
4. Using your own examples, enter

documentation.
5. Open the Address/Symbol Editor.
6. Add, delete, and edit various
addresses and symbols.
Rev. February 2007

DC1sb85r
8--4
Rev. February 2007

DC1sb85r
8--5
Exercise: Documenting an
RSLogix 5 Project
Exercise A
In this exercise, you will practice documenting an RSLogix 5

project.
Context:
To ensure efficient troubleshooting in the future, the
DC1_1785r_A1.rsp project requires additional and updated
documentation. You have been supplied with the relevant project
documentation updates, which you must enter to the project. Once
you have completed the edits to the documentation, you will then
need to download the project and verify that it operates correctly.
Tip "

aid(s).
Directions:
1. Open the DC1_1785r_A1.rsp project.
2. Add the following page titles to the specified rungs:
File Number:Rung Number
Page Title
2:5
RECIPE LOADING SECTION
2:29
LID INSTALLATION SECTION
2:33
PALLET SECTION
3. Add the following rung comments:

Rung Comment
2:26
This timer turns the pump off for 5 seconds
2:27
Activates mixer for 15 seconds
2:32
Reset Reject Counter
4. Add the following address descriptions:

File Number:Rung
Number
Rev. February 2007
Address
Description
2:26
T4:6
Pump Off Delay
2:30
C5:1
Reject CTR

DC1e85r
8--6
5. Add the following instruction comments:

File Number:Rung
Number
Address
Instruction
2:13
N16:0
EQU
Recipe Transfer
2:29
C5:1/DN
XIO
Reject Counter
Comment
6. Assign the following symbols:

File Number:Rung
Number
Address
2:15
B3:0/0
COLOR_DONE
2:24
B3:0/3
MACHINE_RUN
2:29
I:002/10
CAN_FULL
Symbol
7. Use the Address/Symbol Editor to add the following address

descriptions:
Address
Description
C5:1
Counts Rejects
I:002/6
Reject
How Did You Do?
Rev. February 2007

DC1e85r
Rev. February 2007
8--7

DC1e85r
8--8
Answers
Exercise A
7. After you edit the description of the instruction in the
Address/Symbol Editor, you will see the change take effect in
the ladder logic:
Repeat for
I:002/6
Rev. February 2007

DC1e85r
Lesson
Searching Ladder Logic Using

RSLogix 5 Software
What You Will Learn
After completing this lesson, you should be able to search ladder

logic by performing the following tasks:
Search for and replace instructions, symbols, or addresses
Search ladder logic using Advanced Diagnostics
Search using the Go To function

Generate a cross-reference report
Trace ladder logic
? Is any one using search functions in

their current responsibilities?
Before You Begin
Searching ladder logic for occurrences of a specific instruction or

logical or symbolic address within an RSLogix 5 project is essential
for efficient and accurate troubleshooting when that instruction or
address is suspect. When search options are not used, locating and
troubleshooting errors in ladder logic can become a time-consuming
and inaccurate process.
Search Options
Mention that the search options are

useful tools to the troubleshooter, and
that these skills will be used in future
lessons.
Search options highlight specific information for quick and accurate

referencing during the troubleshooting process. Some overlap in
functionality exists among the search options.
Explain that each of these options is an

effective search tool, but some options
may have more utility based on specific
troubleshooting applications.
The following table outlines the search options available in the

RSLogix 5 software:
Then Use This Search
Option:
To:
Explain that the format of the address

does not interfere with the search
functions (e.g., B3/17 gives the same
result as B3:1/1).
Rev. February 2007
Locate and display the next occurrence of a specified

address, symbol, or instruction
Locate all occurrences of a specified address, symbol,
or instruction and list them in a Results window
Locate edit zones
Find
Locate a specified address, symbol, or instruction and

replace it with a different address or instruction
Replace
Locate an output instruction using project

documentation
Advanced Diagnostics
Locate a program file rung, data file, cross-reference,

or address/symbol
Go To
Cross-reference an address or symbol
Right-click an address or
symbol in the Ladder window
SL1sb85r
9--2
Find Search Option

Find Search Option: A dialog box in RSLogix 5 software that
allows a user to locate defined instructions, addresses, symbols, and
edit zones in ladder logic.
A searched object is highlighted in the Ladder window when it is
found.
The following example shows the Find dialog box:
Find Options
Tip "
A quick search for a symbol can be performed by typing the first few
characters of a symbol in the Find What text box.
The following options and buttons are used with the Find dialog box:
Find: Used to enter or select the address, symbol, or instruction
for which you are searching.
Example: A Find All operation on T4:0

would display all occurrences of the
timer address including timer done bit
instructions and preset and accumulator
words.
Mention that Find All is also a menu item
from the right mouse button when the
cursor is on an instruction.
Mention that if the wrap box is not

checked, the search only looks from the
search point to the end of the file.
Find Next: Used to search for instructions one at a time.

Find All: Used to search every occurrence and every related
occurrence of the selected data file element.

Replace: Used to replace an instruction or address that has been
highlighted in the ladder logic. (Used with Find Next to examine
and replace one instruction at a time.)
Rung Zones: Used to to search for edit zones within the ladder
logic.
Scope: Used to specify the search parameters, either globally or
locally within the project.
Direction: Used to specify the search direction within the ladder
logic.
Wrap: Used to wrap from the search point to the beginning of
the file and back to the search point.
Rev. February 2007

SL1sb85r
9--3
Replace Search Option

Mention that the Find dialog box and the
Replace dialog box are very similar in
appearance and function.
Replace Search Option: A dialog box that allows an operator to

locate and replace defined instructions, addresses, symbols, and edit
zones in ladder logic.
Mention that the specific replace options

should be selected carefully, as the user
may not want all instances of an
instruction replaced. Students will need
to be selective and practice.
The following example shows the Replace dialog box.
Replace
Options
Tip "
Mention that additional information on
replace search options can be found
using online Help.
The Replace search option is not available when online to a

processor.
The following three replace options can be used to affect the
description database entries during replace operations:
Ignore: Used to skip over documentation and leave it unaffected.
Copy Descriptions: Used to change the description and symbol

documentation of a replaced item by using selected information
of the found item.
Move Descriptions: Used to move the description and symbol
documentation from the found item to the replaced item.
Rev. February 2007

SL1sb85r
9--4
Advanced Diagnostics Search Option

Mention that the user progresses
through three levels to complete the
Advanced Diagnostic search.
Advanced Diagnostics Search Option: A powerful method of

quickly locating and jumping to a specific ladder logic section or
block between page titles.
Mention that the ladder logic will display

the selected rungs under a page title
and all of the outputs on all of the rungs
contained between that page title and
the next page title. It also displays all
related documentation.
When initiated, the Advanced Diagnostics window opens over the

ladder logic. If page titles are used properly as section headers, the
selected item in the Advanced Diagnostics window also will be
highlighted in the ladder logic in three levels:
Program file
Section of ladder logic (identified by page title)
Specific rung
The following example shows the three levels of the Advanced
Diagnostic window:
Page Title
Target Rung
Program File To
Be Selected
Tip "
You cannot make changes to project documentation in any of the

windows displayed during an Advanced Diagnostics search. All
fields are read-only.
Rev. February 2007

SL1sb85r
9--5
When the Integrate Advanced Diagnostics in Project Tree check box

is selected in the System Options dialog box, Advanced Diagnostics
links are displayed in the project tree:
Project Tree
Advanced Diagnostic Links
This feature allows you to select a page title from the advanced
diagnostic list and go directly to that rung in the ladder logic.
Rev. February 2007

SL1sb85r
9--6
Go To Search Option
Explain that this search option is useful
in searching the data files.
Go To Search Option: A dialog box that allows the user to navigate

to a program file, rung, data file, cross-reference report, an address
or symbol in the Address/Symbol Editor.
The Go To dialog box is used for effective maintenance and
troubleshooting searches outside the ladder logic.
The following example shows the Go To dialog box:
Search Options
Example Text
Mention that the Go to What options are

the target, and that the Go To dialog box
should be closed upon navigating to the
desired window.
Tip "
The functions of the Go to What buttons are presented in the

following table:
To go to . . .
Then select this Go to What button . . .
A specific program and rung number
Program file
A data file dialog with a specific address
Data file
A cross-reference report
Cross-reference
The Address/Symbol Editor with a specified

address or symbol
Address/Symbol
When initiated, the selected window opens behind the Go To dialog

box. From this point, the Go To dialog box can be closed to access
the desired window.
Rev. February 2007

SL1sb85r
9--7
Cross-Reference Report
Explain that this search option is useful
in searching the data files.
Cross-Reference Report: A list containing the logical address,

symbol, instruction mnemonic, program file number, and rung
number for every occurrence of each address in a project.
A cross-reference report display can start with a specific address by
right-clicking on that address in the ladder logic:
Cross-reference report for B3:0/0, generated by

right- clicking on the address in ladder logic.
The following example shows a cross-reference report generated

from the project tree:
Cross-reference report showing
first logical address in the project.
Access to Cross-Reference
from Project Tree
Tip "
Rev. February 2007
To go directly to an instruction at a specific location in the ladder

logic, double-click the rung number in the cross-reference display.
SL1sb85r
9--8
Tracing Shortcut Options

Mention that tracing is used for
troubleshooting purposes.
There are several shortcut options to make tracing ladder logic

easier:
Cross Reference Display
Logic trace arrows
Explain that this feature will reduce the

time it takes to trace ladder logic.
With the Cross Reference Display option, you can set the display
attributes of the ladder logic window to show inputs and outputs with
their related cross reference information directly under the
instruction:
The Display Output Cross Reference for Inputs on Rung check
box will show you the file and rung location of any outputs using
the input address.
The Display Cross Reference for Outputs on Rung will show you
wherever the output addresses occur on the rungs in your
program.
Rev. February 2007

SL1sb85r
9--9
Shows the file and rung

location of any outputs
using the input address.
Mention that the logic trace arrows allow

you to quickly go to recently selected
rungs or instructions.
The logic trace arrows on the toolbar allow you to move through
ladder logic history:
Moves you backward in the

navigation history.
Moves you forward in the

navigation history.
Your navigation history is built as you move your cursor through the
ladder logic. When no back or forward history is available, the logic
trace arrows are disabled (grayed out).
Rev. February 2007

SL1sb85r
9--10
When you click the left arrow, the cursor will move to the previous
location in the navigation history. Once you have moved backward in
the navigation history, clicking the right arrow will move the cursor
forward through your navigation history.
You can also move through the navigation history using the logic
trace arrow drop-down menus:
Clicking
Tip "
Heres How
1. Open the
CCP412_1785r_DEM1.rsp project
and select the search button from
the menu bar.
2. Use the Find option and search for
instructions, addresses, symbols,
and rungs.
3. Use the Replace option and search
for and replace instructions,
addresses, and symbols.
displays the drop-down menu.
The pull down menus are limited to a maximum of 10 entries. Each

entry lists the rung/instruction location.
To search ladder logic by performing these actions:
Search for and replace instructions, symbols, or addresses
Search ladder logic using Advanced Diagnostics
Search using the Go To function
Generate a cross-reference report

Trace ladder logic
4. Use the Advanced Diagnostics

option and locate a specific rung in
the ladder logic.
5. Use the Goto option and display the
available applications.
6. Select a specific address and
generate a cross-reference report for
that address from the ladder logic.
Display the available functions of the
cross--reference report.
Rev. February 2007

SL1sb85r
9--11
Exercise: Searching Ladder Logic

Exercise A
In this exercise, you will practice searching ladder logic using

RSLogix 5 software.
Context:
You are responsible for keeping maintenance logs current and for
keeping record of any changes that have been made to the
documentation of the SL1_1785r_A1.rsp project.The programmers
have made updates to the documentation of the project. They have
provided you with a list of their revisions.By searching the ladder
logic for the revised documentation, you will be able to verify the
revisions and record the occurrences of the changes so that the
maintenance records will be current.
aid(s).
Rev. February 2007

SL1e85r
9--12
Directions:
1. Open the SL1_1785r_A1.rsp project and go online.
2. Search using the Find Next feature to list all the occurrences of
the following instructions, symbols, or addresses.
Mnemonic and/or Address
Example: O:003/12
WHITE_COLOR
BTD
B3:0/3
O:003/16
O:003/10
3. Search using the Find All feature to verify your answers to step 2.
4. Offline, search for and replace the following addresses:
Find Address
Replace Address
I:002/2
I:002/12
I:002/3
I:002/13
5. Search for all undescribed instructions and observe the result in

the Search Results window.
6. Search ladder logic using Advanced Diagnostics to identify the
rungs and output instructions associated with the page title
START STOP SECTION, found in program file 2:
Rung Number
Instruction and Address
Rev. February 2007

SL1e85r
9--13
7. Search using the Go To function to find the following

information:
A. Go to program file 3, rung 3.
B. Go to data table address T4:3.
C. Go to the cross-reference report for B3:0.
D. Go to the following address/symbol: CANS_PER_CASE.
8. Generate a cross-reference report and use it to identify the
instructions and rungs that use the address T4:0 or its status bits:
Instruction Type
9. Trace the output cross references for inputs on rung in file Lad 2
and fill in the following table:
Description
Input Bit
Machine Run
B3:0
Reject Alarm
O:003/16
Output Cross Reference
10. Close the project without saving.
How Did You Do?
Rev. February 2007

SL1e85r
9--14
Answers
Exercise A
2. If you searched correctly, your table should look like the
following:
Mnemonic and/or Address
Example: O:003/12
WHITE_COLOR
BTD
B3:0/3
O:003/16
O:003/10

2:17
2:18
2:16
2:18
2:18
2:19
2:20
2:26
2:4
2:4
2:5
2:17
2:26
2:27
2:1
2:3
2:34
2:43
2:42
2:43
3:2
Rev. February 2007

SL1e85r
9--15
6. To answer this question, you should have displayed the

following dialog box:
Rung Number
Instruction and Address
JSR
U:3
OTE
B3/0
TON
T4:4
OTE
O:003/17
7. Your Go To results should look like the following:

A.
Rev. February 2007

SL1e85r
9--16
B.
C.
Rev. February 2007

SL1e85r
9--17
D.
8. The cross-reference results under T4:0 should display the

following:
Instruction Type
TON
2:18
XIC
2:18, 2:19, 2:20, 2:26
MOV
2:16
9. After tracing the output cross references for inputs on rung in

file Lad 2, your table should appear like the following:
Rev. February 2007
Description
Input Bit
Output Cross Reference
Machine Run
B3:0
2:1
Reject Alarm
O:003/16
2:34

SL1e85r
9--18
Rev. February 2007

SL1e85r
Lesson
10
Interpreting and Editing Counter

Software
What You Will Learn
After completing this lesson, you should be able to interpret and edit
counter instructions.

Correctly interpreting counter instructions is necessary for accurate
troubleshooting of problems that arise with counted events. If
counted events are not properly interpreted or edited, troubleshooting
of the instructions that control those events will be difficult.
Before You Begin

Mention that counters have numerous
applications and that just a few are
mentioned here. Ask students to
contribute additional examples from their
workplace or experience.
Counter Instructions
Counters are used in the following situations:
Count parts coming off of a production line
Monitor the number of units in inventory
Initiate a packaging subroutine when a specific number of units
has been produced
Counter instructions have the following control functions:
To . . .
Then use this instruction . . .
Count up an accumulated value
CTU (Count Up)
Count down an accumulated value
CTD (Count Down)
Counter instructions contain the following components:

Counter: The location in memory where counted information is
stored.
Accumulated Value (.ACC): The number of current counted
events based on the number of times the rung goes from false to
true.
Preset Value (.PRE): The number of events to be counted.
Counter Status Bits: Bits that are set or reset, thereby indicating
the status of an instruction.
Rev. February 2007

CT1sb85r
10--2
Mention that by using the counter files

the counter status bits can be examined
or changed while the counter
instructions are counting
An example of a counter data file showing the counter status bits for
counters C5:0, C5:1, and C5:2 is shown in the following graphic:
C5:0.CU (Count Up)

C5:0.CD (Count Down)
C5:0.DN (Done)
C5:0.OV (Overflow)
C5:0.UN (Underflow)
C5:0.PRE (Preset)
C5:0.ACC (Accumulated Value)
Use the graphic to demonstrate how the

.OV and .UN bits are set.
The count value of a counter must remain in the range of +32,767 to

--32,768:
-1
- 32,768
32,767
.UN set
.OV set
If the count value is greater than +32,767, the counter will continue
counting and the counter status overflow bit (.OV) is set.
If the count value is less than --32,768, the counter will continue
counting and the counter status underflow bit (.UN) is set.
Rev. February 2007

CT1sb85r
10--3
CTU Instructions
Mention that rung transitions might be
triggered by a limit switch or by parts
traveling past a detector.
Explain that the ability of the counter to
detect false-to-true transitions depends
on the frequency of the incoming signal
(i.e., it must not be faster than the scan
time).
CTU (Count Up): An output instruction that counts up for each

false-to-true transition of conditions preceding it in the rung. This
produces an output when the accumulated value reaches the preset
value.
A CTU instruction is shown in the following graphic:
Mention that the CTU continues to count

so that there can be an account of
inventory or parts, etc.
? If the input conditions of a CTU
remain true, will the CTU continue to

increment?
Answer: No, the CTU instruction
increments upon each false-to-true
transition.
Tell students that the counter status bits,
.CU, .DN, and .OV, will be very important
in the interpretation of the status of
counter instructions.
Each count is retained when the rung conditions again become false,
permitting counting to continue beyond the preset value.
Each time the rung containing the CTU instruction changes from
false to true, the accumulated value increments by one. The
following conditions affect a CTU instruction:
When the
rung is . . .
False
Toggled
True
True
Rev. February 2007
And these are . . .
Then the CTU

is . . .
.CU
.DN
.OV
.ACC Value
Reset/Disabled
Counting
Incremented by 1
for each
false-to-true rung
transition
>= preset
Done
> 32767
Overflowed

CT1sb85r
10--4
CTD Instructions
Explain that CTU and CTD instructions
are often used in pairs.
Example: An amusement park wants to
keep track of how many people go into
the park and how many leave, so as to
have an accurate count of the people
actually inside the park at any given
time.
Mention that each count is retained

when the rung conditions again become
false.
CTD (Count Down): An output instruction that counts down for

each false-to-true transition of conditions preceding it in the rung.
This produces an output when the accumulated value reaches the
preset value.
A CTD instruction is shown in the following graphic:
Each time the rung containing the CTD instruction changes from
false to true, the accumulated value decrements by one. The count is
retained until either one of the following conditions is true:
An RES instruction with the same address as the counter is
enabled
Another instruction in the program overwrites the value
The following conditions affect a CTD instruction:
When the
rung is . . .
False
Toggled
True
True
And these are . . .
Then the CTD

is . . .
.CD
.DN
.UN
.ACC Value
Reset/Disabled
>= preset
Preloaded
Counting
Decremented by 1
for each
false-to-true rung
transition
< preset
Finished
< --32768
Underflowed
Rev. February 2007

CT1sb85r
10--5
Counter Instructions Used with RES Instructions

An RES instruction is an output instruction used to reset both timers
and counters. An RES instruction executes when its rung is true.
An example of an RES instruction is shown in the following
graphic:
Counter C5:0 is
reset when the
RES instruction
executes.
Explain that the timer or counter being

controlled by the reset instruction must
have the same address as the reset
instruction. For example, if the CTD is
C5:1, the RES address must also be
C5:1.
When conditions preceding RES in the rung are true, an RES

instruction resets the accumulated value and status bits of the counter
to zero. If the counter rung is enabled, the .CU or .CD bit will be
reset as long as the RES instruction is enabled.
Even if the counter preset value is negative, the
RES instruction sets the accumulated value to
zero, which may set the .DN bit and prevent the
counter instruction from operating the next time it
is enabled.
Heres How
1. Go online to the
To interpret and edit counter instructions using RSLogix 5 software.

examples.

enter a 4.
access to N10:0.
4. Show the operation of each
instruction.
5. Show how to edit the parameters of
CTU and CTD instructions.
Rev. February 2007

CT1sb85r
10--6
Example
Highlight how the CTU instruction will
keep counting past the preset value.
Interpreting CTU Instructions

The following example shows a CTU instruction. In this example,
note the following conditions:
When rung 0 transitions from false to true, the CTU instruction
counts up by one until the preset value equals the accumulated
value.
The .DN bit of the CTU instruction is used to control O:003/6.
Rev. February 2007

CT1sb85r
Example
Use this instruction to decrease the
accumulated value in the C5:0 counter.
Example
10--7
Interpreting CTD Instructions

The following example shows a CTD instruction. In this example,
note the following:
When rung 2 transitions from false to true, the CTD instruction
counts down by one until the preset value equals the accumulated
value.
The .DN bit of the CTD instruction is used to control O:003/13.
Interpreting RES Instructions

The following example shows a reset instruction. In this example,
note that when rung 4 transitions from false to true, counter C5:0 is
reset.
Rev. February 2007

CT1sb85r
10--8
Rev. February 2007

CT1sb85r
10--9
Exercise: Interpreting and Editing

Counter Instructions Using
RSLogix 5 Software
Exercise A
In this exercise you will practice interpreting ladder logic programs

containing counter instructions.
aid(s).
Directions:
1. Review the following ladder logic and answer the questions in the
space provided:
A. When is output O:003/04 on?
B. When is output O:003/05 on?
C. When is output O:003/06 on?
Rev. February 2007

CT1e85r
10--10
2. Review the following ladder logic. When is output O:003/13 on?
3. In the following ladder logic example, what effect does input

I:002/12 have on the counters?
How Did You Do?
Rev. February 2007

CT1e85r
Exercise B
10--11
In this exercise, you will practice editing counter instructions.

Context:
You need to modify a program to decrease the reject count on a paint
mixing line so that when it starts making rejects the line will shut
down sooner.
Tip "

aid(s).
Directions:
1. Open the CT1_1785r_B1.rsp project.
2. Change the Preset on the CTU (C5:1) (REJECT_CTR) counter to
2.
3. How many times does the input I:002/06 (REJECT) have to be
turned on before output O:003/16 (REJECT_ALARM) turns on?
4. Change the preset on the CTU (C5:2) (CASES_PER_PALLET)

counter to 12 by using the data file.
How Did You Do?
Rev. February 2007

CT1e85r
10--12
Answers
Exercise A
1.
A. Output O:003/4 is on while the CTU (C5:0) rung is true.
B. Output O:003/5 is on when the accumulator of the CTU
(C5:0) instruction is equal to or greater than the preset value
(5)
C. Output O:003/6 is on when the accumulated value exceeds
+32,767.
2. After I:002/06 has toggled nine times or is under-range. The
.UN bit is set because the accumulated value has wrapped from
--32,768 to + 32,767.
3. Input I:002/12 causes the down counter to subtract one from the
shared accumulative value each time it comes on.
Tip "
You can check your answers by running program

CT1_1785r_A1.rsp.
Exercise B
3. Input I:002/06 (REJECT) has to be turned on two times before
output O:003/16 (REJECT_ALARM) turns on (assuming that
the .ACC is still equal to zero).
Rev. February 2007

CT1e85r
Lesson
11
Interpreting and Editing Timer

Software
What You Will Learn
timer instructions.

Correctly interpreting timer instructions is necessary for accurate
troubleshooting of problems that arise with timed events. If timed
events are not properly interpreted or edited, troubleshooting of the
instructions that control those events will be difficult.
Before You Begin
Timer Instructions
Mention that timers have numerous

applications and that just a few are
mentioned here. Ask students to
contribute additional examples from their
workplace or experience.
Timers are used in the following situations:

Keep track of the elapsed running time of a system for preventive
maintenance purposes
Open a valve for 10 seconds
Delay the turning off of a cooling pump for 15 seconds after the
system shuts down
Explain that timer accuracy depends on

the processor clock tolerance and the
timebase. Clock tolerance is plus or
minus 0.02 percent, meaning that a
timer could time out early or late by 0.01
seconds for a 0.01 timebase or 1 second
for a 1 second timebase.
Timers have the following possible time bases:

1 second (32,767 time-base intervals equal 9.1 hours)
0.01 seconds (32,767 time-base intervals equal 5.5 minutes)

Timer instructions have the following control functions:
To . . .
Rev. February 2007
Delay turning on an output
TON (Timer On-Delay)
Delay turning off an output
TOF (Timer Off-Delay)
Time an event retentively
RTO (Retentive Timer)

TM1sb85r
11--2
Tell students that before timer

instructions can be programmed or
interpreted, they need to first understand
the parameters of the components and
how timer accuracy works.
Timer instructions contain the following components:

Timer: The location in memory where timed information is
stored.
Accumulated Value (.ACC): The number of elapsed-time
intervals.
Preset Value (.PRE): The number of intervals to be timed.
Timebase: The interval at which the timer instruction increments.
Timer Status Bits: Bits that are set or reset, thereby indicating
the status of an instruction.
Tell students that the timer status bits,

.EN, .TT, and .DN, will be very important
in the interpretation of the status of the
timer instruction.
Mention that by using the timer files the

timer status bits can be examined or
changed while the timer instructions are
timing.
Point out that a data file is used to
monitor data values, change values in
the data table, or see what addresses
are used in the ladder logic.
The specific functions of the timer status bits are outlined in the
following table:
Timer Status Bit
Description
.EN (enable)
Specifies whether or not the timer instruction is enabled:

When .EN is 1, the instruction is in a true rung.
When .EN is 0, the instruction is in a false rung.
.TT (timer timing)
Specifies whether or not the timer instruction is timing:

When .TT is 1, the instruction is timing.
When .TT is 0, the timer is not timing.
.DN (done)
Specifies whether or not the accumulated value of the timer equals

the preset value of the timer.
An example of a timer data file showing the timer status bits for
timers T4:0, T4:1, and T4:2 is shown in the following graphic:
T4:0.EN
T4:0.TT
T4:0.DN
T4:0.PRE
T4:0.ACC
Rev. February 2007

TM1sb85r
11--3
TON Instructions
Mention that when power loss or
processor mode changes occur while
the timer is timing, the .EN and .TT bits
remain set and the .ACC remains
unchanged.
TON (Timer On-Delay): An output instruction that can be used to

turn an output on or off after the timer has been timing for a preset
time interval.
A TON instruction is shown in the following graphic:
Explain that during pre-scan these bits

are cleared; therefore, they will be
cleared upon power-up or mode
changes.
A TON begins timing when its ladder logic rung is true. The
following conditions affect TON instructions:
When the rung
is . . .
False
True
And these are . . .
Then the TON

is . . .
.EN
.TT
.DN
.ACC Value
Reset
Increasing
Timing
> = preset
Timed Out
If the rung goes false (loses logical continuity),

the accumulated value is reset, and the .DN, .EN,
and .TT bits all reset whether or not the timer has
reached the preset value.
Rev. February 2007

TM1sb85r
11--4
TOF Instructions
TOF (Timer Off-Delay): An output instruction used to turn an
output on or off after its rung has been false for a preset time
interval.
The following graphic shows a TOF instruction:
? When does a TOF time and when is

its .DN bit set?
Answer: When the rung conditions are

true, the TOF resets and the .DN bit is
set. The timer begins timing when the
rung goes false.
The TOF instruction begins to count timebase intervals when the

rung makes a true-to-false transition. As long as rung conditions
remain false, the timer increments its accumulated value until it
reaches the preset value.
The following conditions affect TOF instructions:
When the rung
is . . .
True
False
And these are . . .
Then the TOF

is . . .
.EN
.TT
.DN
.ACC Value
Reset
Increasing
Timing
> = preset
Timed Out
Rev. February 2007

TM1sb85r
11--5
RTO Instructions
Mention that the RTO instruction holds
its count of time even in the case of a
fault, mode change, or power failure.
RTO (Retentive Timer): An output instruction used to turn an

output on or off after the timer has been timing for a preset time
interval (like a TON). Once it has begun timing, it holds its count of
time even when rung continuity is lost.
An example of an RTO instruction is shown in the following graphic:
Mention that by retaining its .ACC value,

RTOs measure the cumulative period
during which rung conditions are true.
When rung continuity returns (rung goes true again), an RTO begins
timing from the accumulated time that was held when rung
continuity was lost.
The following conditions affect RTO instructions:
When the rung
is . . .
Rev. February 2007
And these are . . .
Then the RTO

is . . .
.EN
.TT
.DN
.ACC Value
False
0
(reset)
Reset
True
Increasing
Timing
False
Suspended at
current count
Disabled
True
> = preset
Timed Out

TM1sb85r
11--6
Timer Instructions Used with RES Instructions

Explain that the timer or counter being
controlled by the reset instruction must
have the same address as the reset
instruction. For example, if the TON is
T4:1, the RES address must also be
T4:1.
An RES instruction is an output instruction used to reset both timers

and counters. An RES instruction executes when its rung is true.
An example of an RES instruction is shown in the following graphic:
Timer T4:2 is reset.
When conditions preceding an RES in the rung are true, the RES
instruction resets the accumulated value and status bits of the timer.
Mention that using the RES instruction
with the TOF instruction could result in
unpredictable machine operation or
injury to personnel.
Heres How
1. Go online to the
The RES instruction should not be used with the

TOF instruction because RES always clears the
status bits as well as the accumulated value.
To interpret and edit timer instructions using RSLogix 5 software.

examples.

enter a 5.
access to N10:0.
4. Show the operation of each
instruction.
5. Show how to use the data file or a
CDM to change a timer preset value.
Rev. February 2007

TM1sb85r
Example
Display rungs 0 through 3. Turn on SW0.
Discuss the activation of the .EN, .TT,
.DN bits.
Rev. February 2007
11--7
Interpreting TON Instructions

The following graphic shows an example of a TON instruction. In
this example, note the following conditions:
When rung 0 transitions from false to true, the TON instruction
resets and starts to time. It continues timing until the preset value
reaches the accumulated value or rung 0 goes false.
Several of the TON status bits are used to control outputs on
subsequent rungs.

TM1sb85r
11--8
Example
Emphasize the fact that a TOF timer will
begin timing when the rung makes a
true-to-false transition.
Show students how the ladder logic in
this example can be modified to have
the fan run while the motor is active and
continue running for 5 seconds after the
motor is turned off (to do this change the
timing status bit in rung 5 to a .DN bit).
Interpreting TOF Instructions

The following graphic shows an example of a TOF instruction. In
this example, note the following conditions:
When rung 4 transitions from true to false, the motor turns off
and the TOF instruction resets and starts to time. It continues
timing until the preset value reaches the accumulated value or
rung 4 goes true.
While the TOF instruction is timing, a cooling fan is on. When
the TOF instruction is not timing, the cooling fan is off.
Rev. February 2007

TM1sb85r
Example
Increase the preset in the T4:2 timer and

make several true-to-false transitions to
illustrate how the RTO instruction
maintains the accumulated value.
11--9
Interpreting RTO and RES Instructions

The following graphic shows an example of an RTO and an RES
instruction. In this example, note the following conditions:
Whenever rung 6 transitions from false to true, the RTO
instruction times. The RTO instruction continues to time until the
preset value equals the accumulated value or until rung 6 goes
false.
Several of the RTO status bits are used to control output
instructions.
The RTO instruction is not reset with the RES instruction until
rung 9 becomes true.
Rev. February 2007

TM1sb85r
11--10
Rev. February 2007

TM1sb85r
11--11

Timer Instructions Using RSLogix 5
Software
Exercise A
In this exercise you will practice interpreting timer instructions.

aid(s).
Directions:
space provided:
Rev. February 2007

TM1e85r
11--12
D. If input I:002/02 is turned on and off in 5-second intervals,

will output O:003/16 come on? If not, why?
space provided:
A. When will output O:003/14 be on?
B. When will output O:003/14 be off?
space provided:
A. How much time has to elapse before O:003/00 comes on?
Rev. February 2007

TM1e85r
11--13
B. What has to happen before the RTO will reset?
How Did You Do?
Exercise B
In this exercise you will practice editing timer instructions.

Context:
You are responsible for adjusting a motor off delay timer to delay a
paint mixing motor.
Tip "

aid(s).
Directions:
1. Open the file TM1_1785r_B1.rsp.
2. Make the following modifications to the program.
A. Change the preset on the motor off delay timer (TOF, T4:6,
PUMP_OFF_DELAY) to 7.
B. Change the time base for the same timer to 1.0.
3. How much time must now pass before timer MIX_TIMER (T4:5)
starts timing?
4. Change the preset on the TON (T4:5) timer to 1000 using the data
file.
How Did You Do?
Rev. February 2007

TM1e85r
11--14
Answers
Exercise A
1.
A. When TON instruction (T4:0) is enabled or true (I:002/02 is
on), then output O:003/17 is on.
B. When TON instruction (T4:0) is done timing or when the
accumulator is equal to preset (I:002/02 is on and remains on
for 10 seconds), then output O:003/16 is on.
C. Output O:003/15 is on as the TON instruction (T4:0) is
timing.
D. No, because the timer rung goes false every 5 seconds,
thereby resetting the timer. Therefore, the accumulated value
can never reach the preset to turn on the .DN bit.
2.
A. Output O:003/14 will be on as long as PRE > ACC..
B. Output O:003/14 will be off 5 seconds after the input
I:002/03 has been turned off.
3.
A. 60 seconds or 1 minute is the time that must elapse before
output O:003/00 comes on.(The RTO has been enabled for a
total elapsed time of 60 seconds and the timer is not reset or
I;002/04 remains false.)
B. Input I:002/4 has to be enabled before the RTO will reset.
Tip "
If time permits, open the file TM1_1785r_A1.rsp to test your

answers.
Exercise B
3. After the change to the preset and to the time base, 7 seconds
must pass before timer mix timer T4:5 starts timing.
Rev. February 2007

TM1e85r
Lesson
12
Integrated Practice: Searching and

Interpreting Basic Ladder Logic
What You Will Learn
After completing this lesson, you should be able to perform the

following tasks:
Search ladder logic
Interpret counter and timer instructions

When search options are not used to locate occurrences of specific
instructions, locating and troubleshooting errors in ladder logic can
become an inaccurate process. Proper interpretation of bit, timer, and
counter instructions is necessary for accurate troubleshooting of
systems using those instructions. Being able to integrate searching
and interpretation skills during a troubleshooting episode will
increase the accuracy and efficiency of the effort.
Rev. February 2007

IPSsb85r
12--2
Integrated Practice: Searching and Interpreting Basic Ladder Logic Using RSLogix 5 Software
Rev. February 2007

IPSsb85r
Exercise: Integrated Practice: Searching and Interpreting Basic Ladder Logic Using RSLogix 5
12--3
Exercise: Integrated Practice:

Searching and Interpreting Basic
Ladder Logic Using RSLogix 5
Software
Exercise A
In this exercise, you will practice searching and interpreting basic

ladder logic using an RSLogix 5 project.
Context:
You have been asked to run a new RSLogix 5 software project and
verify the inputs and outputs by searching and interpreting basic
ladder logic.
Directions:
The goal of the exercise is to turn on each output light on the
workstation, one at a time and in sequence, starting with LT0 and
ending with LT17. To accomplish this, use search functions to find
the input instructions that turn on each of the 16 output lights.
1. Open the IPS_1785r_A1.rsp project.
2. Search the ladder logic for the input instructions that must be true
to energize output LT0.
3. Make the input instructions true to energize output LT0.
Tip "
The next light to be energized is displayed on LED 1.

4. Confirm that the actual output light is activated on the
workstation.
Tip "
Once a light has been energized in the proper sequence, the output
need not remain energized. Leave the pushbuttons on the on position
after they are energized.
5. Repeat Steps 2. through 4. for each of the remaining output lights.
How Did You Do?
Rev. February 2007
Turn to the answer section.

IPSe85r
12--4
Exercise: Integrated Practice: Searching and Interpreting Basic Ladder Logic Using RSLogix 5
Answers
Exercise A
Use the search and find functions in RSLogix 5 software to locate
the input instructions in the ladder logic that turn on each output
light, LT0 through LT17.
Rev. February 2007

IPSe85r
Lesson
13
Interpreting and Editing Compare

Software
What You Will Learn
compare instructions.

Knowing how to take advantage of all of the components of the
compare instructions enables you to control output devices based on
compared values.
Before You Begin
Compare Instructions Overview
Note that a programmer uses compare

instructions to compare a value to
another value and then takes some
action based upon a true or false
comparison.
Compare Instructions: Input instructions that test the relationship

between two values from two different sources.
Briefly explain the different compare

functions in a PLC-5 processor.
The following compare instructions are available:
A compare instruction typically tests the following sources:

Source A: A word address.
Source B: Either a word address or a constant.
To . . .
Mention that, unlike bit-level inductions,

compare instructions are not highlighted
when they are true.
Rev. February 2007
Then use this

comparison instruction . . .
Compare values and perform logical

comparisons
CMP (Compare)
Test whether two values are equal
EQU (Equal)
Test whether one value is not equal to a

second value
NEQ (Not Equal)
Test whether one value is less than a

second value
LES (Less Than)
Test whether one value is less than or

equal to a second value
LEQ (Less Than or Equal To)
Test whether one value is greater than a

second value
GRT (Greater Than)
Test whether one value is greater than or

equal to a second value
GEQ (Greater Than or Equal To)
Test portions of two values to see whether

they are equal
MEQ (Masked Comparison for Equal)
Test whether one value is between two

other values
LIM (Limit Test)

CM1sb85r
13--2
Tip "
When the comparison is logically true, the rung goes true and the
output is energized (provided no other instructions affect the rungs
status).
CMP Instructions
Mention that a CMP instruction can
complete the functions of other
comparison instructions, but it takes
more scan time.
CMP (Compare): An input instruction that compares values and

performs logical comparisons.
Point out that complex expressions

(using more than two operands) are
supported in enhanced PLC-5
processors.
The CMP instruction allows rung continuity if the mathematical

statement given in the expression is true. Otherwise, the rung is false.
The following graphic shows an example of an CMP instruction

displaying a greater than expression:
EQU Instructions
Mention that for EQU instructions,
Source A must be a word address and
Source B can be either a program
constant or a word address.
EQU (Equal): An input instruction that tests whether two

user-specified values are equal.
The following graphic shows an example of an EQU instruction:
If the values are equal, the instruction is logically true. If the two
values are not equal, the instruction is logically false.
Rev. February 2007

CM1sb85r
13--3
NEQ Instructions
Mention that for NEQ instructions,
Source A must be a word address and
Source B can be ether a word address
or a program constant.
NEQ (Not Equal): An input instruction that tests whether two

user-specified values are not equal.
The following graphic shows an example of an NEQ instruction:
If Source A and Source B are not equal, the instruction is logically

true. If the two values are equal, the instruction is logically false.
LES Instructions
Mention that LES instructions require a
word address for Source A and either a
word address or a constant for Source
B.
LES (Less Than): An input instruction that tests whether one value
is less than a second value.
The following graphic shows an example of an LES instruction:
If the value at Source A is less than the value at Source B, the

instruction is logically true. If the value at Source A is greater than or
equal to the value at Source B, the instruction is logically false.
Rev. February 2007

CM1sb85r
13--4
LEQ Instructions
Mention that the LEQ, GRT, and GEQ
instructions require a word address for
Source A and Source B can be either a
constant or word address.
LEQ (Less Than or Equal): An input instruction that tests whether

one value is less than or equal to a second value.
The following graphic shows an example of an LEQ instruction:
If the value at Source A is less than or equal to the value at Source B,

the instruction is logically true. If the value at Source A is greater
than the value at Source B, the instruction is logically false.
GRT Instructions
GRT (Greater Than): An input instruction that tests whether one
value is greater than a second value.
The following graphic shows an example of a GRT instruction:
If the value stored in Source A is greater than the value stored in

Source B, it allows rung continuity. If the value at Source A is less
than or equal to the value at Source B, the instruction is logically
false.
Rev. February 2007

CM1sb85r
13--5
GEQ Instructions
GEQ (Greater Than or Equal): An input instruction that tests
whether one value is greater than or equal to a second value.
The following graphic shows an example of a GEQ instruction:
If the value stored in Source A is greater than or equal to the value

stored in Source B, it allows rung continuity. If the value at Source A
is less than the value at Source B, the instruction is logically false.
MEQ Instructions
Mention that this instruction can be used
when entering the mask parameter as
an encoded value rather than an
address or a file address.
MEQ (Masked Comparison for Equal): An input instruction that

tests portions of two values to see whether they are equal.
Remind students that they can learn

more about instructions via online Help.
This input instruction compares the 16-bit data of a source address to

the 16-bit data at a reference address through a mask. If the values
match, the instruction is true. The instruction becomes false as soon
as it detects a mismatch.
Rev. February 2007
The following graphic shows an example of an MEQ instruction:

CM1sb85r
13--6
LIM Instructions
LIM (Limit Test): An input instruction that tests whether a value is
within or outside of defined limits.
Limit test instruction uses the following limits:
If the test value is a constant, the limits are word addresses.
If the test value is a word address, the limits are either word
addresses or constants.
The following graphic shows an example of an LIM instruction:
The following table outlines the function of an LIM instruction:

If the low limit is . . .
? Can anyone provide an example of
Then the LIM instruction is true when

the test value is . . .
Less than or equal to the high limit
Between or equal to either of the limits
Greater than the high limit
Equal to either limit or outside the limits
how this instruction is or could be used

in the projects that they maintain?
Example: A programmer needs to make
sure the weight of manufactured parts
falls within a given range.
Example: A programmer wants a
warning message to appear if an
operator enters a value outside of
specified range.
Rev. February 2007

CM1sb85r
Heres How
1. Go online to the
13--7
To interpret and edit compare instructions in an RSLogix 5 project.

examples:

enter a 6.
" The project contains a CDM monitor
for easy access to N10:0.
4. Demonstrate the operation of each
instruction. To change the value of
N11:0, use thumbwheel input..
" Point out that the value of an
address is displayed below the
address.
Example
Show how the output is de-energized or
energized by using thumbwheel input 1
to change the value in N11:0.
Interpreting CMP Instructions

The following graphic shows an example of a CMP instruction. In
the example, note that the CMP instruction makes a comparison
involving a simple mathematical expression:
When the value is N11:0 is greater than the value in F8:0, output
O:003/0 is energized.
When the value in N11:0 is less than the value in F8:0, the rung is
false.
Additional examples of the CMP instruction are shown below:

Source
A
Rev. February 2007
Source
B
Logical Continuity of Rung Based on Comparative Expression

EQU
GEQ
GRT
LEQ
LES
NEQ
10
10
True
True
False
True
False
False
False
False
False
True
True
True
21
20
False
True
True
False
False
True
--30
--31
False
False
False
False
False
True
--15
--14
False
False
False
True
True
True

CM1sb85r
13--8
Example
Show how the output is de-energized by
using thumbwheel input 1 to change the
value in N11:0.
Example
Use the thumbwheel 1 input to alter the
value in N11:0.
Interpreting EQU Instructions

The following graphic shows an example of an EQU instruction. In
When the value in N11:0 equals the value in N11:30, the rung is
true and output O:003/1 is energized.
When the value in N11:0 does not equal the value in N11:30, the
rung is false.
Interpreting NEQ Instructions

The following graphic shows an example of an NEQ instruction. In
When the value in N11:0 is not equal to the value in N11:30, the
rung is true and output O:003/2 is energized.
When the value in N11:0 is equal to the value in N11:30, the rung
is false.
Rev. February 2007

CM1sb85r
Example
Use the thumbwheel1 input to energize
and de-energize output O:003/3.
Example
Use thumbwheel input 1 to enter the
value of 5 in N11:0. Show that output
O:003/4 is energized when N11:0 is less
than or equal to 5.
13--9
Interpreting LES Instructions

The following graphic shows an example of an LES instruction. In
When the value in N11:0 is less than N11:40, the output O:003/3
is energized.
When the value in N11:0 is equal to or greater than N11:40, the
rung is false.
Interpreting LEQ Instructions

The following graphic shows an example of an LEQ instruction. In
When the value in N11:0 is less than or equal to N11:40, the
output O:003/4 is energized.
When the value in N11:0 is greater than the value in N11:40, the
rung is false.
Rev. February 2007

CM1sb85r
13--10
Example
Use thumbwheel input 1 to energize and
de-energize O:003/5.
Example
Use thumbwheel input 1 to enter a value
of 6 in N11:0. Show that output O:003/6
is energized when N11:0 contains a
value of 5 or more.
Interpreting GRT Instructions

The following graphic shows an example of a GRT instruction. In
When the value in N11:0 is greater than the value in N11:40,
O:003/5 is energized.
When the value in N11:0 is less than or equal to N11:40, the rung
is false.
Interpreting GEQ Instructions

The following graphic shows an example of a GEQ instruction. In
When the value in N11:0 is greater than or equal to the value in
N11:40, O:003/6 is energized.
When the value in N11:0 is less than the value in N11:40, the
rung is false.
Rev. February 2007

CM1sb85r
Example
Remind students that a mask is a type of
filter. Show students that a mask value
can also be entered in binary or decimal.
13--11
Interpreting MEQ Instructions

The following graphic shows an example of an MEQ instruction. In
The 16 bits of data at the source address B3:0, less the masked
bits, are compared to the 16 bits of data at the compare address,
B3:10.
The value in the mask field indicates that bit numbers 8 through
11 of the word B3:0 are being looked at for a match.
When bit numbers 8 through 11 of word B3:0 match bit numbers

8 through 11 of word B3:10, O:0003/7 is energized.
Example
Point out that making the low limit higher
than the high limit can be used to
energize an output when the test value
is outside of a particular numerical
range.
Change the value in N11:1 to make the
test value higher than the low limit.
Rev. February 2007
Interpreting LIM Instructions

The following graphic shows an example of an LIM instruction. In
When the test value, N11:1, is between the limits or equal to
either limit, B3:22/0 is energized.
When the test value, N11:1, is higher than the low limit, N7:6, or
lower than the high limit, N7:5, B3:22/1 is energized.

CM1sb85r
13--12
Rev. February 2007

CM1sb85r
13--13

Compare Instructions Using
RSLogix 5 Software
Exercise A
In this exercise you will practice interpreting compare instructions.

aid(s).
Directions:
space provided:
Rev. February 2007

CM1e85r
13--14
D. When is output O:003/14 on?
How Did You Do?
Exercise B
In this exercise, you will practice editing compare instructions.

Context:
A paint mixing line has a variable speed cycle that is controlled by
two compare instructions, one GEQ and one LEQ. The programmers
for the system have decided to delete the one GEQ instruction. It is
your responsibility to delete the instruction to change the cycle
speed.
Tip "

Directions:
1. Open the CM1_1785r_B1.rsp project.
2. Look at the GEQ and LEQ instructions on rung 3.
3. What values will allow output O:003/17 to turn on?
4. Delete the GEQ instruction.

5. What values will now allow output O:003/17 to turn on?
6. Close the file without saving.
How Did You Do?
Rev. February 2007

CM1e85r
Rev. February 2007
13--15

CM1e85r
13--16
Answers
Exercise A
1.
A. O:003/17 is on when the value stored in N15:0 is greater than
the value stored in N15:1.
B. O:003/16 is on when the value stored in N15:0 is less than or
equal to 200.
C. O:003/15 is on when the value stored in N15:1 is not equal to
50.
D. O:003/14 is on when the value stored in N15:0 is greater than
or equal to 100 and less than or equal to 500.
Tip "
Thumbwheel 1 is being stored in integer file N15:0. Thumbwheel 2

is being stored in integer file N15:1.
Tip "
If time permits, download CM1_1785r_A1.rsp to test your answers.
Exercise B
3. O:003/17 will turn on when B3:0/0 has a logic value of 1 and
when the value stored in T4:0.ACC is greater than or equal to
50 and less than or equal to 150.
5. O:003/17 will turn on when B3:0/0 has a logic value of 1 and
when the value that is stored in T4:0.ACC is less than or equal
to 150.
Rev. February 2007

CM1e85r
Lesson
14
Interpreting and Editing Data

Manipulation Instructions Using
RSLogix 5 Software
What You Will Learn
data manipulation instructions using RSLogix 5 software.

Knowing how to take advantage of all the components of the data
manipulation instructions enables you to shift or copy data, or
sections of data, to different locations within a processors data table.
Being able to properly interpret and edit data manipulation
instructions is necessary for accurate troubleshooting of systems
using those instructions.
Before You Begin

Explain that, for simplicity, the
instructions covered in this lesson are
categorized as data manipulation
instructions and are common
instructions from the following instruction
sets: conversion instructions, move
instructions, and file instructions.
Data Manipulation Instructions Overview

Data Manipulation Instructions: Output instructions (file,
conversion, and move instructions) that enter (move) source value(s)
into a destination file.
Data manipulation instructions typically have the following
outcomes:
Elements or groups of elements are moved.
Data may be converted to a different data format.
Source values remain unchanged.
The following instructions are commonly used to manipulate data:
Briefly explain the common instructions

that transfer and/or change data.
Rev. February 2007
To . . .
Convert the source value from BCD to decimal and

copy the result in the destination
FRD (Convert from BCD to Integer)
Convert the source value from decimal to BCD and

copy the result in the destination
TOD (Convert to BCD)
Move specified bits within a word or between words
PT (Bit Distribute)
Copy the source value into the destination
MOV (Move)
Copy the unmasked bits of a source value into the

destination
MVM (Masked Move)
Copy data from the source file into the destination

file
COP (Copy File)
Copy the source value into each element of the

destination file
FLL (Fill File)
Covert the source data type to another data type at

the destination
FAL (File Arithmetic and Logic)

DM1sb85r
14--2
FRD Instructions
Mention that FRD and TOD are
examples of conversion instructions.
FRD (Convert from BCD to Integer): An output instruction that

converts a BCD value to an integer value.
An example of a FRD instruction is shown in the following graphic:
Inform the students that the BCD value

should be converted to integer before
manipulating those values in the ladder
logic program, because the processor
treats BCD values as integer numbers.
Actual BCD values may otherwise be
lost or distorted.
When rung conditions are true, this output instruction converts a

BCD value in the math register or the source to an integer and stores
that integer in the destination.
TOD Instructions
TOD (Convert to BCD): An output instruction that converts an
integer value to BCD.
An example of a TOD instruction is shown in the following graphic:
Point out that if the integer value is

greater than 9999, the processor stores
9999 and sets the overflow bit. If the
integer value entered is negative, the
processor stores 0 in the destination and
sets the overflow and status bits.
When rung conditions are true, this output instruction converts a

16-bit integer source value to BCD and stores it in the destination.
Rev. February 2007

DM1sb85r
14--3
BTD Instructions
State that this instruction allows
information to be shared and updated
between two distinct words or the initial
word itself.
BTD (Bit Distribute): An output instruction that moves up to 16

bits within a word or between words, leaving the source unchanged.
An example of a BTD instruction is shown in the following graphic:
Specified Length of
Moved Bits
Mention the importance of the length of

the bit field for the BTD instruction. If the
length of the bit field extends beyond the
destination word, the processor does not
save the overflow bits. These overflow
bits are lost and are not wrapped to the
next higher word.
Tip "
On each scan, when the rung that contains the BTD instruction is
true, the bit field is moved from the source word to the destination
word. The instruction writes over the destination with the specified
bits.
Bits are lost if they extend beyond the end of the destination word;
the bits are not wrapped to the next word.
For movement of data within a word, the same address is used for
both the source and destination, as shown in the following graphic:
Destination Bit N70:22/10
Source Bit N70:22/3

00
08 07
15
1 0 1 1 0 1
N70:22
1 0 1 1 0 1
The following graphic shows movement of bits between words

N7:20 and N7:22:
15
Source Bit N7:20/3

00
08 07
N7:20
0 1 1 1 0 1 1 1 0 1
Destination Bit N7:22/5

15
08 07
0 1 1 1 0 1 1 1 0 1
Rev. February 2007
00
N7:22

DM1sb85r
14--4
MOV Instructions
Mention that MOV and MVM are move
and logical instructions that perform
move and logical operations on
individual words.
MOV (Move): An output instruction that copies the source value to

the destination.
An example of an MOV instruction is shown in the following
graphic:
When rung conditions preceding this instruction are true, the MOV
instruction moves a copy of the source to the destination each scan.
The original value remains intact and unchanged in its source
location.
The following graphic shows how the data from source N7:0 is
copied to destination N7:8 in one processor scan:
Data Table
1 0 1 1 0 0 1 0 1 1 1 1 0 1 0 0 N7:0
Source
Moves (Copies) Data
1 0 1 1 0 0 1 0 1 1 1 1 0 1 0 0 N7:8
Destination
Rev. February 2007

DM1sb85r
14--5
MVM Instructions
Mention that the MVM instruction
operates in a similar fashion as the MEQ
comparison instruction (discussed in the
previous lesson).
MVM (Masked Move): An output instruction that defines what bits

from a source location will be copied to a destination by allowing
portions of the destination data to be masked by a separate word.
An example of an MVM instruction is shown in the following
graphic:
When rung conditions are true, data at the source address passes
through the mask to the destination address. As long as the rung
remains true, the instruction moves the data each scan.
Explain that the mask acts as a filter,
with the patterns of the characters in the
mask determining which bits will be
passed from the source to the
destination. Bits in the mask word mask
data when reset and they pass data
when set.
Only bits in the mask that are set (1) will pass data to the destination,
as shown in the following graphic:
1010101010101010
Destination before a Move
1111000011110000
Bit Values in the Source
0000000011111111
1010101011110000
Bit Values in the Mask

Destination after a Move
The following table outlines the function of the mask in the MVM
instruction:
If a bit in the mask is. . .
Rev. February 2007
Then the state of the

corresponding source bit is . . .
Copied to the destination bit
Not copied to the destination bit

DM1sb85r
14--6
Mention that COP and FLL instructions

are file manipulation instructions, which
are used to modify existing files by either
copying file data to them from other files
or by filling a selected file with specific
source data.
Tell the students to make certain that the
source and destination files contain at
least the number of elements specified
in the length.
Tip "
COP Instructions
COP (Copy File): An output instruction that copies a block of data
from one location into another.
An example of a COP instruction is shown in the following graphic:
A pound sign (#) is used to denote the starting address of a file of

word elements.
When rung conditions are true to this output instruction, a

Point out that source and destination
elements may be of a different type;
user-defined source file is copied to a destination file, as shown in
however, the destination file type
the following graphic:
determines how many words of
data will be transferred.
Destination File
Source File
N7:2
N7:3
N7:4
10 11 00 00 111100 00
1 0 1 1 0 0 0 0 1 1 1 1 0 0 0 0 N7:10
N7:11
N7:12
N7:5
10 11 00 10 111101 00
1 0 1 1 0 0 1 0 1 1 1 1 0 1 0 0 N7:13
Rev. February 2007

DM1sb85r
14--7
FLL Instructions
FLL (Fill File): An output instruction that fills the words of a file
with a source value.
An example of an FLL instruction is shown in the following graphic:
Mention that FLL instructions require the

same file type be used for both the
source and destination.
The source value (typically a program constant) is sent to the

destination file each time the rung logic is true. Elements are filled in
ascending order until the number of elements (length that was
entered) is reached, as shown in the following graphic:
Destination File
N15:5
Source Value
1011000011110000
Rev. February 2007
1 0 1 1 0 0 0 0 1 1 1 1 0 0 0 0 N40:1
N40:2
N40:3
N40:4
N40:5
1 0 1 1 0 0 0 0 1 1 1 1 0 0 0 0 N40:6

DM1sb85r
14--8
FAL Instructions
Explain how a file arithmetic and logic
instruction can do all of the functions
discussed previously in this lesson. Also
explain that an FAL instruction can do
comparisons, mathematics, logics, and
conversions.
FAL (File Arithmetic and Logic): An output instruction that

performs operations (copy, arithmetic, logic, and function) defined
by addresses and operators in an expression.
The following graphic shows an example of an FAL instruction:
FAL instructions have the following status bits:

Enable Bit (.EN): Set when the rung goes true.
Briefly discuss the use of FAL status bits
in a ladder logic program and how they
relate to the troubleshooting function.
Done Bit (.DN): Set after the instruction has completed its operation.
Usually the .DN bit will be examined later in the program to allow
further action. (i.e., --] [-- of R22:14/DN)
Error Bit (.ER): Set when the operation generates an overflow.
"
When the error bit is on, this is usually a result of a programming

error.
Troubleshooting Tips for FAL Instructions
If the .DN bit is not on, determine why the FAL rung is not true.
Note the fact that standard processors

allow the FAL instruction to be
performed on simple expressions only.
Enhanced processors do not require
values to be converted to decimal
numbers prior to using the FAL
instruction, provided the instruction
indicates the number system being
used.
If the mode is set to INCREMENTAL, the rung needs to go false to

true enough times for the FAL to completely finish its operation and
turn on the .DN bit. The FAL instruction is done when the position is
one less than the length (or when position = length --1).
If the mode is set to ALL, the entire file is operated on before
continuing to the next rung of the program. The operation begins
when the rung goes from false to true and the operation stops when
the function completes or when the processor detects an error.
Rev. February 2007

DM1sb85r
Heres How
1. Go online to the
enter a 7.
14--9
To interpret and edit data manipulation instructions using RSLogix 5

software.
examples:

access to N10:0.
Example
For the FRD instruction, demonstrate
the conversion steps in the operation.
Use thumbwheel input 1 to change the
source.
Point out that the value of an address is
displayed below the address.
Example
For the TOD instruction, demonstrate
the conversion steps in the operation.
Point out that the value of an address is
displayed below the address.
Interpreting FRD Instructions

The following graphic shows an example of an FRD instruction. In
If I:012/10 is set, the BCD value in D17:3 is converted to an
integer.
The integer value is then stored in destination N7:3.
Interpreting TOD Instructions

The following graphic shows an example of a TOD instruction. In
If I:012/10 is set, the integer value from source N7:3 is converted
to BCD.
The BCD value is stored in destination D17:3.
Rev. February 2007

DM1sb85r
14--10
Example
Display rung 7:2, open the binary file,
and toggle the first bit from 1 to 0. Then
close I:002/2 to show the bit transfer.
Example
Interpreting BTD Instructions

The following graphic shows an example of a BTD instruction. In
If I:002/2 is set, the processor copies 6 bits, as specified by
length, starting with the source bit, 0, of the source, B3:2.
The copied values from the source, B3:2, are moved to the
destination, B3:4, starting with the destination bit, 4.
Interpreting MOV Instructions

The following graphic shows an example of an MOV instruction. In
this example, note that the data in N7:10 is copied to N7:30:
Example
Interpreting MVM Instructions
Show how the mask also can be entered

in binary or decimal.
The following graphic shows an example of an MVM instruction. In

this example, note that the first four and the last four bits in N7:1 are
copied to N7:9:
Rev. February 2007

DM1sb85r
Example
For the COP and FLL instructions,
display data file N7 in the decimal radix
and manipulate the data in N7 to show
how the elements are copied or filled.
Example
14--11
Interpreting COP Instructions

The following graphic shows an example of a COP instruction. In
this example, note that N7:60 through N7:63 are copied to N7:80
through N7:83.
Interpreting FLL Instructions

The following graphic shows an example of an FLL instruction. In
this example, note that the FLL instruction sets 5 words in N7 to 0,
starting with N7:35.
Example
Edit this instruction to demonstrate how
it works using the incremental, all, and
numeric modes.
Rev. February 2007
Interpreting FAL Instructions

The following graphic shows an example of an FAL instruction. In
this example, note that the FAL instruction performs four
calculations and stores the results in four successive words in N7,
starting at N7:15:

DM1sb85r
14--12
Rev. February 2007

DM1sb85r
Exercise: Interpreting and Editing Data Manipulation Instructions Using RSLogix 5 Software
14--13

Data Manipulation Instructions
Exercise A
In this exercise, you will practice interpreting data manipulation

instructions.
aid(s).
Directions:
space provided:
A. What happens to the data table when I:002/00 is on?
B. What happens to the data table when I:002/01 is on?
C. What happens to the data table when I:002/02 is on?
Rev. February 2007

DM1e85r
14--14
D. What happens to the data table when I:002/03 is on?
E. What does the mask value in the MVM instruction do to the

data in N20:1?
F. When I:002/12 is on, what happens to the data currently

stored in N22:0 to N22:4?
G. What happens to the data stored in N22:0 through N22:4

when it is copied into N30:0 to N30:4?
Rev. February 2007

DM1e85r
14--15
space provided:
A. What is the range of words affected by the FAL (R6:0)?
B. When is output instruction (O:003/00) true?
C. What happens each time input (I:002/15) goes from false to

true?
During this
increment . . .
The source
address is . . .
And is converted
to . . .
Then moved to
this
destination . . .
First Time
Second Time
Third Time
Fourth Time
Fifth Time
Sixth Time
Seventh Time
Eighth Time
Ninth Time
How Did You Do?

Rev. February 2007

DM1e85r
14--16
Exercise B
In this exercise, you will practice editing data manipulation

instructions.
Context:
You are responsible for editing a program and adding a new paint
color recipe. The necessary instructions are provided for you.
aid(s).
Directions:
1. Open the DM1_1785r_B1.rsp project.
2. On rung 15, replace the OTE B3/4 with an FAL instruction with
the following parameters:
Control: R6:9
Length: 2
Position: 0
Mode: ALL
Destination: #N14:0
Expression: #N26:0
3. When rung 15 is true, what happens to the file N14:0?
How Did You Do?
Rev. February 2007

DM1e85r
Rev. February 2007
14--17

DM1e85r
14--18
Answers
Exercise A
1.
A. When I:002/00 is on, the BCD values stored in N15:0 are
converted to an integer value and the result is stored in
N20:0.
B. When I:002/01 is on, the integer values stored in N15:0 are
converted to BCD and stored in N20:0.
C. When I:002/2 is on, the processor copies 5 bits, starting with
bit 5 of the source,B3:2, and moves the copied values to the
destination, B3:5, starting with the destination bit, 10.
D. When I:002/03 is on, the data value stored in N15:0 is copied
into N20:0.
E. Due to the mask value, only the upper 8 bits of the data value
stored in N15:1 are copied into N20:1.
F. When I:002/12 is on, the data values stored in N22:0 through
N22:4 will be replaced by the value stored in N15:0.
G. Nothing happens to the data, the source values remain
unchanged in a copy operation.
2.
A. The range of words is from N12:20 to N12:28.
B. O:003/00 is true when I:002/14 is true and causes the FAL
(R6:0) to be done. (.DN is on.)
C. The following table shows the operation of the FAL
instruction each time I:002/06 goes from false to true:
During this
increment
The source
address Is . . .
And is converted
to . . .
Then moved to
this
destination . . .
First Time
N12:20
BCD
O:001
Second Time
N12:21
BCD
O:001
Third Time
N12:22
BCD
O:001
Fourth Time
N12:23
BCD
O:001
Fifth Time
N12:24
BCD
O:001
Sixth Time
N12:25
BCD
O:001
Seventh Time
N12:26
BCD
O:001
Eighth Time
N12:27
BCD
O:001
Ninth Time
N12:28
BCD
O:001 and the done

bit (.DN) is on
Tip "
Thumbwheel 1 is being stored in integer file N15:0. Thumbwheel 2

is being stored in integer file N15:1.
Tip "
If time permits, download DM1_1785r_A1.rsp to test your answers.
Rev. February 2007

DM1e85r
14--19
Exercise B
3. When rung 15 is true, the data values stored in N26:0 and
N26:1 will be copied into N14:0 and N14:1.
Rev. February 2007

DM1e85r
14--20
Rev. February 2007

DM1e85r
Lesson
15
Interpreting and Editing Program

Control Instructions Using
RSLogix 5 Software
What You Will Learn
program control instructions using RSLogix 5 software.

Being able to accurately interpret and edit program control
instructions will allow you to minimize scan time, create a more
efficient program, and effectively troubleshoot a ladder logic
program.
Before You Begin
Program Control Instructions Overview

Program Control Instructions: Input and output instructions that,
when used together, change how and where a PLC-5r processor
scans. Program control instructions dictate the sequence in which the
program is executed, thereby interrupting the normal sequence of the
processor operating cycle.
Processor Operating Cycle and Program Control Instructions
Review the normal operations that occur

during a processors scan. You may wish
to elaborate on how program control
instructions influence this cycle. On
subsequent pages, further details and
applications will be given.
The following graphic provides a review of how the processor

operating cycle, without program control instructions, is divided:
Processor
Housekeeping
Input Scan
Communications
Program Scan
Output Scan
Rev. February 2007

PC1sb85r
15--2
Common Program Control Instructions

The following program control instructions are commonly used:
Then use this program control
instruction . . .
To . . .
Mention that the sequence in which

ladder logic rungs are read depends on
the type of output instruction used in the
processor operating cylcle.
Point out that timing could be inaccurate
if JMP, LBL, JSR, or SBR instructions
skip over rungs containing a timer
instruction while the timer is timing.
Jump forward or backward to a

corresponding label instruction
JMP (Jump to Label); LBL (Label)
Jump to a designated subroutine and then

return to the main program or originating
subroutine
JSR (Jump to Subroutine); SBR

(Subroutine); RET (Return from
Subroutine)
Enable or inhibit a master control zone in

the ladder logic program
MCR (Master Control Reset)
Mark a temporary end that halts program

execution behind it
TND (Temporary End)
Disable a rung
AFI (Always False)
JMP and LBL Instructions

JMP (Jump to Label): An output instruction that directs the
processor to skip rungs (forward or backward).
LBL (Label): An input instruction that is the target of JMP
instructions having the same label number.
Mention that a zone can also be a
section of ladder logic that contains
outputs the programmer may want to
disable when specific conditions are
met.
Mention that multiple JMP instructions
can be linked to the same LBL
instruction.
JMP and LBL instructions are used in pairs to skip portions (zones)
of the ladder logic program, which reduces scan time.
Zone: A section of ladder logic.
The following graphic shows examples of single and multiple JMP
instructions:
] [ ] [
(JMP)
] [ ] [
(JMP)
] [ ] [
] [
-( )-
] [ ] [
] [
-( )-
] [ ] [ ] [
-( )-
] [ ] [ ] [
(JMP)
] [ ] [
] [ ] [
-( )-
] [ ] [
] [
[LBL}
] [ -( )] [ -( )-
Single JMP Instruction
Skips These
Rungs When
JMP Rung Is
True
[LBL}
] [ -( )] [ -( )-
Multiple JMP Instructions
Rev. February 2007

PC1sb85r
15--3
When a JMP rung is true, then the following conditions exist:

The program skips from the rung containing the JMP instruction
to the rung containing the designated LBL instruction.
The program continues executing.

The zone rungs between the JMP and LBL instructions are not
executed.
The zone outputs remain in their last state.
When a JMP rung is false, then the following conditions exist:

The program does not execute the JMP instruction.
The zone rungs will be executed.
The zone outputs function normally.
JSR, SBR, and RET Instructions

Mention that subroutines are used to
store recurring sections of ladder logic
that must be executed from several
points within the program.
Subroutine: A program file that performs a specific task.

A subroutine will interrupt the program scan based on the specified
instruction. For PLC-5 processors, program files 3 to 999 are
designated for subroutines.
Subroutines are used in the following situations:
Loading a recipe
Performing a calculation
Use the graphic to review the operations

that occur during a typical processors
scan, and then highlight the influence of
subroutines on the processor operating
cycle.
Cleaning a vat
Purging a system
Emptying a tank
Packing and sealing a carton
The following graphic represents subroutines in a processor

operating cycle:
Input Scan
Processor Housekeeping
Program Scan
Communications
Output Scan
Subroutine
Scan
Program Scan
Continues
Rev. February 2007

PC1sb85r
15--4
Point out that the JSR, SBR, and RET

instructions are used to pass selected
values to a subroutine so that the
subroutine can perform mathematical or
logical operations on the data and return
the results to the main program.
JSR (Jump to Subroutine): An output instruction that directs the

controller to jump to a targeted subroutine file.
An example of a JSR instruction is shown in the following graphic:
SBR (Subroutine): An input instruction that marks the beginning of

a subroutine and stores incoming parameters (optional).
RET (Return): An output instruction that marks the end of a
subroutine execution or the end of the subroutine file (optional).
Mention that if a sequence of nested
subroutines is used, the RET instruction
will cause the processor to resume
program execution in the previous
subroutine.
JSR, SBR, and RET instructions direct the processor to go to a

separate subroutine file within the ladder logic program, scan that
subroutine once, and return to the point of departure. The following
graphic shows the instructions used to execute a subroutine file:
Main Program
Subroutine File 6
SBR
6
JSR
RET
Mention that an error occurs if more than

eight subroutines are called (subroutine
stack overflow) or if more returns are
executed than there are call levels
(subroutine stack underflow).
Point out that subroutine level 2 is
nested in subroutine 1.
Main Program
5
JSR
Nested Subroutine File: A subroutine executed from a JSR

instruction in another subroutine.
Nesting subroutines allows you to direct program flow from the main
program to a subroutine and then on to another subroutine, as long as
there are no more than seven levels of subroutines. The following
graphic shows the instructions used to execute nested subroutines:
Level 1
Subroutine File 5
Level 2
Subroutine File 6
SBR
SBR
Level 3
Subroutine File 7
SBR
6
JSR
7
JSR
RET
RET
RET
Rev. February 2007
PC1sb85r
15--5
MCR Instructions
MCR (Master Control Reset): An output instruction that, when
used in pairs, defines program zones where all non-retentive outputs
may be disabled at the same time for the same length of time.
Reinforce the idea that TON, TOF, and
OTE instructions represent all of the
non-retentive instructions.
Non-retentive outputs reset when rung conditions go false; retentive

outputs do not. MCR instructions turn off all non-retentive outputs in
a section of ladder logic.
The following graphic shows the non-retentive instructions:
Non-Retentive Instructions
TON
TIMER ON DELAY
Timer
Time base
Preset
Accum
TOF
TIMER OFF DELAY
Timer
Time base
Preset
Accum
(EN)
(DN)
(EN)
(DN)
O:4
( )
2
Mention that MCR zones are used to

enable or inhibit segments of the
program, such as for recipe applications.
Rungs within an MCR zone are still scanned.

The true and false states for MCR instructions are summarized in the
following table:
If the MCR rung that starts
the zone is . . .
Tell students that a hard-wired master

control relay should still be installed to
provide emergency I/O power shutdown.
Remind students that an MCR
instruction should be placed as the last
instruction in a rung.
Then all non-retentive outputs within the

MCR zone are . . .
True
Turned on or off according to rung continuity (as if the zone

did not exist)
False
Turned off regardless of rung continuity
Keep these points in mind when interpreting MCR instructions:

The MCR instruction is not a substitute for a hard-wired master
control relay that provides emergency stop capability.
TOF timers will activate when placed inside of false MCR zone.
If an unmatched MCR instruction exists in the project, the END
instruction is used to mark the end of the MCR zone.
Rev. February 2007

PC1sb85r
15--6
Temporary End (TND) Instruction

Temporary End (TND): An output instruction that controls the
scanning operation of a processor.
The following graphic shows an TND instruction:
When the logic preceding the TND is true, then the following
operations are completed:
The processor is stopped from scanning the rest of the program
The I/O are updated

The processor resumes scanning at rung 0 of the main program
(file 2)
Point out that when the TND instruction

is used inside a nested subroutine,
execution of all nested subroutines is
terminated.
If this instruction rung is false, the processor continues the scan until
the next TND instruction or the END statement.
AFI Instruction
Explain how an AFI can be used to
temporarily disable a rung or branch of
ladder logic.
AFI (Always False): An input instruction that makes the rung false
when inserted in the condition side of the rung.
The following graphic shows an AFI instruction as the first input
instruction on a rung:
An AFI instruction is used to disable a rung temporarily for program

debugging.
Rev. February 2007

PC1sb85r
Heres How
Demonstrate the following actions using
CCP412_1785r_DEM1.rsp:
1. Place processor in Remote Run
mode.
15--7
To interpret and edit program control instructions using RSLogix 5

software.
examples:

enter a 8.
access to N10:0.
4. Demonstrate the JMP instruction.
Example
Interpreting JMP and LBL Instructions

The following graphic shows an example of JMP and LBL
instructions. In the example, note the following:
When I:002/1 is closed, the processor scan jumps forward to the
corresponding label instruction.
Program execution continues at the LBL instruction.
Rev. February 2007

PC1sb85r
15--8
Example
Interpreting JSR, SBR, and RET Instructions
? Are the SBR and RET instructions

required in a subroutine?
Answer: No.
The following graphic shows an example of JSR, SBR, and RET

instructions. In the example, note the following:
When rung 0 in program file 2 is true, the processor calls program
file 3. When the processor finishes scanning program file 3 it
returns to program file 2 and begins scanning rung 1.
When rung 2 in program file 3 is true and the processor is
scanning program file 3, the processor calls program file 4. When
the processor finishes scanning program file 4, it returns to
program file 3 and begins scanning rung 3.
Jump to Subroutine
(File 3)
Jump to Nested
Subroutine (File 4)
Return to File 2
Return to File 3
Rev. February 2007

PC1sb85r
Example
1. Turn on Pushbuttons 0, 5, and 1.
2. Using I:002/7, demonstrate the MCR
instruction.
3. Point out which outputs are retentive
and which are non-retentive.
4. Press Pushbutton 6 to show that
O:003/6 does not unlatch in the
MCR zone.
15--9
Interpreting MCR Instructions

The following graphic shows an example of an MCR instruction. In
the example, note the following:
When inputs I:002/0, I:002/5, and I:002/1 are set, outputs
O:003/0 and O:003/6 are energized and the T4:6 timer begins
timing.
When input I:002/7 is closed, the MCR zone is activated.
O:003/0 is de-energized, and the TON timer stops timing.

O:003/6 remains on because it is a retentive output.
When I:002/1 is de-energized, the T4:7 timer begins timing.
? What are some examples of
non-retentive outputs? Retentive

outputs?
Answer: TON and TOF
instructions are non-retentive.
RTO, CTU, and MOV
instructions are examples
of retentive outputs.
? In an MCR zone, do
outputs turn off when the

first MCR rung is true or false?
Answer: If the first rung is
true, then all non-retentive
outputs are turned on or off
according to rung continuity.
If the first rung is false, then all
non-retentive outputs are
turned off, regardless of
rung continuity.
? If a second MCR instruction

does not mark the end of an
MCR zone, where does the
zone end?
Answer: The END instruction

marks the end of the MCR zone.
Rev. February 2007

PC1sb85r
15--10
Example
1. Point out the execution of the
free-running counter in rung 8:11.
(Its only a demonstration.)
2. Demonstrate that the counter is not
executed when Pushbutton 10 is off.
(The TND instruction is executed.)
Example
1. Point out that the rung is disabled
with the AFI instruction in place.
2. Demonstrate that the run is disabled
by pressing Pushbutton 3 and
displaying B3:0/6 in the
data table.
Interpreting TND Instructions

The following graphic shows an example of a TND instruction. In
When I:002/10 is set, the TND instruction stops the processor
from scanning the rest of the program file.
I/O is updated, and the processor resumes scanning at rung 0 of
the main program file.
Interpreting AFI Instructions

The following graphic shows an example of an AFI instruction. In
The AFI instruction makes the rung false, even if I:002/3 is set
The rung is disabled
Rev. February 2007

PC1sb85r
Exercise: Interpreting and Editing Program Control Instructions Using RSLogix 5 Software
15--11

Program Control Instructions
Exercise A
In this exercise, you will practice interpreting program control

instructions.
Context:
A PLC-5 processor is showing a fault at powerup. You have the
responsibility to determine the processor status and to clear the error.
aid(s).
Rev. February 2007

PC1e85r
15--12
Directions:
space provided:
A. When is the JMP instruction true?
B. What will happen when the JMP instruction is true?
C. Is the CPT instruction affected by the JMP-LBL zone? Why

or why not?
Rev. February 2007

PC1e85r
15--13
space provided:
A. When are the rungs within the MCR zone executed false?
B. What happens to O:003/04 as a result of I:002/05 being

false?
C. What is the purpose of the last MCR instruction?
Rev. February 2007

PC1e85r
15--14
3. In the following ladder logic, when is the subroutine file 4

executed?
Rev. February 2007

PC1e85r
15--15
4. In the following ladder logic, when does the program return to the
main program?
How Did You Do?
Rev. February 2007

PC1e85r
15--16
Exercise B
In this exercise you will practice editing program control

instructions.
Contexts:
You have been assigned the task of modifying a program to include a
new packaging system. You have been given a printout of the
instructions with hand-written instructions from the lead
programmer.
aid(s).
Directions:
1. Open the PC1_1785r_B1.rsp project.
2. Make the modifications to the program indicated:
3. When I:002/17 is on, which rungs will be skipped?
Rev. February 2007

PC1e85r
How Did You Do?
Rev. February 2007
15--17

PC1e85r
15--18
Answers
Exercise A
1.
A. The JMP instruction is true when input instruction (I:002/07)
is true.
B. When the JMP instruction is true, the second, third, and
fourth rungs will not execute (freeze in last state).
C. The CPT is not affected because it is outside of the
JMP--LBL zone.
2.
A. The rungs within the MCR zone are executed false when
input instruction (I:002/05) is false.
B. O:003/04 remains in its last state (on remains on, off remains
off).
C. The last MCR instruction signifies the end of the zone.
3. Subroutine file 4 is executed while input instruction (I:002/17)
is true.
4. The program returns to the main program after one program
scan of the subroutine.
Tip "
If time permits, download PC1_1785r_A1.rsp to test your answers.
Rev. February 2007

PC1e85r
15--19
Exercise B
2. The result of the edits are shown below:
Skipped
Rungs.
3. The rungs within the JMP and LBL zone, rungs 1 through 3
will be skipped as shown in the above graphic; therefore, the
CTU instructions on those rungs will be skipped.
Rev. February 2007

PC1e85r
15--20
Rev. February 2007

PC1e85r
Lesson
16
Forcing Inputs and Outputs Using

RSLogix 5 Software
What You Will Learn
After completing this lesson, you should be able to force inputs and
outputs using RSLogix 5 software by performing the following
tasks:
Force an I/O bit using the Ladder window or the force files
Remove or disable forces from I/O bits using the Ladder window
or the force files

Forcing I/O bits allows the troubleshooter to verify inputs and
outputs. When forcing mistakes are made, unintended machine
motion or loss of process control can occur, thereby injuring
personnel and damaging equipment.
Before You Begin
? How often do you use forcing at your

company? For what situations?
Force Functions
Force: A software function that allows a user to energize or
de-energize an input or output independent of the ladder logic.
Forcing an I/O bit can be used for any of the following
troubleshooting situations:
Checking the field wiring
Checking the functionality of field output devices

Testing a portion of the ladder logic
Simulating inputs that have not been wired
Temporarily correcting mis-wired field devices
Forcing an I/O bit can be accomplished by using either of the

following functions:
Force-On Function: A function that allows a user to turn on
either a bit in the input image table, regardless of the state of the
input circuit, or an output circuit, regardless of the state of the bit
in the output image table.
Force-Off Function: A function that allows a user to turn off
either a bit in the input image table, regardless of the state of the
input circuit, or an output circuit, regardless of the state of the bit
in the output image table.
Rev. February 2007

FRCsb85r
16--2
Rules for Forcing

Follow these rules when forcing I/O bits:
Always check for installed forces in the program before enabling
forces
Apply forces only to real inputs and outputs

Explain that if force protection exists,
forces cannot be enabled.
Understand the following points when using forcing functions:

Enabling or disabling forces acts on all installed forces.
Uploading the program uploads the forces.
If forces are enabled, any additional installed forces will take
effect immediately.
Forces are saved and downloaded with a project.
Tip "
? Does your company have a policy

regarding forcing?
Forcing has priority over ladder logic and ladder logic has priority
over toggling a bit.
Safety Precautions
All force functions can result in sudden machine movement.
Consider these factors before forcing:
Potential danger to personnel
Machine response to forced I/O
Possible effects on other portions of the machine/process
Company policy concerning forcing I/O (Is authorization

required?)
Use EXTREME CAUTION when using forcing.

All force functions can result in sudden machine
movement, possibly injuring personnel or damaging
equipment. If forces are established, enabling forces
will enable all forces without prompting. If forces
are enabled, any additional forces will take effect
immediately. Before proceeding, verify the status of
forces, verify that you are online to the correct
processor, notify personnel of the proposed
changes, and take adequate safety precautions.
Rev. February 2007

FRCsb85r
16--3
Force Files
Force Files: Tables used to monitor forces, install forces, or enable
or disable an installed force.
? How can you determine if forces

exist in a project?
The force files for both inputs and outputs are accessed from the
project tree:
Answer: Examine the force files or the

ladder logic.
Location of
Force Files in
the Project Tree
Point out that all enabled forces are

shown in red.
A forced input, displayed in both the Ladder window and the force
file, is shown in the following graphic:
Input Bit (I:002/14) Forced

on in the Ladder Logic
Force Value
Displayed in
Grid
Rev. February 2007

FRCsb85r
16--4
? Does forcing an output affect any

logic that examines that bit?
Answer: No.
R
E
A
L
Input
Force
Table
I
N
P
U
T
S
An input force file modifies the data that is received from the input
modules, and an output force file modifies the data that is being sent
to the output modules, as shown in the following graphic:
Input
Image
Table
Program
Files
Output
Image
Table
1110000000
- - ] [- - - - - - - - - - - - - - - - - - - - - - ( )-
1110000111
0011000000
- - ] [- - - - - - - - - - - - - - - - - - - - - - ( )-
0011000100
0000000000
- - ] [- - - ] [- - - - - - - - - - - - - - - - - ( )-
0000010100
1111111001
- - ] [- - - - - - - - - - - - - - - - - - - - - - ( )-
1101111001
Output
Force
Table
R
E
A
L
O
U
T
P
U
T
S
CR
Relationship between Forcing Inputs and Input Image Tables

Forcing inputs influences the input image table bit, and the forces
override real-world input conditions.
Point out that forces can be installed,

enabled, or disabled while monitoring
the file offline or in any processor mode
while monitoring the file online.
Forcing allows users to override the actual status of external input

circuits by forcing external input data file bits on or off. The value of
the inputs is written to the data table and not to real field devices.
An example of an input image table is shown in the following
graphic:
Forced Bit
? Does forcing an input affect any logic

that examines that bit?
Answer: Yes.
Rev. February 2007

FRCsb85r
16--5
Relationship between Forcing Outputs and Output Image Tables

Mention that when you force an output,
the value is written to real I/O not the
data table.
Forcing outputs influences the output device but does not affect the
output image table bit.
Point out that all enabled

forces are shown in red. The
file type and number and
the data file bit will be
highlighted in red.
A forced output, displayed in both the Ladder window and the output
image table, is shown in the following graphic:
Ladder logic
output is
forced on.
Force Value
Displays 0 (Off)
Heres How
1. Go online to the
enter a 3.
access to N10:0.
To force input and outputs using RSLogix 5 software by performing

the following tasks:
Forcing an I/O bit using the Ladder window or the project tree
Remove or disable forces from I/O bits using the Ladder window
or the project tree


4. From the force files, force inputs and
outputs on and off.
Show that forced inputs affect the
data file and ladder logic.
Show that forced outputs do not
affect the data file or ladder logic.
5. From the ladder logic, force inputs
and outputs on and off.
Cover these points:
nProcessor LED indicates force status
n Online toolbar indicates force status
n Enabled forces enable all forces
n Additional forces take immediate
affect when forces are enabled
Rev. February 2007

FRCsb85r
16--6
Rev. February 2007

FRCsb85r
16--7
Exercise: Forcing Inputs and

Outputs Using RSLogix 5 Software
Exercise A
In this exercise, you will practice forcing inputs and outputs using
RSLogix 5 software.
Context:
You are setting up a new lid-installation station on the paint line. You
need to check out the output devices and the wiring to them. To do
this, you decide to turn on the outputs temporarily by forcing them.
Tip "

refer to the Application Overview appendix .
aid(s).
Directions:
1. List the situations that might determine when forcing is used.
2. List the factors to consider before using forcing.
3. Open the FRC_1785r_A1.rsp project, download it, go online,

and verify that the processor is in Run mode.
Rev. February 2007

FRCe85r
16--8
4. On your workstation, turn off I:002/10 (CAN_FULL) and turn on

I:002/11 (SEALER_DONE).
5. From the Ladder window, force the I/O device either on or off
using the information in the table below as a guide. Push the
buttons as indicated. Record the results in the third column and
then remove or disable the forces:
If you force I:002/10 . . .
On
Off
And . . .
Then light 7 is . . .
Turn on button 10
Turn off button 10
Turn on button 10
Turn off button 10
6. From the project tree, force the I/O device either on or off using
the information in the table below as a guide. Push the buttons as
indicated. Record the results in the third column and then remove
or disable the forces:
If you force O:003/05 . . .
On
Off
How Did You Do?
And . . .
Turn on button 2
Turn off button 2
Turn on button 2
Turn off button 2
Rev. February 2007

FRCe85r
Rev. February 2007
16--9

FRCe85r
16--10
Answers
Exercise
1. The following situations might determine when forcing is used:
Checking the field wiring

Checking functionality of field output devices
Testing a portion of the program logic
Simulating inputs that have not been wired
Correcting mis-wired field devices temporarily
2. The following factors should be considered before using

forcing:
Potential danger to personnel

Machine response to forced I/O
Possible effects on other portions of the machine/process
Company policy concerning forcing I/O (Do you have
authorization?)
6.
If you force I:002/10 . . .
On
Off
And . . .
Turn on Switch 10
Turn off Switch 10
Turn on Switch 10
Turn off Switch 10
On
On
Off
Off
And . . .
Turn on Switch 2
Turn off Switch 2
Turn on Switch 2
Turn off Switch 2
On
On
Off
Off
7.
If you force O:003/05 . . .
On
Off
Rev. February 2007

FRCe85r
Lesson
17
Configuring and Previewing a

Project Report Using RSLogix 5
Software
What You Will Learn
After completing this lesson, you should be able to configure and

preview a project report using RSLogix 5 software.

Being able to print ladder logic, multiple program files, or database
information is key to formulating troubleshooting analysis and
strategy. Printed project information provides a professional means
of sharing critical information with other operators and superiors.
Project reports also can be used as a valuable hard-copy archive.
Before You Begin
Print Options
RSLogix 5 software provides two options for creating printouts:
Print View: Used to print the ladder logic of a program file.
Print Report: Used to print multiple program files or additional
information such as the database or data files.
Printing is only accomplished offline.
Tell the students that all of the options

for report configuration are listed in the
online Help.
Report Options
The report options can be activated from the File pull down menu:
Report Options
Point out the print options in the file

menu.
Rev. February 2007

CP1sb85r
17--2
Configuring and Previewing a Project Report Using RSLogix 5 Software
Report Options Dialog Box: A dialog box that allows for a variety
of printing options.
The Report Options dialog box, as shown in the following graphic, is
used to select the report(s) to be previewed or printed:
Mention that the Procedures Guide lists
all of the procedures for configuring and
printing a report.
Report Selection
Layout Selection
Print and Print Preview
Mention that a program file or data file

report also can be viewed by selecting
File and then Print Preview, when those
files are in the
current view.
Tell students that the print preview
window is the same as the report
preview window except that it lacks the
following toolbar items: Report Selection
List, Next File, Prev File, and
Options.
Heres How
1. Open the CCP412_1785r_DEM1
project offline.
Rung numbers, documentation, and address

formats print according to how they are
configured in the Ladder setup of the Report
Options dialog box.
Print Preview: A print preview window that allows ladder logic to

be viewed before printing.
Report Preview: A print preview window that allows various
processor files to be viewed before printing.
To configure and preview a project report using RSLogix 5 software.
2. Walk through the various report

options and configure the report
options based on student interest.
3. Set up a preview of a report to be
printed and use the toolbar buttons
on the preview screen to view
different pages of your report
4. If no printer is available, discuss how
printing would be accomplished.
Rev. February 2007

CP1sb85r
17--3
Exercise: Configuring and

Previewing a Project Report Using
RSLogix 5 Software
Exercise A
In this exercise, you will practice configuring and previewing a

project report using RSLogix 5 software.
Context:
You have found that it is easier to troubleshoot problems with your
system while looking at a paper copy of the project. You want to
have a copy of the ladder logic and cross-reference reports on hand
in case of an emergency.
aid(s).
Directions:
1. Open the CP1_1785r_A1.rsp project.
2. Configure and preview a report that includes these items:
Title Page (include RSLogix logo)
Processor information
I/O configuration
Channel configuration
Enable even/odd page margins
Program file 2
Database addresses and symbols
Start rung on new page
3. Save the print settings for reuse.
4. Optional: print the report.
How Did You Do?
Rev. February 2007

CP1e85r
17--4
Answers
Exercise A
2. If you configured your report options correctly, they should
appear like the following graphics:
Rev. February 2007

CP1e85r
Rev. February 2007
17--5

CP1e85r
17--6
3. Click the Save/Load option in the Report Options dialog and

name the configuration like the following graphic:
Rev. February 2007

CP1e85r
Lesson
18
Creating a Histogram Using

RSLogix 5 Software
What You Will Learn
After completing this lesson, you should be able to create a

histogram using RSLogix 5 software by performing the following
tasks:
Determine when to create a histogram
Create, save, and modify a histogram

Being able to create a graphical representation of data changes over a
specified period of time is critical to capturing fast-moving or
intermittent data changes. When such data are not logged, erratic
online problems may go undetected. Histograms also provide a
professional means of sharing data changes with other operators and
superiors.
Before You Begin

Mention that a trend chart should not be
confused with a histogram. A trend chart
logs data for more than one address
over a period of time.
Histogram
Histogram: A function of RSLogix 5 software that graphs the on
and off status or data changes of one specified word or bit address
over time.
The histogram function is used to capture data changes that are either
fast moving or infrequent.
Rev. February 2007

HTGsb85r
Creating a Histogram Using RSLogix 5 Software
18--2
Point out that the bottom portion of the

histogram display shows the state of the
bits in the address.
An example of a histogram is shown in the following graphic:
Elapsed
Time
Data Log
Bit 6 On
Bit 6 Off
Mention that a frequently used

histogram configuration can be saved
and loaded, so that the parameters
would not need to be entered each time.
Data that are collected for a histogram are subject to the following
performance limitations:
Speed of the computer
Speed of the communications link to the processor
Number of views active
Point out that a histogram

Tip "
show a picture of bit changes
during the communications scan of the
processor operating cycle.
For data changing faster than one change per second, every change
may not be represented on the histogram view.
Heres How
Demonstrate how to create, save, and
modify a histogram using file
CCP412_1785r_DEM1.rsp.
To create, save, and modify a histogram:

Explain that the terminal must be

dedicated to the histogram.
Note: If you write the histogram to a file
on a personal computer, keep track of
the monitoring process:
--
The write process continues to fill

the hard disk.
--
When remaining disk space on

computer is about 50K, the software
stops recording the histogram and
displays a message that the disk is
full.
Rev. February 2007

HTGsb85r
18--3
Exercise: Creating a Histogram

Exercise A
In this exercise, you will practice creating a histogram.

Context:
You have detected an infrequent sticking problem with a start button.
Based on your intuition, you decide to investigate the problem by
viewing the problem at the bit level with a histogram.
Tip "

aid(s).
Directions:
1. You have an intermittent problem on your process line. You
decide to use a histogram to find the problem. List two reasons
for creating a histogram.
2. Open HTG_1785r_A1.rsp, download it, go online, and verify

the PLC-5 processor is in Run mode.
3. Locate I:002/06 in the ladder logic.
4. Create a histogram on I:002/06.
5. Turn I:002/06 on and off several times and watch the data on the
screen.
6. Begin the recording function on the histogram, and turn I:002/06
on and off several more times.
7. Display vertical grid lines in the graphical display.
8. Modify the histogram by changing the color of the data line for
I:002/06.
9. Save the histogram configuration.
10. Exit the histogram and view the data that was collected in the
hist.log file.
11. If you have access to a printer, print the histogram.
Rev. February 2007

HTGe85r
18--4
How Did You Do?
Rev. February 2007

HTGe85r
Rev. February 2007
18--5

HTGe85r
18--6
Answers
Exercise
1. Histograms are created to capture data changes that are
fast-moving or infrequent.
6. Your histogram should look similar to the following graphic:
7. Display vertical gridlines in the General tab of the histogram

properties as shown in the following graphic:
Rev. February 2007

HTGe85r
18--7
8. Modify the colors of the histogram in the Chart Colors tab of

the histogram properties as shown in the following graphic:
10. The histogram data should be saved in a text file called hist.log
as shown:
Rev. February 2007

HTGe85r
18--8
Rev. February 2007

HTGe85r
Lesson
19
Creating a Trend Chart Using

RSLogix 5 Software
What You Will Learn
After completing this lesson, you should be able to create a trend

chart using RSLogix 5 software by performing the following tasks:
Determine when to create a trend chart
Create and modify a trend chart

Being able to log data by either time or event for more than one
address over a period of time is critical to capturing real and
historical process data changes. When such data are not logged,
erratic online problems that stem from multiple addresses may go
undetected.
Before You Begin

Point out that RSTrendX software is not
a standard feature in RSLogix 500
software.
Trend Overview
RSTrendt software is a flexible and powerful Microsoftr
Windowsr-based software program for collecting and displaying
process data. RSTrendX ActiveX control is a standard feature of
RSLogix 5 software. RSTrendX software can log data based on time
or event and acquires data from the data table.
The trend function should be used in the following situations:
Data acquisition
Explain that the display configurations

within the trend files are saved with the
project; however, logged data is not
retained.
Historical analysis
Process monitoring
Maintenance and troubleshooting
Reporting
The Trends folder is located in the project tree:
Files Containing Trend Charts
Rev. February 2007

TRDsb85r
19--2
Trend Chart
Mention that a trend chart should not be
confused with a histogram. A trend chart
logs data for more than one address
over a period of time.
Trend Chart: In RSTrendX software, a function that displays on and

off status or data changes of up to 100 specified words or bit
addresses in a strip-chart recorder format.
An example of a trend chart for a timer, T4:9, is shown in the
following graphic:
Pens
Data Log
Emphasize the versatility and benefits of

the trend feature, such as data
comparison.
A trend chart has the following features:

Change scaling, time, and display settings
Tip "
Plot one variable against another with X-Y plotting

Switch between real-time and historical displays
Customize trend displays and analysis
Display batch data from a list of time stamped batch trends
Overlay trend snapshots
Display several trend views in multiple windows
A trend configuration can be created while offline or online. The

processor must be online to trend data.
Rev. February 2007

TRDsb85r
Heres How
19--3
To create and modify a trend chart:

1. Open the
3. In the project tree, click the trends
folder to create a new trend chart.
monitor different data points.
5. Use the control buttons at the
bottom of the trend chart to
maneuver forward, backward, or
pause the pen values.
NOTE: Direct students to refer to the

simplified procedure presented here, as
no procedure exists for creating a trend
chart in the Procedures Guide.
1. In the project tree, right-click the Trends folder and select New.
The Add Trend dialog box opens.
2. In the trend name field, type a name for the trend chart.
3. To create an empty chart, click OK.
An icon for the new chart appears under the trends folder in the
project tree.
4. To add pens to the chart, perform the following actions:
A. Double-click the trend icon, to open it.
B. Drag addresses from the ladder logic window or data tables
to the open trend chart. An address does not need to have live
data.
5. To modify the trend chart, right-click within the grid and then
select Chart Properties.
The RXTrend Properties dialog box opens.
6. Configure the trend charts display properties by choosing the
appropriate option(s).
Then select this
tab . . .
To . . .
Tip "
Edit the chart title and configure the chart mode
General
Configure chart display properties, including timebase and radix
Display
Change pen attributes, including tag name, color, width, and style
Pens
Change chart time range and grid lines
X-Axis
Change ordinate values and scale options
Y-Axis
Add snapshot files to the RSTrendx control
Overlays
Configure template commands or select default options
Template
For a description of the parameters listed in each tabbed section,

click Help.
7. If the Apply button is active, click Apply.
8. Click OK.
9. To save the display configuration, close the project.
Rev. February 2007

TRDsb85r
19--4
Rev. February 2007

TRDsb85r
19--5
Exercise: Creating a Trend Chart

Exercise A
In this exercise, you will practice creating a trend chart.

Context:
The reject sensor, I:002/06, of an inspection station needs to be
monitored. The reject sensor identifies improper lid installation. You
are responsible for creating and modifying a trend chart for the reject
sensor and the run-strobe timer.
aid(s).
Directions:
1. List the situations that might determine when to create a trend
chart.
2. Open the TRD_1785r_A1.rsp project.

3. Create a new trend chart for I:002/06 and T4:4.
4. Turn I:002/06 ON and OFF several times and watch the data on
the screen.
5. Change the color of the T4:4.ACC pen.
6. Push the start button for I:002/04 to start the process.
7. Change the refresh rate from 1 second to 3 seconds and then to 50
milliseconds.
8. Close the trend chart.
How Did You Do?

Rev. February 2007

TRDe85r
19--6
Answers
Exercise A
1. A trend chart can be created when the following situations
exist: data acquisition, historical analysis, process monitoring,
maintenance and troubleshooting, and reporting.
3. The configuration of your trend should look similar to the
following graphic:
4. The following graphic shows a trend chart for I:002/06 and

T4:4 :
Rev. February 2007

TRDe85r
19--7
6. The following graphic shows a trend chart for I:002/06 and

T4:4 with a refresh rate of 1 second (to the left), 3 seconds
(center), and 50 milliseconds (to the right):
Rev. February 2007

TRDe85r
19--8
Rev. February 2007

TRDe85r
Lesson
20
Troubleshooting Noise-Related
Problems Using RSLogix 5
Software
What You Will Learn
After completing this lesson, you should be able to troubleshoot

noise-related problems by performing the following tasks:
Identify noise-related problems
Complete a noise diagnosis
Why These Skills are Important

Being able to describe the indications and corrective actions
regarding noise-related problems will help resolve costly project
down-time due to unwanted electrical disturbances. Unsolved
noise-related problems may result in erratic or prolonged project
corruption and system shutdown.
Before You Begin

Emphasize that the Troubleshooting
Guide is a job aid that is designed to
assist in the troubleshooting process
with the assumption that the system has
been up and running properly and that
no changes have been made to the
ladder logic.
PLC-5 Processors Troubleshooting Guide

Use the Troubleshooting Guide to diagnose and correct problems
occurring with a previously operational PLC-5 system. The
troubleshooting guide provides the following information:
Safety precautions and warnings
A flow chart outlining troubleshooting decisions and actions
Reference information for completing steps

Hardware and software procedures used in diagnosing problems
Initial Troubleshooting Actions
Describe activities that may be of

importance but are not covered in the
Troubleshooting Guide, such as
examining maintenance records for
similar occurrences.
The Getting Started section of the troubleshooting guide outlines

the initial actions that you should perform whenever a malfunction or
failure occurs:
1. Ask the operator what happened when the failure occurred.
2. If the problem has occurred before, try the same corrective
action(s).
3. Rule out as the cause or repair all apparent machine or process
problem(s).
4. If the problem is erratic or intermittent, follow the appropriate
tabs in the Troubleshooting Guide.
Rev. February 2007

TNPsb85r
20--2
Noise Diagnosis
Discuss the system areas where
noise-related problems can occur.
Point out that tabs 1 and 10 of the
troubleshooting guide provide the initial
diagnoses that a problem is related to
noise.
Noise: Unwanted electrical disturbances imposed upon a signal that

tend to obscure its data content.
If the problem is erratic or intermittent, it is probably noise-related.
Noise-Related Problems
? Does anyone have an example of a

noise-related situation that occurred at
their work site?
The following factors most often produce memory corruption and

other noise-related problems:
Improper grounding
Power transients and fluctuations
Mis-wired communications networks
Interference from I/O devices, especially inductive loads

Excessive heat
Grounding Requirements
Grounding: The fastening of electrical equipment to a position of
zero potential (earth ground).
Mention that a steel enclosure protects
the processor system from atmospheric
contaminants, electricomagnetic
interference (EMI) and radio frequency
interference (RFI).
The following items should be checked to determine if the system is

properly grounded:
Is paint stripped from all points of contact between the chassis
and the mounting plate?
Are ground wires the proper size and length?
Are ground wires routed away from power wires and potential
noise-generating devices?
Discuss what makes a good chassis and

main bus ground system.
A good chassis and main bus ground system include the following
specifications:
Ground paths are permanent and continuous.
Star washers are used on stud mountings.

Mounting connections are tight.
A 1-inch copper braid or 8 AWG copper wire is used to connect
Discuss minimum impedance, as well as
local codes and ordinances, in regard to
earth ground.
to the chassis.
Rev. February 2007

TNPsb85r
20--3
Example: Grounding Configuration for Remote I/O Systems

Use the graphic to point out standard
wiring practices, such as making contact
with the ground bus.
Enclosure Wall
Standard wiring and grounding guidelines for a remote I/O

system are shown in the following graphic:
Grounding Electrode Conductor
(To Grounding Electrode System)
Ground Bus
I/O Chassis Wall
I/O Chassis
Ground Stud
Ground Lug
Nut
Star Washer
Ground Lug
Rev. February 2007

TNPsb85r
20--4
Example: Grounding Configuration for Extended Local I/O

Systems
Use the graphic to point out the shared
grounding point used in this complex
system.
Enclosure Wall
Standard wiring and grounding configuration for an extended

local I/O system is shown in the following graphic:
Enclosure Wall
Ground Bus
Ground Bus
To Grounding
Electrode System
(Single Point
Only)
Extended
Local I/O
Cables
Power Supply Requirements

Relate the effect of power fluctuations to
potential noise problems.
Power Supply: Electrical circuit that filters, conditions, and supplies

appropriate voltages for system components and circuitry.
The following items should be checked to determine if the system
has an adequate supply of power:
Are excessive power-line fluctuations and transients feeding the
chassis power supply?
Are MOVs (metal oxide varistors) used to suppress power
fluctuations and transients?
Communications Network Requirements
Emphasize the importance of following

standard communications network
connections.
Communications Network: A series of stations that are physically

connected together.
Rev. February 2007

TNPsb85r
20--5
The following items should be checked to determine if

communications networks are properly wired:
Are cables correct for all connections?
Is a termination resistor at each physical end of the DH+t

Discuss how noise-related problems
may be introduced by poor sheilding.
network?
Are communications cables not running in wireways with power
wires?
Do communications cables cross power wires at 90_angles?
Example: Remote I/O Cable Connections
Standard remote I/O cable connections are shown in the
following graphic:
Explain the proper way to connect

shields on the system.
1771-ASB
PLC-5r Processor
Terminals on the
Processor Module
Blue
Shield
Clear
1771-ASB
Terminals on Remote I/O

Adapter Module
Two-Conductor
Shielded Cable
Blue
Shield
Clear
Blue
Shield
Clear
Blue
Shield
Clear
Resistor:
(Switch Selectable on Standard Processor;
External on Enhanced Processor)
Input and Output Requirements

The following items should be checked to determine if inputs and
outputs may be producing electrical interference:
Is the power source the same for chassis power supply and I/O
devices?
Are inductive devices properly suppressed?
Are modules properly seated and locked?
Temperature Requirements
Heat: The transfer of energy from one device to another as a result
of a difference in temperature.
Rev. February 2007

TNPsb85r
20--6
The acceptable operating temperature range for PLC-5 processors is

between 0 to 60 _C (32 to 140 _F).
Point out the importance of spacing
requirements of one or more chassis
within an enclosure.
The following items should be checked to determine if excessive

heat may be causing memory corruption:
Do chassis have required space for convective cooling?
Is enclosure ventilated with a fan if ambient temperature exceeds

60 _C (140 _F)?
Are redundant power supply modules properly derated?
Is chassis mounted horizontally?
Heres How
1. Read through the examples below
with the class.
2. Walk through the tabs of the
troubleshooting guide for each of the
examples.
To troubleshoot noise-related problems by performing the following

tasks:
Identify noise-related problems
Complete a noise diagnosis

As your instructor demonstrates these procedures using the following
examples, follow along in the associated job aid(s).
3. Provide a rationale for your

diagnosis based on the elimination
of non-existent problems.
Example
? What clues indicate that a problem

may be caused by noise?
Answer: It is most likely to be

intermittent.
? Because of the new installation, what

type of noise problem might you
suspect?
Troubleshooting Noise-Related Problems

1. Malfunction Report: The entire system periodically shuts off
and must be restarted. The shut-down does not follow a pattern
and a similar system at another location does not experience the
problem.
2. Operator Reports the Following: A new machine was installed
on the line and is now in start-up. The PLC-5 processor is
experiencing I/O communication errors intermittently.
Answer: The I/O communications

cables are possibly bundled with the
power cables of the new machine.
Rev. February 2007

TNPsb85r
20--7
Exercise: Troubleshooting
Noise-Related Problems Using
RSLogix 5 Software
Exercise A
In this exercise, you will practice troubleshooting noise-related

problems.
Context:
You typically receive reports that describe various malfunctions in
your facility. From past experience, you find that it is most expedient
to suspect and rule out noise-related problems as the first step in your
troubleshooting routine.
aid(s).
Directions:
Troubleshoot the following malfunctions and determine which are
noise-related problems. For each scenario that is a noise problem,
suggest some solutions.
1. Operator Reports the Following: The system works fine,
except the speed of the output conveyor never changes speed in
response to commands from a pressure sensor in the process.
Noise-related problem? Yes _____
If yes, list possible solutions.
Rev. February 2007
No ______

TNPe85r
20--8
2. Operator Reports the Following: In one particular chassis

there are occasional failures of every output device. You have
spent hours watching this system and have never witnessed a
failure. Similar systems in the plant work just fine. You think it is
the operator, so you convince the foreman to rotate the operators
among the other systems. Different operators continue reporting
random failures on the same system.
No ______
If yes, list things you would start looking for.
3. Operator Reports the Following: The solenoid-operated reject

plunger occasionally fails to extend far enough to push the bad
parts completely off the conveyor line. This causes the line to
jam. Your observation indicates that the plunger at least tries to
extend every time that it should, but sometimes fails to extend far
enough.
If yes, list possible solutions.
No ______
4. Operator Reports the Following: Some I/O points are added to

an existing chassis, an application program is acting erratically,
and proximity switches are not providing true data.
No ______
If yes, list things you would start looking for.
How Did You Do?
Rev. February 2007

TNPe85r
Rev. February 2007
20--9

TNPe85r
20--10
Answers
Exercise A
1. This is probably not a noise-related problem because exactly the
same error occurs every time. A noise-related problem would
probably cause the conveyor to randomly change speeds.
2. This is probably a noise-related problem because it is random and
not related to the operator.
You should concentrate on the particular chassis and look for
tightness and continuity of earth grounds to the cabinet and
chassis ground buses. Also check incoming and outgoing remote
I/O cables for appropriate clearances from the AC power cables.
3. This is not a noise-related problem. The output point energized
every time as it should. The plunger is probably starting to stick
or jam.
4. This is probably a noise-related problem because it is random and
not related to the operator.
Verify that the output wires controlling motor starters are not
placed in the same raceway and bundled with the proximity
switch wires.
Rev. February 2007

TNPe85r
Lesson
21
Troubleshooting Discrete I/O

Software
What You Will Learn
After completing this lesson, you should be able troubleshoot

discrete I/O problems by performing the following tasks:
Identify a discrete device by identifying the corresponding I/O
module
Troubleshoot discrete I/O problems

Because the discrete I/O system provides the most common physical
connection between the PLC-5 processor and field devices, and
because over 80 percent of system failures are related to field
devices, being able to correctly identify problems related to discrete
devices will streamline your efforts while troubleshooting problems
related to digital signals.
Before You Begin

Mention that digital signals are
noncontinuous and only have two states:
On or Off. Contrast this with analog
signals, which are continuous.
Discrete I/O System Overview

Discrete I/O System: A system that provides the physical
connection between a PLC-5r processor and field devices that
transmit and receive digital signals.
Discrete Signal: A signal that only has two states: on or off.
Discrete Input Device: An input device that produces a digital
signal. The following examples are discrete input devices:
Circuit breakers
Limit switches and photoelectric eyes
Motor starter contacts

Pushbuttons
Relay contacts
Discrete Output Device: An output device that receives a digital
signal. The following examples are discrete output devices:
Alarms
Lights
Motor starters
Solenoids
Valves
Rev. February 2007

TDPsb85r
21--2
Discuss these simplified schematics for

the operation of the input modules.
Discrete Input Module: A device that interprets non-continuous

signals from field devices into discrete data that can be interpreted
by a PLC-5 processor.
An input module responds to an input signal in the following
manner:
Input
Input
Filtering
Optical
Isolation
Module
Logic Circuit
Backplane
LED
1. Input filtering limits the effects of voltage transients caused by

contact bounce and/or electrical noise.
Point out that the backplane is the
pathway along which data moves.
2. Optical isolation shields backplane circuits and module logic

circuits from possible damage due to electrical transients.
3. The module logic circuit process the signal.
4. An input light-emitting diode (LED) turns on or off, which
indicates the status of the corresponding input device.
Example: Discrete Input Module
Mention that terminal identification

diagrams are located on each module,
thereby making terminal identification
easier.
An example of a 16-point discrete input module (1771-IAD) is

Not Used
Not Used
Not Used
Not Used
Input 00
Input 01
Input 02
Input 03
Input 04
Input 05
Input 06
Input 07
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
Input 17
L2
A
B
C
D
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
E
Terminals A through D
are not used.
L1
AC/DC High
L2 (Common)
AC/DC Low
Rev. February 2007

TDPsb85r
21--3
Discrete Output Module: A device that converts discrete data to a

digital signal and passes it to a field output device.
Note that discrete output modules are

available in 8-, 16-, and 32-bit types.
An output module controls the output signal in the following

manner:
Backplane
Module
Logic Circuit
Optical
Isolation
Output
Filtering
Output
LED
Note that if an output is to be energized,

the logic section of the output module
will maintain a 1, which corresponds to
the output image table. This will send an
on signal through the isolation circuit,
which in turn, switches the voltage to the
field device via the power section of the
module.
1. Module logic circuits determine the output status.

2. An output LED indicates the status of the output signal.
3. Optical isolation separates logic conditions (module logic circuit
and backplane circuit) from the output field signal.
4. Output filtering protects the circuit from electrical noise.
Example: Discrete Output Module
Mention that status LEDs will be

discussed in the diagnosis portion of the
lesson.
L1
L1
L1
L1
Output 00
Output 01
Output 02
Output 03
Output 04
Output 05
Output 06
Output 07
Output 10
Output 11
Output 12
Output 13
Output 14
Output 15
Output 16
Output 17
L2
An example of a 16-point discrete output module (1771-OAD) is

A
B
C
D
00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
E
L1
AC High
Output
Device
L2 (Common)
AC Low
Rev. February 2007

TDPsb85r
21--4
Troubleshooting Discrete I/O Problems

If the problem is not erratic or intermittent, it is probably not
noise-related. Tabs 1A and 5 of the PLC-5 and RSLogix 5
Troubleshooting Guide provide the initial diagnoses that a problem is
related to discrete I/O:
Is the system running
but 1 or 2 devices
appear to have
failed?
Yes
Is the malfunctioning device

controlled by a discrete output
module?
Refer to Appendix E
Yes
Troubleshooting
Discrete I/O
Status LEDs and fuse indicators are used to troubleshoot discrete I/O
modules. Status LEDs provide information about the following
components:
Field devices
Wiring
I/O modules
Mention that if fuse replacement does
not correct the problem, the module
should be replaced.
Tip "
Point out that in Program mode the
indicator will not come on, even if the
fuse is blown.
A blown fuse indicator indicates the status of the protective fuse in

the output circuit.
The fuse indicator light will only work in Run mode.
Examples of front panel indicators in typical discrete I/O modules
are shown in the following graphic:
Module Active
Indicator
(Green)
Module Active
Indicator
(Green)
00 to 17 Status
Indicators (Red)
00 to 17 Status
Indicators (Red)
1771-IAD Input Module
1771-OAD Output Module
Fuse Blown
Indicator (Red)
Rev. February 2007

TDPsb85r
Heres How
Provide troubleshooting situations and
demonstrate how you would identify
failed I/O as connected to a discrete
device. The following are possible
examples:
21--5
To identify a discrete device by identifying the corresponding I/O

module:
1. Product is not stopping at labeling

station.
2. Temperature control is not shutting
down at the proper temperature.
3. Product loading station is not putting
enough product in the container.
Heres How
Using your workstation and the
CCP412_1785r_DEM2.rsp project,
simulate troubleshooting the following
malfunctions:
To troubleshoot a discrete I/O problem:

1. Output does not turn on, status

indicator is off, and the output
instruction is intensified.
2. Output does not turn on, status
indicator is off, and the output
instruction is not intensified.
3. Output does not turn on, but the
status indicator is on.
4. Output does not turn off, the status
indicator is on, and the output
instruction is intensified.
5. Output does not turn off, the status
indicator is on, and the output
instruction is not intensified.
6. Output does not turn off, and the
status indicator is off.
Rev. February 2007

TDPsb85r
21--6
Rev. February 2007

TDPsb85r
21--7
Exercise: Troubleshooting Discrete

I/O Problems Using RSLogix 5
Software
Exercise A
In this exercise, you will practice identifying discrete devices by

identifying the corresponding I/O module.
aid(s).
Directions:
Use the Troubleshooting Guide to determine if a problem device
connected to the following modules is a discrete device:
The problem device is connected to a . . .
Is it a discrete device?
1771--IA
1771--OFE2
1771--IBD
1771--E4
1771--IG
How Did You Do?
Rev. February 2007

TDPe85r
21--8
Exercise B
In this exercise, you will practice troubleshooting discrete I/O

problems.
Context:
You have been provided with information regarding certain discrete
I/O problems, and you need to provide suggestions for correcting the
problem.
Directions:
Look at each of the following modules, indicators, and devices. Use
the Troubleshooting Guide to find the likely cause and determine
corrective actions.
R5
G2 G
1771--OBD
G3 G
D
C 1
0
O TO
U 6
T 0
P V
U
T
Tip "
ACTIVE
00 10
01 11
02 12
03 13
04 14
05 15
06 16
07 17
FUSE
Winder will not start.
Shaded areas indicate lights or indicators are on.

1. The winder will not start. Suggested corrective action:
Rev. February 2007

TDPe85r
R5
G2 G
21--9
1771--OAD
G3 G
A
C 1
2
O TO
U 1
T 2
P O
U V
T
ACTIVE
00 10
01 11
02 12
03 13
04 14
05 15
06 16
07 17
FUSE
SOL- 12
Solenoid will not energize.
Tip "

2. The solenoid will not energize. What has failed?
Rev. February 2007

TDPe85r
21--10
R 26 1771--OBN
I:074
] [
11
G4 G5 G6 G7
D
C 1
0
O TO
U 6
T 0
P V
U
T
00 10 00 10
01 11 01 11
02 12 02 12
03 13 03 13
04 14 04 14
05 15 05 15
06 16 06 16
07 17 07 17
FUSE
O:267
( )
10
Note: There are no MCR, JMP, or JSR
instructions in this program.
Note: The rung agrees with program
documentation.
Heater element will not turn off.
R7
G4 G
1771--IA
G4 G
AC INPUT
120V
Tip "
Fuse Place Holder

3. The heater element will not turn off. What has failed?
Rev. February 2007

TDPe85r
R3
G6 G
1771--OBD
G7 G
D
C 1
0
O TO
U 6
T 0
P V
U
T
Tip "
21--11
ACTIVE
00 10
01 11
02 12
03 13
04 14
05 15
06 16
07 17
FUSE
Alarm will not turn off.

4. The alarm will not turn off. What has failed?
Rev. February 2007

TDPe85r
21--12
R7
G6 G
1771--OA
G6 G
AC OUTPUT
120V
FUSE
BLOWN
Motor will not turn on.

Motor
Tip "

5. The motor will not turn on. Suggested corrective action:
Rev. February 2007

TDPe85r
R3
G4 G
1771--OBD
G5 G
D
C 1
0
O TO
U 6
T 0
P V
U
T
Tip "
21--13
ACTIVE
00 10
01 11
02 12
03 13
04 14
05 15
06 16
07 17
FUSE
Motor
Motor will not turn on.

6. The motor will not turn on. What has failed?
Rev. February 2007

TDPe85r
21--14
R4
G4 G
1771--OAD
I:023
] [
00
G5 G
B3
] [
19
I:021
] [
11
O:045
( )
11

A
C 1
2
O TO
U 1
T 2
P O
U V
T
ACTIVE
00 10
01 11
02 12
03 13
04 14
05 15
06 16
07 17
FUSE
Supply
Pump

documentation.
Pump will not turn on.
R2
G1 G
1771--IA
G1 G
AC INPUT
120V
Fuse Place Holder
O:045/11
Tip "

7. The pump will not turn on. What has failed?
Rev. February 2007

TDPe85r
R7
G6 G
21--15
1771--OA
G6 G
AC OUTPUT
120V
Fuse Blown
Panel light will not turn on.

L- 1
Tip "

8. The panel light will not turn on. What has failed?
How Did You Do?
Rev. February 2007

TDPe85r
21--16
Answers
Exercise A
The problem device is connected to a . . .
Is it a discrete device?
1771--IA
Yes
1771--OFE2
No
1771--IBD
Yes
1771--E4
No
1771--IG
Yes
Exercise B
1. Perform the following actions:
A. Determine the cause of the blown fuse.
B. Repair the problem.
C. Replace the fuse.
D. Reapply power.
2. One of the following situations exist:
I/O chassis power failure

Output module failure
Swing arm/swing arm wiring failure
I/O chassis failure
Input module failure

Adapter module failure
I/O chassis failure
4. One of the following devices has failed, stopped, or been
disconnected:
Output device
Swing arm/swing arm wiring
Output module
I/O chassis
Rev. February 2007

TDPe85r
21--17
5. Perform the following actions:

A. Determine the cause of the blown fuse.
B. Repair the problem.
C. Replace the fuse.
D. Reapply power.
Power to the device has failed, stopped, or been disconnected.

Output device has failed, stopped, or been disconnected.
Swing arm/swing arm wiring has failed, stopped, or been
disconnected.
Field wiring has failed, stopped, or been disconnected.
Output module has failed, stopped, or been disconnected.
I/O chassis power failure

Input module failure
Adapter module failure
I/O chassis failure
Rev. February 2007
Device power failure

Swing arm/swing arm wiring failure
Output device failure
Field wiring failure
Output module failure

TDPe85r
21--18
Rev. February 2007

TDPe85r
Lesson
22
Troubleshooting Analog I/O

Software
What You Will Learn

analog I/O problems by performing the following tasks:
Interpret block transfer status bits
Troubleshoot an analog I/O problem

Knowledge of analog input and output data (i.e., block transfer status
bits) in conjunction with analog I/O module diagnostics can enable
you to correctly identify problems related to analog devices, thereby
streamlining your troubleshooting efforts while troubleshooting
problems related to analog signals.
Before You Begin

Explain that temperature is an example
of an analog signal because it
continuously changes by infinitesimal
amounts (between each degree).
Mention that the analog input and output
data are updated by the processor once
during each scan of the user program.
? What types of analog input devices

are used on your job site?
Analog I/O System Overview

Analog Signal: An infinitely variable voltage or current signal.
Analog I/O System: A system that provides the physical connection
between a PLC-5r processor and analog input and output devices
that produce and receive continuous signals.
Analog Input Device: An input device that produces an analog
signal.
The following examples are analog input devices:
Flow transducers
Humidity transducers
Rev. February 2007
Potentiometers
Pressure transducers
Vibration transducers
Temperature transducers

TAPsb85r
22--2
Remind students that PLC-5 processors,

like other digital computers, are discrete
systems that only understand 1s and 0s;
hence, they cannot interpret analog
signals in their continuous form.
Analog Input Module: A device that translates analog signals into

discrete data that can be interpreted by a PLC-5 processor.
Prior to entering an analog input module, an analog signal typically
passes through the following devices:
Transducer: A device that converts one form of energy to
another (e.g., temperature into electrical signals).
Transmitter: A device that sends data.

Explain that an analog-to-digital
converter (ADC) performs the signal
conversion in the analog input module.
Translation of the analog signal to discrete data is summarized in the

following graphic:
PLC-5
Register/Word
Memory
Location
Analog
Input
Module
Continuous Signal from
Analog Input Device
Discuss the typical wiring connections

for an analog input device.
Analog Signal Transformed to

Digital Data
The following graphic shows a typical connection of an analog input

device:
+
Analog Source
-
Analog Source
+
-
Source Ground
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Channel 1+
Channel 1Channel 2+
Channel 2Not Used
Channel 3+
Channel 3Channel 4+
Channel 4Not Used
Channel 5+
Channel 5Channel 6+
Channel 6Not Used
Channel 7+
Channel 7Channel 8+
Channel 8Module Common
Module Common
1771-WG
Field Wiring Arm
Rev. February 2007

TAPsb85r
22--3
Analog Output Device: An output device that receives an analog

signal.
? What types of analog output devices
The following examples are analog output devices:

Analog valves
are used on your job site?
Actuators
Chart recorders
Electric motor drives
Analog meters
Analog Output Module: A device that converts discrete data to

analog data and passes that data to field control devices.
Analog output modules are connected to analog output devices
through transducers.
Explain that a digital-to-analog converter
(DAC) performs the signal conversion in
the analog output module, exactly
opposite that of the analog input module.
Conversion of discrete data to an analog signal is summarized in the

following graphic:
PLC-5
Register/Word
Memory
Location
Analog
Output
Module
Digital Data Converted to
Analog Signal
Discuss the typical wiring connections

for an analog output device.
Continuous Signal to
Analog Output Device
The following graphic shows a typical connection of an analog

output device:
User
Analog
Device
Ground
A
0
1
2
3
4
5
6
7
B
Channel 1 output (+) lead

Channel 1 output (- ) lead
Not Used
Not Used
Field Wiring Arm

Catalog Number 1771-WC
Rev. February 2007

TAPsb85r
22--4
Interpreting Block Transfer Status Bits

Underscore the differences between
discrete and analog I/O modules;
namely, discrete modules have terminal
points that correspond to bits in the I/O
image table where as analog modules
have channels that correspond to a word
in a data table.
Tip "
For review, PLC-5 processors transfer discrete I/O data and status
data using discrete data transfers. Discrete transfers allow the
processor to transfer up to eight words per rack, and they occur
automatically during the processors input and output scans.
Block transfers are a special type of data transfer that require ladder
logic instructions. Block transfers allow processors to transfer up to
64 words of data between themselves and analog modules.
Block transfers also allow a processor in scanner mode to transfer
large blocks of data to and from a processor in adapter mode.
The following graphic shows a representation of discrete and block
transfers:
Programming
System
Communications
System (Network)
Processor 1
Discrete Modules
Key
Discrete Transfers
Block Transfers
Emphasize that every analog module,

regardless of whether it is an input or
output analog module, requires one BTR
and one BTW instruction to
communicate with a PLC-5 processor.
Data from
Input Devices
Analog Modules
Local I/O System
Control
Outputs
Machine/Process 1
There are two block transfer instructions: BTR (block transfer read)
and BTW (block transfer write). The processor uses BTR and BTW
instructions as follows:
BTW: When the rung goes true, the BTW instruction tells the
processor to write data stored in the data file to the specified
address.
BTR: When the rung goes true, the BTR instruction tells the
processor to read data from a specified address and store it in the

data file.
Every analog module must have one BTR and
one BTW instruction assigned to it.
Rev. February 2007

TAPsb85r
22--5
Example: BTR and BTW Instructions

Mention that information from the BTR
and BTW instructions are stored in
either BT data files or integer files.
An example of BTR and BTW instructions, used by a processor

to communicate with a 1771-IFE module (input analog module),
is shown in the following graphic. Note that the BTW instruction
is used to send status and control information to the module,
while the BTR instruction is used to obtain information from the
module:
The processor runs block transfer instructions

asynchronously to the program scan. The status of
these bits could change at any point in the program
scan.
If you examine these bits in ladder logic, copy the
status once to a storage bit whose status is
synchronized with the program scan; otherwise,
timing problems may invalidate your program with
possible damage to equipment and/or injury to
personnel.
Rev. February 2007

TAPsb85r
22--6
Block Transfer Instruction Components

The eight main components associated with BTR and BTW
instructions are defined as follows:
Component
The type of analog module.
Rack
The rack number of the analog module.
Group
The group number of the analog module.
Module
The slot number (0-1) within the group.
Control Block
The location in memory where information from the BTR or BTW

instruction is stored:
With enhanced PLC-5 processors, this is a six-word block transfer
control file (BT).
With standard PLC-5 processors, this is an integer file (N) with five
words.
Data File
The data file the information is transferred to (BTR) or is transferred from

(BTW). Data files can be I, O, S, N, F, B, BCD, or ASCII.
Length
The number of words to be transferred.
Continuous
Note that when storing the BTR or BTW

information in an integer file instead of a
BT file, you will not be able to use the
status bit references. You will have to
use the appropriate bit address for the
bits in the integer file.
Description
Module Type
The data transfer method for the instruction:

Yes indicates that once the rung containing the BTR or BTW
transitions from false to true, data flows continuously until the CO bit is
set and the rung goes false, or until the BTR or BTW instruction is
edited.
No indicates that only one data transfer occurs per false-to-true
transition of the rung containing the BTR or BTW instruction.
The following status bits of BTR and BTW instructions are used in
troubleshooting analog I/O problems:
This Status Bit . . .
Is Set . . .
When the rung goes true.
.EN -- Bit 15
In non-continuous mode, the .EN bit remains set until the

block transfer finishes or fails and the rung goes false.
In continuous mode, the .EN bit remains set regardless
of the rung condition.
When the block transfer has been completed and the
data is valid.
.DN -- Bit 13
The .DN bit is reset the next time the associated rung
goes from false to true.
When the processor detects that the block transfer has
failed.
.ER -- Bit 12
The .ER bit is reset the next time the associated rung
goes from false to true.
Tip "
Block transfer error codes for enhanced PLC-5 processors are

presented in the Block Transfer Error Codes for Enhanced PLC-5
Processors appendix. This information also is available via online
help in RSLogix 5 software.
Rev. February 2007
TAPsb85r
Remind students that following the

Troubleshooting Guide will narrow the
diagnosis of most analog problems.
Reinforce the idea that distinguishing

between discrete I/O and analog I/O is
the first and major aspect of
troubleshooting analog I/O.
22--7
Analog I/O Diagnosis and Correction

noise-related. Tabs 1A and 5 of the Troubleshooting Guide provide
the initial diagnosis that a problem is related to analog I/O:
Is the system running
but 1 or 2 devices
appear to have failed?

controlled by a
discrete output module?
Refer to Appendix E
Yes
No

controlled by a module
using block transfer?
Reinforce the idea that distinguishing

between discrete I/O and analog I/O is
the first and major aspect of
troubleshooting analog I/O.
Yes
Troubleshooting
Analog I/O
Analog Input Testing

When troubleshooting a voltage-analog input, the analog device
should be disconnected, and a known (good) voltage source should
be provided:
Point out that the variable power source

should be a precision instrument.
+
Analog Source
-
Analog Source
+
-
Source Ground
Variable
External
Power
Source
Rev. February 2007
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Channel 1+
Channel 1Channel 2+
Channel 2Not Used
Channel 3+
Channel 3Channel 4+
Channel 4Not Used
Channel 5+
Channel 5Channel 6+
Channel 6Not Used
Channel 7+
Channel 7Channel 8+
Channel 8Module Common
Module Common
1771-WG
Field Wiring Arm

TAPsb85r
22--8
Analog Output Testing

Remind students that following the
Troubleshooting Guide will narrow the
diagnosis of most analog problems.
When troubleshooting a voltage-controlled analog output, the analog

device should be disconnected, and the voltage at the swing arm
terminals should be measured:
+
User
Analog
Device
Voltmeter
Ground
-

Not Used
Not Used
A
0
1
2
3
4
5
6
7
B
Field Wiring Arm

When troubleshooting a current-controlled analog output, the analog

device should be disconnected, and the current at the swing arm
terminals should be measured:
+
User
Analog
Device
Ammeter
Ground
Load
A
0
1
2
3
4
5
6
7
B

Not Used
Not Used
Field Wiring Arm

Rev. February 2007

TAPsb85r
Heres How
22--9
To troubleshoot analog I/O problems by performing the following

tasks:
Interpret block transfer status bits
Using the troubleshooting guide, walk

students through the example below.
Lead the students through tabs 1, 1A, 5,
and 9B. On tab 9B show that the
possible solutions are as follows:
Troubleshoot an analog I/O problem

1. Cycle power.
2. Reset/restore program.
3. Replace the module.
Example
Troubleshooting an Analog I/O Problem

The following graphic shows an example of an analog output module
and a block transfer instruction. In this example, note the following:
The suspect analog I/O module corresponds to the rack, group,
and module information displayed in the BTW instruction.
Both the .EN and .ER status bits are blinking.
R2
1771-OFE1
G6 G
G7 G
I:074
] [
11
BTW
BLOCK TRANSFER WRITE
2
Rack
7
Group
0
Module
N20:0
Control block
N21:8
Data file
13
Length
N
Continuous
(EN)
(DN)
(ER)
RUN
Valve appears to be stuck closed.
FLT
Tip "
Rev. February 2007

TAPsb85r
22--10
Rev. February 2007

TAPsb85r
22--11
Exercise: Troubleshooting Analog

I/O Problems Using RSLogix 5
Software
Exercise A
In this exercise, you will practice troubleshooting an analog I/O

problem.
Context:
You have been with information regarding certain analog I/O
problems and you need to provide suggestions for correcting each
problem.
aid(s).
Directions:
Look at each of the following modules, indicators, and ladder logic.
Use the Troubleshooting Guide to find the likely cause and suggest
corrective action.
Rev. February 2007

TAPe85r
22--12
R5
G2 G
1771-OFE2
G3 G
I:074
] [
11
BTW
5
Rack
3
Group
0
Module
N20:0
Control block
N21:8
Data file
13
Length
N
Continuous
(EN)
(DN)
(ER)
RUN
Flow valve is not functioning properly.
FLT
Tip "

1. The flow valve is not functioning properly. Suggested corrective
action:
Rev. February 2007

TAPe85r
R2
22--13
1771-OFE3
G6 G
G7 G
I:074
] [
11
BTW
2
Rack
7
Group
0
Module
N20:0
Control block
N21:8
Data file
13
Length
N
Continuous
(EN)
(DN)
(ER)
RUN
Level meter always reads empty.
FLT
Tip "

2. The level meter always reads empty. Suggested corrective action:
Rev. February 2007

TAPe85r
22--14
R7
G0 G
1771-OFE1
G1 G
BTW
7
Rack
1
Group
0
Module
N20:0
Control block
N21:8
Data file
13
Length
N
Continuous
LIM
LIMIT TEST (CIRC)
Low lim
100
Test
High lim
N22:4
0
180
I:074
] [
11
RUN
R7
FLT
G0 G
1771-IFE
BTR
BLOCK TRANSFER READ
7
Rack
0
Group
0
Module
N20:5
Control block
N22:0
Data file
20
Length
N
Continuous
(EN)
(DN)
(ER)
(EN)
(DN)
(ER)
G1 G
documentation.
RUN
FLT
1. Variable range heating element is off.

2. Parts weight scale appears to function properly.
Tip "

3. The variable range heating element is off. Parts weight scale
appears to function properly. Suggested corrective action:
Rev. February 2007

TAPe85r
R5
1771-OFE2
G2 G
G3 G
22--15
Bit is changing states.

BTW
5
Rack
3
Group
0
Module
N20:0
Control block
N21:8
Data file
13
Length
N
Continuous
I:074
] [
11
(EN)
(DN)
(ER)
RUN
Meter is always reading zero.
FLT
Tip "
Tip "
The proper voltage/current is present at the swing arm.

4. The meter is always reading zero. What has failed?
How Did You Do?
Rev. February 2007

TAPe85r
22--16
Answers
Exercise A
1. Possible solutions include cycling power or replacing the failed
module.
2. It is possible that either there is no power to the module or the
power source fuse failed.
3. The possible solutions include cycling power or replace the
failed module:
4. It is possible that the field wiring, the analog device, or the
device power supply has failed.
Rev. February 2007

TAPe85r
Lesson
23
Troubleshooting I/O Channel and

Chassis Problems Using RSLogix 5
Software
What You Will Learn
After completing this lesson, you should be able to troubleshoot I/O

channel and chassis problems using RSLogix 5 software.

I/O channel and chassis problems are indicated in close association
on channel configuration screens and adapter module status
indicators. Being able to discern the difference between I/O channel
and chassis faults can enable you to quickly resolve problems related
to I/O channels or the chassis, thereby streamlining your
troubleshooting efforts and reducing overall downtime.
Before You Begin

Discuss the relationship of the I/O link
between PLC-5 processor and
remote/extended local I/O adapter
modules:
Rev. February 2007
I/O Channel Overview

Standard PLC-5r processors have only one remote I/O channel:
1771- ASB
1771- ASB
1771- ASB
1771- ASB

TCPsb85r
23--2
Discuss the maximum number of remote

I/O channels.
Enhanced PLC-5 processors can have up to four remote I/O

channels:
1771- ASB
1771- ASB
1771- ASB
1771- ASB
1771- ASB
1771- ASB
1771- ASB
Discuss the maximum number of remote

I/O and extended local I/O channels.
Enhanced PLC-5 processors with extended local I/O capabilities can

have up to two remote I/O channels and one extended local I/O
channel:
1771- ASB
1771- ALX
1771- ASB
1771- ALX
1771- ASB
1771- ALX
1771- ASB
Rev. February 2007

TCPsb85r
Use the graphics and examples that

follow that will be most useful to your
students.
Point out that this graphic is what a
normal status screen should look like.
23--3
Channel Configuration Screen Indications

The following graphic shows a channel status screen for a
PLC-5/40t processor, normal remote I/O scanner channel:
No Faults Indicated
Explain that, with the assumption of a

sequential layout, the channel status
screens indicate either channel or
chassis problems based on the
probability of several chassis failing at
one time.
The following graphic shows channel status screens for a PLC-5/40

processor that indicate a faulted remote I/O scanner channel and a
faulted chassis (assume that the system channel was laid out
sequentially):
More than one faulted

chassis indicates a
channel problem.
One faulted chassis usually

indicates a chassis problem.
Rev. February 2007

TCPsb85r
23--4
Remote I/O and Extended Local I/O Adapter Indications

The remote (1771-ASB) and extended local (1771-ALX) I/O adapter
modules have three status indicators on the front plate that can be
used in troubleshooting channel and chassis problems.
Remote I/O Adapter Normal Indications
Explain that a normal indication is when
all adapters active lights are green.
Rack
2
All Active
Lights Are
Green
I/O
LINK
ACTIVE
Communications and hardware are functioning well when the remote

I/O adapters active light is green:
Rack
3
ACTIVE
Rack
4
ACTIVE
Rack
5
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
Remote I/O Adapter Channel Problem

Explain that a channel problem can be
detected when several adapters active
lights are off.
Rack
2
Rack
4
Rack
5
ACTIVE
ACTIVE
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
ACTIVE
I/O
LINK
A channel problem would be indicated by a series of active lights

being off when they should be on:
Rack
3
A series of
active
lights are
off.
Rev. February 2007

TCPsb85r
23--5
Remote I/O Adapter Chassis Problem

A chassis problem would be indicated by a active light off and the
I/O rack fault light on:
Explain that a channel problem can be

detected when several adapters active
lights are off.
Rack
2
ACTIVE
Rack
3
ACTIVE
Rack
4
Rack
5
ACTIVE
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
Heres How
demonstrate the following procedures
and troubleshooting simulations:
One Adapter
with I/O Rack
Fault Light
Indicated
ADAPTER
FAULT
I/O RACK
FAULT
I/O
LINK
REMOTE I/O
ADAPTER
To troubleshoot an I/O channel and chassis problem:

1. Display the I/O status or channel

status screen (refer students to
Appendix B of the troubleshooting
guide).
2. Use the troubleshooting guide to
interpret an I/O status screen.
3. After creating a channel or chassis
problem (such as moving the blue
hose to another channel, removing
the blue hose from the processor, or
lowering a wiring arm from an
adapter module), use the
troubleshooting guide to resolve
those problems.
4. Interpret remote I/O adapter module
indicators.
Rev. February 2007

TCPsb85r
23--6
Rev. February 2007

TCPsb85r
23--7
Exercise: Troubleshooting I/O

Channel and Chassis Problems
Exercise A
In this exercise, you will practice troubleshooting I/O channel and

chassis problems.
Context:
You have been called by an operator of a paint packaging line. The
operator has provided you with the information that more than one
chassis is faulted. This general information makes you suspect that
there may be channel or chassis problem involved, but you need to
review the configuration screens.
aid(s).
Directions:
Use the Troubleshooting Guide to evaluate the problem and suggest
a corrective action in each of the following situations, where all I/O
chassis are wired consecutively by rack number.
Rev. February 2007

TCPe85r
23--8
1. Review the following configuration screen:
A. Is this a channel or chassis problem?
B. What is the rack and channel where the failure occurred?
Rev. February 2007

TCPe85r
23--9
B. What is the rack and channel where the failure occurred?
B. What is the rack where the failure occurred?
Rev. February 2007

TCPe85r
23--10
4. What are the possible solutions to these remote I/O adapter

indications?
Key:
G = Green
Rack
2
Rack
3
Rack
4
Rack
5
R = Red
= Off
I/O
LINK
ACTIVE
ACTIVE
ACTIVE
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
5. What are the possible solutions to these remote I/O adapter

indications?
Key:
G = Green
Rack
2
Rack
3
Rack
4
Rack
5
ACTIVE
ACTIVE
ADAPTER
FAULT
R = Red
= Off
I/O
LINK
ACTIVE
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
I/O RACK
FAULT
REMOTE I/O
ADAPTER
Rev. February 2007

TCPe85r
23--11
6. What are the possible solutions to the following remote adapter

indications?
Rack
2
Rack
3
Rack
4
Rack
5
Key:
G = Green
R = Red
= Off
I/O
LINK
ACTIVE
ACTIVE
ACTIVE
G
R
Alternately
Blinking
ACTIVE
ADAPTER
FAULT
ADAPTER
FAULT
ADAPTER
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
I/O RACK
FAULT
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
REMOTE I/O
ADAPTER
How Did You Do?
Rev. February 2007
ADAPTER
FAULT

TCPe85r
23--12
Answers
Exercise A
1.
A. From the information given, more than one faulted chassis,
this is a channel problem.
B. Racks 3, 4, and 5 on channel 1B have failed.
2.
A. From the information given, one faulted chassis, this is a
chassis problem.
B. Rack 4 on channel 1B has failed.
3.
A. From the information given, one faulted chassis, this is a
chassis problem.
B. Rack 2 has failed.
4. Possible solutions include the following situations:
Troubleshoot power supply problem.

Check to see if wiring is loose or broken between the
processor and the problem I/O chassis.

Repair or replace 1771-AS, -ASC, or -ASB module swing
arm.
Replace adapter module.
5. Possible solutions include the following situations:
Cycle power to the chassis to clear problem resulting from
high noise.
Reseat adapter module.
Remove and replace all I/O modules one at a time.
Replace adapter module.
Replace I/O chassis.
6. Given that the adapter module was reset by processor/scanner,

then immediately faulted, the following possible solutions exist:
Depress the adapter reset button if installed, or cycle power to

the I/O chassis.
Verify proper connection between the module and the swing

arm or cable.
Rev. February 2007

TCPe85r
Lesson
24
Troubleshooting Processor and

Power Supply Problems Using
RSLogix 5 Software
What You Will Learn

processor and power supply problems by performing the following
tasks:
Interpret processor front panel indicators
Determine problems with processor battery backup
Determine problems with power supply elements
Clear a fault

Effective troubleshooting of processor and power supply problems
will avoid costly periods of system faults. Failure to properly
diagnose processor and power supply problems may result in system
or equipment damage due to electrical shorts.
Before You Begin
Processor Front Panel Indicators

Front Panel Indicators: Light-emitting diode (LED) displays
located at the top of the processor.
Emphasis that the LEDs that will be

discussed in this lesson refer directly to
the processor or the power supply and
not to peripheral devices.
All PLC-5r processors have LEDs that provide information

regarding errors in the following areas:
Battery
Processor
Forced I/O
Communications
Rev. February 2007

TPPsb85r
24--2
Point out that, based on the model of the

processor, the relative position of the
LEDs will vary.
An example of front panel indicators of an enhanced PLC--5

processor is shown in the following graphic:
LED Display
Mention the importance of inspecting the

front panel LEDs for quickly identifying
problems.
If the system is operating properly, the processor LED should be

steady green.
Battery LEDs
Interpretation of the battery LED can be summarized as follows:
If the battery
LED is . . .
The probable
cause is . . .
And the recommended action is . . .
Red
Battery low
Replace battery
Off
Normal operation
No action required
Processor LEDs
Emphasize the use of the processor as
a troubleshooting tool.
Interpretation of the processor LED can be summarized as follows:

If the processor
LED is . . .
The probable
cause is . . .
Green (steady)
Normal operation
No action required
Green (blinking)
Normal operation
(EEPROM transfer)
No action required
Red (blinking)
Major fault (Run-time

error)
Check major fault bit in status file (S:11)

for error definition
Clear fault bit
Correct problem
Return to run mode
Red (steady)
Major fault (checksum

error, memory module
error, or internal
diagnostics have failed)
Clear memory and reload program

Check backplane switch settings
Power down
Reseat processor
Power up and then clear memory and
reload the program
Off
Processor is in
Program mode, or Test
mode, or is not
receiving power
Check power supply and connections
Rev. February 2007

TPPsb85r
24--3
Force LEDs
Mention that the 1785 PLC-5
Programmable Controllers Quick
Reference lists all the possible status
indicators under the troubleshooting tab.
Interpretation of the force LED can be summarized as follows:

If the force LED
is . . .
The probable cause is

...
Amber (steady)
Normal operation
(forces enabled)
No action required
Amber (blinking)
Normal operation
(forces present but not
enabled)
No action required
Communications LEDs
Interpretation of communications LED can be summarized as
follows:
If the
communications
LED color is . . .
The probable cause

is . . .
Off
No transmission on
channel 0 (normal
operation if channel is
not being used)
No action required
Green (blinking)
Transmission on
channel 0 (normal
operation if channel is
being used)
No action required
Battery Backup
Explain that lithium batteries are primary
(non-rechargeable) cells that give
extended memory support to the
processor.
Battery Backup: A battery that will provide power to maintain the

contents of processor memory only when the main power source is
off.
Point out that lithium batteries have

specific installation, storage, and
disposal guidelines, which are presented
in the Allen-Bradley publication AG-5.4.
An example of a battery and its relative placement in a PLC-5

processor is shown in the following graphic:
Chassis
PLC-5/20t Processor
Battery Connector
Battery
Battery Cover
Rev. February 2007

TPPsb85r
24--4
Power Supply Elements

Power Supply Elements: Electrical circuitry that includes fuse,
wiring terminals, and jumpers.
All power supplies have an LED that indicates proper power supply
voltage when on.
Mention that the power supply fuse is

intended to guard against fire hazard
due to short-circuit conditions but may
not protect the power supply from
damage.
If power supply voltage is indicated as a potential problem, the

following items should be checked to determine status of these
power supply elements:
Power Supply Fuse: A fuse used to prevent load-side
over-current.
Power Supply Wiring Terminals: Screws on the power supply
to which its power source is wired.
Power Supply Jumper: A short conductor with which two
points are connected and used to select the input voltage to the
power supply.
An example of power supply jumpers is shown in the following

graphic:
Top of Power Module
Cover
Printed Circuit
Board
Jumpers
Turn off all power supply modules before removing

modules from or inserting modules into a chassis.
Failure to observe this warning could alter
processor memory, damage module circuitry, and
cause unintentional operation which could possibly
cause injury to personnel.
Fault
Mention that a watchdog timer monitors
a cyclical process and is cleared at the
conclusion of each cycle, but a fault is
caused when the watchdog runs past its
programmed time period.
Fault: Any malfunction that interferes with the normal operation of

an application.
Faults include the following examples:
Memory errors
Data corruption errors (caused by noise)

Watchdog timer errors
Momentary power problems
Rev. February 2007

TPPsb85r
24--5
Processor and Power Supply Diagnosis and Correction

Have students refer to Tab 1 of the
Troubleshooting Guide as you describe
the initial actions.

noise-related. Tab 1A of the Troubleshooting Guide provides the
initial diagnoses that a problem is related to the processor or power
supply:
Is the entire system shut down?
(Nothing appears to be running.)
Yes
Troubleshooting Processor and

Power Supply Problems
Heres How
simulate troubleshooting processor
problems that are covered by Tab 2 and
2A of the Troubleshooting Guide.
Demonstrate how to use the
troubleshooting guide to isolate power
supply problems.
Use the Procedures Guide to
demonstrate how to clear a fault code.
To troubleshoot processor and power supply problems by performing

the following tasks:
Interpret processor front panel indicators
Determine problems with processor battery backup
Determine problems with power supply elements

Clear a fault
To create a fault:
1. Place the processor in Run mode.
enter a 10.
" The project contains a custom data
monitor for easy access to N10:0.
Rev. February 2007

TPPsb85r
24--6
Rev. February 2007

TPPsb85r
Exercise: Troubleshooting Processor and Power Supply Problems Using RSLogix 5 Software
24--7
Exercise: Troubleshooting
Processor and Power Supply
Software
Exercise A
In this exercise, you will practice troubleshooting processor and

power supply problems.
Context:
You have been provided with general information regarding LEDs
and you are aware that one processor is faulted on a paint line. Using
your knowledge of processor and power supply problems, you are
ready to begin troubleshooting.
aid(s).
Directions:
1. Assume the following hardware indications for an enhanced
processor with an internally mounted power supply:
Power supply LED is on.
Processor LED is flashing RED.
Diagnose and correct the situation:
Rev. February 2007

TPPe85r
24--8
2. Assume the following indications for an enhanced processor with

an internally mounted power supply:
Power supply LED is off.
All processor LEDs are off.
3. Assume the following indications:

Power supply LED is on.
All processor LEDs are off.
Processor is not in Program or Remote Test mode.
4. Open the TPP_1785r_A1.rsp project.

5. Start the project by performing these actions:
A. Place the processor in Remote Run mode.
B. In the ORDER_ENTRY thumbwheel (I:000), enter an order
of 22 gallons.
Tip "
Change the radix in the input data table to Hexidecimal to be sure the
proper number was entered through the thumbwheel.
C. Press START (I:002/04).
Rev. February 2007

TPPe85r
24--9
6. Using bit S:26/1, produce and clear a fault by perform these

actions:
A. To produce a fault:
-----
Set S:26/1 (Control tab of the S2 Data File window).

Turn the keyswitch in the processor to Run mode
Turn off the power to the chassis.
Turn on the power to the chassis.
B. Clear the fault.
How Did You Do?
Rev. February 2007
Turn to the Answer section.

TPPe85r
24--10
Answers
Exercise A
1. Based on the information provided, and starting on tab 2A of
the Troubleshooting Guide, you should have gone to tab 2I. The
instruction boxes on tab 2I instruct you to check the errors tab
of the Processor Status file for error definition and problem file
location. Then the following should be performed: (1) Call
plant engineering to correct program errors, (2) Clear fault
bit(s) by entering a zero in the faulted bit(s), or click Clear
Major Error, (3) Return processor to the Run mode.
the Troubleshooting Guide, you should have gone to tabs 2K
and 3. Tab 3 instructs you to inspect the power switch and the
P/S ACTIVE indicator.
the Troubleshooting Guide, you should have gone to tabs 2K.
Tab 2K instructs you to check power supply cable, replace the
processor, and then restore the program and put the processor in
Run mode.
6. You should see the following graphics when you produce and
clear the fault:
Rev. February 2007

TPPe85r
Lesson
25
Integrated Practice: Maintaining

and Troubleshooting a PLC-5
System
What You Will Learn
After completing this lesson, you should perform the following

tasks:
Communicate with a PLC-5 processor
Identify memory layout and PLC-5 system addressing
Monitor and enter data
Search ladder logic
Force inputs and outputs

Troubleshoot processor and power supply problems, discrete I/O
problems, and analog I/O problems

Being able to maintain and troubleshoot a PLC-5 system involves an
integration of identification and interpretation skills. An efficient use
of these skills will help resolve costly production downtime.
Unresolved problems may result in prolonged project corruption and
system shutdown.
Rev. February 2007

IP1sb85r
25--2
Integrated Practice: Maintaining and Troubleshooting a PLC-5 System
Rev. February 2007

IP1sb85r
25--3
Exercise: Integrated Practice:

Maintaining and Troubleshooting a
PLC-5 System
Exercise A
In this exercise, you will practice maintaining and troubleshooting a

PLC-5 system.
Context:
You are assigned to verify that the IP1_1785r_A1.rsp project
operates correctly. Test and troubleshoot the project as outlined in the
exercise.
aid(s).
Directions:
As you proceed with the exercise, follow these guidelines:
1. Open the IP1_1785r_A1.rsp project and go online.
2. Test the operation of the IP1_1785r_A1p.rsp project by
completing the following checks:
A. Place the processor in Remote Run mode.
B. In thumbwheel 1, enter a paint order of 0506 (50 gallons of
recipe number 6) and then enable MANUAL_LOAD
(I:002/05).
Tip "
Change the radix in the input data table to Hexidecimal to be sure the
proper number was entered through the thumbwheel.
C. Press START (I:002/04) and verify that the RUN_LIGHT
(O:003/17) is flashing.
Tip "
The project was saved with CAN_FILLER forced off, so you may
have to remove the force to complete step C.
D. Load the paint recipe by pressing I:002/00.
E. Load the colors by pressing LOAD_COLORS (I:002/01).
F. Verify that the color mixer is turned on for 15 seconds.
G. Momentarily turn off (then on) the mixer tank drain valve
(O:003/05) by pressing I:002/2.
Rev. February 2007

IP1e85r
25--4
H. Verify that the lid installation process is working properly by

monitoring CAN_FILLER (O:003/06) and LID_INSTALL
(O:003/07).
I. Search for REJECT_ALARM (O:003/16).
J. Momentarily force on the REJECT_ALARM (O:003/16) to
verify that it is operational, then disable the force.
K. Verify that the 4_CANS_PER_CASE input is functional.
3. Once the system checks out according to Step 2., create a CDM
that monitors the following addresses:
B3:0/0
O:003/16
N15:3
C5:2.PRE
4. In N15:3, enter 15.
6. Backup the project, storing the backup in a folder on your
computer desktop.
How Did You Do?
Rev. February 2007

IP1e85r
Rev. February 2007
25--5

IP1e85r
25--6
Answers
Exercise A
Step through the code to be sure that everything is working as
expected. The following tools are useful for troubleshooting this
project:
To find addresses and symbols in the ladder logic, use Goto and
Find functions.
To assist in determining the addresses of symbols, display the
cross-reference report and sort by symbols.
Perform forcing procedures as needed.

Make the recommended edits online.
If necessary, use a backup copy of the project.
Rev. February 2007

IP1e85r
Appendix
Application Overview
Explain how the application will be used
in the course. Mention that this section
can be used as a reference for the
application during the exercises.
Many of the hands-on exercises in this course are based on a

fictitious scenario in which you are the maintenance engineer for
a paint factory that manufactures paint products. During this course,
you will be asked to interpret and modify a PLC-5 project for the
paint mixing process.
The paint factory operates one facility that mixes paint, fills
containers, and packages those containers. The entire operation relies
on PLC-5 processors and RSLogix 5 software for its automation
requirements. The facility contains a number of paint mixing lines
surrounded by four support areas: ingredients storage, container
filling, maintenance, and administrative.
Demonstrate the context-based

application, paint factory, by opening the
CCP412_1785r_App.exe file.
The paint factory uses a patented mixing process that begins with
pumping the primary colors into a mixing vat. The ingredients are
then thoroughly mixed. After mixing, the paint is loaded into
3.78-liter (1-gallon) cans, 4 or 6 cans per case, and shipped to the
retail locations for sale to customers.
The paint mixing, filling, and packaging system is shown in the
following graphic:
Mixing Tank
Filling Station
Lid Installation
Inspection
Packaging Station
Palletizing Station
Rev. February 2007

APOa85r
A--2
A PLC-5 project file contains the ladder logic for the entire
manufacturing process. The following functional sections of the
paint processing line and their relation to the classroom workstation
are provided:
1. Start-Stop Section: The process is started by pressing START
(I:002/04). The process is stopped by pressing STOP (I:002/07).
A run light (O:003/17) indicates that the system is in operation.
2. Order Section:
A manual order is loaded by pressing MANUAL_LOAD
(I:002/05).
An order is entered via the thumbwheels (digital input 1).
The left-most digit (0 to 8) is the paint color recipe number.
The right-most three digits (000 to 999) are quantity in
gallons.
An order must be entered into the system before the system is
started.
3. Recipe Loading Section: A paint color recipe is loaded by
pressing LOAD_RECIPE (I:002/00).
4. Color Loading Section: The percentages of each color are
loaded into the mixing tank according to an amount of time
specified by the recipe. The operation is initiated by pressing
LOAD_COLORS (I:002/01).
5. Color Mixer Section: After the pumps for the color loading have
been off for 5 seconds, the mixer motor is turned on for 15
seconds.
6. Lid Installation Section: After the mixer is done, the tank drain
valve is opened (O:003/05). A 3.78-liter (1-gallon) can is then
filled (O:003/06), and a lid is installed (O:003/07).
7. Lid Installation Inspection Section: If a lid is not installed
properly, it is rejected and an alarm is set (O:003/16).
8. Packaging Section: Cans are packaged in cases of either 4 or 6
cans per case (I:002/17). A maximum of 16 cases can be loaded
on a pallet.
Rev. February 2007

APOa85r
If you are not using a standard

workstation, then provide alternate
addresses.
The following symbolic and I/O image addresses are used in the
project file. Use alternate addresses only if they are assigned by your
instructor.
Logical Address
Symbolic Name
Description
O:003/00
WHITE_LOAD
Controls loading of white paint into

mixing tank
O:003/01
RED_LOAD
Controls loading of red paint into

mixing tank
O:003/02
BLUE_LOAD
Controls loading of blue paint into

mixing tank
O:003/03
YELLOW_LOAD
Controls loading of yellow paint into

mixing tank
O:003/04
COLOR_MIXER
Color mixer motor
O:003/05
MIXER_DRAIN
Opens mixer drain to allow paint to

flow out of the mixing tank
O:003/06
CAN_FILLER
Controls valve that allows paint to

enter an empty can
O:003/07
LID_INSTALL
Moves can to to lid installer
O:003/10
CASE_SEALER
Controls case sealing operation
O:003/12
LOAD_PUMP
O:003/15
ORDER_COMPLETE
Indicates that the order is filled and

packaged
O:003/16
REJECT_ALARM
Indicates that a filled can of paint has

been rejected due to improper lid
installation
O:003/17
RUN_LIGHT
Indicates that the system is in

operation
I:000
ORDER_ENTRY
I:002/00
LOAD_RECIPE
Loads paint color recipe
I:002/01
LOAD_COLORS
Activates the color loading operation
I:002/02
MIX_TANK_FS1
Indicates that some paint is in tank
I:002/03
EMPTY_CAN
Indicates that an empty can is in

position for filling
I:002/04
START
Starts system operation
I:002/05
MANUAL_LOAD
Controls manual loading of paint

color recipe number and quantity in
gallons
I:002/06
INSPECTION_STATION
Identifies improper lid installation
I:002/07
STOP
Stops system operation
I:002/10
CAN_FULL
Identifies that a can of paint is

completely full
I:002/11
SEALER_DONE
Indicates that lid has been properly

installed and sealed
B3:0/0
MACHINE_RUN
Controls RUN_LIGHT
B3:0/1
Prevents duplicate order
B3:0/2
Prevents duplicate order
B3:0/3
COLOR_DONE
B3:0/4
R6:0 to R6:8
Rev. February 2007
A--3
Controls PUMP_OFF_DELAY
Indicates end of recipe transfer
XFER_RECIPE_X
Contains recipe transfer information

APOa85r
A--4
Logical Address
Symbolic Name
Description
T4:0
Controls timed amount of white color
T4:1
Controls timed amount of red color
T4:2
Controls timed amount of blue color
T4:3
Controls timed amount of yellow

color
T4:4
RUN_STROBE
T4:5
MIX_TIMER
Controls the time for the mixer motor
T4:6
PUMP_OFF_DELAY
Controls mixer pump
C5:0
CANS_PER_CASE
Counts number of cases that contain

16 cans
C5:1
REJECT_COUNTER
Counts number of rejected cans
C5:2
CANS_PER_PALLET
Counts number of number of cans

per pallet
C5:3
ORDER_COUNTER
Counts number
C5:4
4_PER_CASE
Counts number of cases that contain

4 cans
Rev. February 2007

APOa85r
Appendix
Cable Selection for PLC-5

Processors
The following table provides an overview of cable selections for
PLC-5 processors:
If you have this
processor . . .
And you have this

communication board . . .
PLC-5/10t, -5/12t,
-5/15t, -5/25t
1784-KT, -KT2, -KL, -KLB

1784-KTK1
1784-PCMK/B
1784-KTX, -KTXD
1784-KT, -KT2, -KL, KL/B
PLC-5/11t, -5/20t,
-5/26t, -5/30t, -5/40t,
-5/46t, -5/40Lt, -5/60t,
-5/60Lt, -5/80t, -5/86t
1784-KTK1
1784-PCMK/B
1784-KTX, -KTXD
Rev. February 2007
Then use this cable . . .

1784-CP
1785-CP5
1784-PCM5
1784-CP12
1784-CP6 or 1784-CP with
1784-CP7 adapter
1784-CP5 with 1784-CP7
adapter
1784-PCM5 with 1784-CP7
adapter
1784-CP12 with 1784-CP7
adapter or 1784-CP13

CABa85r
B--2
Cable Selection for PLC-5 Processors
Rev. February 2007

CABa85r
Appendix
Block Transfer Error Codes for

Enhanced PLC-5 Processors
Block transfer error codes for enhanced PLC-5 processors are
presented in the following table. This information also is available
via online help in RSLogix 5 software.
Error Number
Rev. February 2007
Description
-1, -2
Not used
-3
The size of the block transfer plus the size of the index in the block
transfer data table was greater than the size of the block transfer
data table file.
-4
There was an invalid transfer of block transfer write data between

the adapter and the block transfer module.
-5
The checksum of the block transfer read data was wrong.
-6
The block transfer module requested a different length than the

associated block transfer instruction. This could happen if a
64--word block transfer instruction was executed and the block
transfer modules default length was not 64 words.
-7
Block transfer data was lost due to a bad communication channel.

Possible reasons are noise, bad connections, and loose wires.
-8
Error in block transfer protocolunsolicited block transfer.
--9
The block transfer timeout, set in the instruction, timed out before
completion.
-10
No communication channels are configured for remote I/O or rack

number does not appear in rack list. Caused when the rack/group
that the block transfer references is not in the scan list. For
example, the block transfer instruction references rack 2, group 0,
but rack 2 (the entire rack) is not in the scan list.
-11
No communication channels are configured for requested rack or

slot. Caused when the rack that the block transfer references is in
the scan list but the group that the block transfer references is not in
the scan list. For example, only the first half of rack 1 is in the scan
list (010--013) but the block transfer references group 4 that is not in
the scan list. This error is generated regardless of whether or not
the PLC--5 processor is communicating with the rack.
-12
The adapter is faulted or not present for the block transfer

command.
-13
Queues for remote block transfers are full.

BTEa85r
C--2
Block Transfer Error Codes for Enhanced PLC-5 Processors
Rev. February 2007

BTEa85r
The following are trademarks of Rockwell Automation, Inc.:

1336 FORCE
1336 PLUS
ControlBus
Data Highway Plus
DriveTools
Flex
Logix5000
PanelBuilder
PLC-5
PowerFlex
RSLinx
RSView
SCANPort
SoftLogix
1336 IMPACT
CompactLogix
ControlLogix
DH+
FactoryTalk
FlexLogix
Logix5550
PanelView
PHOTOSWITCH
RediSTATION
RSLogix
RSNetWorx
SLC
Ultra
EtherNet/IP and ControlNet are trademarks of ControlNet International Ltd.

DeviceNet is a trademark of the Open DeviceNet Vendor Association, Inc. (ODVA).
The following are registered trademarks of Microsoft Corporation:
MS-DOS
Windows
PowerPoint
Windows NT
IBM is a registered trademark of International Business Machines Corporation.

Pentium is a registered trademark of Intel Corporation.
All other trademarks are the property of their respective holders and are hereby acknowledged.
Catalog Number ABT-CCP412--TSM -- February 2007

Supersedes Catalog Number ABT--1785-TSM22 -- March 2004

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