200016-C PLCMotion
PLCMotion
User Manual
Catalog #200016 Rev. C
Copyright ©2014 Intelitek Inc.
PLCMotion User Manual
Catalog No. 200016 Rev. C
August 2014
Every effort has been made to make this book as complete and accurate as possible. However, no warranty of
suitability, purpose, or fitness is made or implied. Intelitek is not liable or responsible to any person or entity for
loss or damage in connection with or stemming from the use of the software, equipment and/or the information
contained in this publication.
Intelitek bears no responsibility for errors which may appear in this publication and retains the right to change
specifications without prior notice.
Intelitek Inc.
444 East Industrial Park Drive
Manchester, NH 03109-5317
USA
Tel: (603) 625-8600
Fax: (603) 625-2137
Website: http://www.intelitek.com
Email: [email protected]
Table of Contents
1.
Introduction ............................................................................................................................... 1
2.
Starting PLCMotion ................................................................................................................... 2
3.
2.1.
System Requirements ............................................................................................................. 2
2.2.
Installing the Software ............................................................................................................ 3
2.3.
Uninstalling PLCMotion........................................................................................................... 3
2.4.
Activating the Software ........................................................................................................... 4
2.5.
Quitting the Software.............................................................................................................. 4
PLC Editor ................................................................................................................................. 5
3.1.
3.1.1.
Activating PLC Editor ......................................................................................................................... 5
3.1.2.
Quitting PLC Editor ............................................................................................................................ 6
3.2.
File Menu ........................................................................................................................................... 6
3.2.2.
Edit Menu .......................................................................................................................................... 8
3.2.3.
Ladder Menu.................................................................................................................................... 11
3.2.4.
Help Menu ....................................................................................................................................... 15
Creating a Ladder with PLC Editor ........................................................................................ 16
3.3.1.
Editing Tools .................................................................................................................................... 16
3.3.2.
Using the Activation Button ............................................................................................................. 16
3.3.3.
Using the Submenus ........................................................................................................................ 16
3.3.4.
Using the PLC Editor Dialog Boxes ................................................................................................... 20
PLC Simulator.......................................................................................................................... 23
4.1.
Overview ............................................................................................................................... 23
4.1.1.
Activating the PLC Simulator Window .............................................................................................. 23
4.1.2.
Quitting PLC Simulator .................................................................................................................... 24
4.2.
5.
PLC Editor Menus .................................................................................................................... 6
3.2.1.
3.3.
4.
Overview ................................................................................................................................. 5
PLC Simulator Menus ............................................................................................................ 24
4.2.1.
File Menu ......................................................................................................................................... 24
4.2.2.
View Menu ....................................................................................................................................... 26
4.2.3.
Simulate Menu ................................................................................................................................. 26
4.2.4.
Window Menu .................................................................................................................................. 27
4.2.5.
Map Menu........................................................................................................................................ 27
4.2.6.
Help Menu ....................................................................................................................................... 28
4.2.7.
Working with the Memory Map ........................................................................................................ 28
Working with HMIs .................................................................................................................. 29
5.1.
Overview ............................................................................................................................... 29
5.2.
Human Machine Interfaces (HMIs) .......................................................................................... 31
5.2.1.
PLC Line HMI ................................................................................................................................... 31
5.2.2.
Sorting System HMI ......................................................................................................................... 32
5.2.3.
Three Conveyor HMI ........................................................................................................................ 33
5.2.4.
Rotating Disk HMI ............................................................................................................................ 34
5.2.5.
Gate HMI ......................................................................................................................................... 35
5.2.6.
Platform Lift HMI ............................................................................................................................. 36
5.2.7.
Ice Cream Filling Station HMI ............................................................................................................37
5.2.8.
Oven Conveyor HMI ......................................................................................................................... 38
5.2.9.
Pneumatic HMI ................................................................................................................................ 39
5.2.10.
6.
Allen Bradley (AB™) Controllers Instruction List ...................................................................... 41
6.1.
6.1.1.
6.2.
7.
Overview ............................................................................................................................... 41
Address Organization ...................................................................................................................... 41
Instruction Descriptions ......................................................................................................... 41
6.2.1.
Relay Type Instructions .................................................................................................................... 41
6.2.2.
Computational Instructions .............................................................................................................. 41
6.2.3.
Program Control Instructions ........................................................................................................... 42
6.2.4.
Timer and Counter Instructions ........................................................................................................ 42
6.2.5.
Compare Instructions ....................................................................................................................... 43
6.2.6.
Logical Instructions .......................................................................................................................... 44
6.2.7.
Move Instructions ............................................................................................................................ 45
6.2.8.
Shift Register Instructions ................................................................................................................ 46
Online Operation ..................................................................................................................... 47
7.1.
Overview ............................................................................................................................... 47
7.2.
Connecting a Controller to a PC ............................................................................................. 47
7.2.1.
7.3.
8.
Hydraulic HMI.............................................................................................................................. 40
Allen Bradley (AB) SLC-500 or Micrologix PLC .................................................................................. 47
PC-Controller Communication .............................................................................................. 47
7.3.1.
Configuring Communication Settings ............................................................................................... 47
7.3.2.
Testing Communication ................................................................................................................... 48
Software Licensing .................................................................................................................. 50
1.
Introduction
PLCMotion is an interactive graphic tool for teaching, designing, simulating and executing automatic control
TM
TM
TM
applications for the Allen Bradley SLC500 and MICROLOGIX Programmable Logic Controllers. The
program is suitable for use at the tech-ed and higher education levels, according to the Standard I.E.C. 1131-3
Instruction List of the International Electrical Committee. (Geneva, Switzerland).
PLCMotion allows you to use almost all the features of the following PLC: input contacts:
One shot pulses, output coils, bit-flags, and 28 instructions/boxes (e.g., timers, counters, arithmetic or logic
functions, move, shifts, sequencers, etc).
The PLCMotion system contains:

PLC Editor (to edit ladder diagrams):
Compatible with the Allen Bradley SLC500 / MICROLOGIX

A Translator to I.E.C.1131-3 Instruction List for simulation

An interactive Simulator, in a graphic display.

An Emulator to run real applications.
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2.
Starting PLCMotion
2.1. System Requirements
PLCMotion computer recommended requirements are:

Intel Core 2 CPU 6300 2GHZ

2 GB RAM

CD ROM drive

Windows 7 Home Premium 64 bits SP1

Hard drive with at least 1 GB of free disk space

Super VGA or better graphics display, minimum 256 colors

Fully Windows compatible LAN interface card

Separate RS232 port or USB port with RS232 – USB adapter on the PC

Mouse or other pointing device
Minimum PC requirements are:

Pentium 4 Dual Core with 2 GHz processor

512 MB RAM

CD ROM drive

Windows XP Professional 32 bits SP3

Hard drive with at least 1 GB of free disk space

Super VGA or better graphics display, minimum 256 colors

Fully Windows compatible LAN interface card

Separate RS232 port or USB port with RS232 – USB adapter on the PC

Note
Supported Windows versions:

Windows XP Professional 32 bit SP3

Windows 7 Home Premium/Enterprise/Professional/Ultimate 32/64 bit SP1

Windows 8/8 Pro/8 Enterprise

Windows 8.1/ 8.1 Pro/8.1 Enterprise
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2.2. Installing the Software
PLCMotion software is supplied on a CD. The software is copy-protected.
To install the software, do the following:
1.
Start Windows.
2.
Close any applications that are open before you begin the installation. If you are about to reinstall the
software or install a newer version to an existing PLCMotion directory, it is recommended that you
backup any existing user-created files before you begin the installation. It is also recommended that you
remove the previous PLCMotion installation by means of the Uninstall utility included with the software.
3.
Insert the CD into the CD-ROM drive. The installation should begin automatically. If it does not, run
setup.exe from the CD-ROM \Install folder.
4. Follow the instructions that appear on the screen.
By default, the software is installed to the folder PLCMotion. During the installation process you have the option
to change this. It is not recommended that you do so.
2.3. Uninstalling PLCMotion
To uninstall PLCMotion, do the following:
1.
From the PLCMotion program group, select Uninstall PLCMotion.
2.
Follow the instructions that appear on the screen.
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2.4. Activating the Software
From the PLCMotion program group, select any of the following:
PLC Editor
Activates the PLC Editor. For further information on how to
create a ladder using the PLC Editor see Chapter ‎3.
PLC Simulator
Activates the PLC Simulator. For more information about
the PLC Simulator see Chapter ‎4.
HMI PLC Line
Activates the PLC Simulator with the
HMI PLC Line interface. This configuration allows you to run
a previously programmed ladder and observe it in the HMI
PLC Line panel simulation. For more information see
Chapter ‎5.
HMI Gate
Activates the PLC Simulator with the HMI Gate interface.
This configuration allows you to run a previously
programmed ladder and observe it with the simulation of a
PLC-controlled Gate. For more information see section ‎5.2.5.
HMI IceCream
Activates the PLC Simulator with the
HMI IceCream interface. This configuration allows you to run
a previously programmed ladder and observe it with the
simulation of a PLC-controlled ice cream filling line. For
more information see section ‎5.2.7.
2.5. Quitting the Software
To close the PLCMotion modules, refer to the specific chapter for the module you want to quit.
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3.
PLC Editor
3.1. Overview
3.1.1. Activating PLC Editor
To open PLC Editor, do one of the following:

Double click the PLC Editor icon from the PLCMotion program group folder.
OR

From the Start menu, select Programs | PLCMotion | PLC Editor.
The PLC Editor window opens:
:
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3.1.2. Quitting PLC Editor
To exit PLC Editor, do the following:
1.
Select File | Exit.
2.
Click Yes in the Exit dialog box.
3.2. PLC Editor Menus
3.2.1. File Menu
The file menu contains the usual Windows functions that allow you to load and save
files, and exit the software. In addition, you may change the properties and view the
instruction list through this menu.
New
Opens a new file called NEWFILE, for a new ladder diagram.
Open
The Open dialog box opens.
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To open an existing ladder diagram from the dialog box, do
the following:
Save
1.
Select the file you want to open.
2.
Click OK.
Saves the current ladder diagram.
The first time you save a ladder diagram file, use the Save
As command and assign a file name.
Save As
Saves the active ladder diagram under a new file name.
Properties
Opens the File Properties dialog box.
You may enter the author of the file, and make comments.
You can also view the following information:
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
File

Directory (Path)

Time last opened

Size of file
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Instruction List
Opens the Text File dialog box. This displays the name and
type of the active ladder diagram. Click on Display to see a
list of all the instructions in the active ladder diagram.
Exit
Closes the PLC Editor.
3.2.2. Edit Menu
The Edit menu contains the commands that allow you to edit ladder diagram files.
Cut
Deletes selected texts or objects in the ladder diagram. To
delete an object or rung, do the following:
1.
Select Edit | Cut.
OR
Click the Cut button.
2.
Click the activation button
object to be deleted.
of the rung with the
3.
Click on the object to be deleted.
The object is deleted.
To delete an empty rung, follow steps 1 and 2 above. The
rung is deleted.
Paste
Pastes the contents of the clipboard into the ladder diagram.
To paste rungs form the clipboard into a ladder diagram, do
the following:
1.
Click on the activation button of the rung above
where you want to insert the clipboard selection.
2.
Select Edit | Paste.
The selection is inserted after the selected rung.
The rungs are automatically renumbered.
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Undo
Undoes the last operation.
To undo an editing operation, do the following.

Select Edit |Undo.
OR

Click the Undo button.
The last operation is undone.
Find
Opens the Find dialog box.
To find addresses and comments in a ladder diagram, do the
following:
1.
Select Edit | Find.
2.
From the dialog box, select the desired text.
3.
Click OK.
The selected text will be highlighted. The rung with
the text will be active.
Find Next
Finds the next occurrence of the selected text.
Use this command after using the Find command. This will
automatically locate the next occurrence of the text located
with the Find command.
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Replace
Opens the Replace Text dialog box:
To replace addresses in a series of rungs, do the following:
1.
Select Edit | Replace.
2.
Type the address you want to replace in the Text to
Find field.
3.
Type the new address in the New Text field.
4. From the Select field in the dialog box, select the
rung number where the address is to be replaced.
5.
Go To
Click Replace.
Opens the Go To dialog box.
To choose a rung number directly, do the following:
1.
Select Edit | Go to Rung Number.
The Go To dialog box opens.
2.
From the dialog box, select the desired rung
number.
3.
Click OK.
The selected rung appears and is selected.
You can also select a rung by scrolling through the
ladder diagram, and selecting the ladder’s activation
button.
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3.2.3. Ladder Menu
The ladder menu contains the commands needed to edit and create ladders.
Relay
Activates the add relay function. To add a relay to a ladder
diagram, do the following:
1.
Select Ladder | Relay.
OR
Click on the Add Relay button.
A submenu with a list of instructions opens.
2.
Select the type of instruction you wish to use.
3.
Click on the activation button of the rung to add the
relay.
4. Click anywhere on the left side on the rung to add
the relay.
The Object Properties dialog box opens.
5.
Enter the variable address in the Address field by
using the on-screen keyboard.
6. Enter a comment or description in the comment
field (optional).
7.
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Click OK to insert the relay on the rung.
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Coil
Activates the add coil function. To add a coil to a ladder
diagram, do the following:

Select Ladder | Coil.
OR
Click on the Add Coil button.
A submenu with a list of instructions opens.
1.
Select the type of instruction to add to the ladder
from the submenu.
2.
Click on the activation button of the rung to add the
coil.
3.
Click on the appropriate section of the rung to add
the box.
The Object Properties dialog box opens.
4. Enter the variable address in the Address field by
using the on-screen keyboard.
5.
Enter a comment or description in the comment
field (optional).
6. Click OK to insert the coil on the rung.
Box
Activates the Add Box function. To add a box to a ladder
diagram, do the following:
1.
Select Ladder | Box.
OR
2.
Click on the Add Box button.
A submenu with a list of function boxes opens.
3.
Select the type of function box to add to the ladder
from the submenu.
4. Click on the Activation button of the rung to add the
box.
5.
Click on the appropriate section of the rung to add
the box.
A dialog box with the name of the selected function
opens.
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6. Enter the information in the appropriate field using
the on-screen keyboard. For more information on
how to enter information in the function dialog
boxes, see the section Creating a Ladder with
PLC Editor.
7.
Line
Click OK to insert the box on the rung.
Inserts vertical and horizontal lines to connect elements in
the ladder.
To add a line to a ladder, do the following:
1.
Select Ladder | Line.
Or
2.
Click on the Line button.
3.
Click on the Activation button of the rung to
connect the line.
4. Click on the appropriate part of the grid above or
below the selected rung to connect the elements.
You can select the Show Grid command (see below)
to help in placing the lines.
Object Properties
Opens the Object Properties dialog box or a function box
dialog box of a selected object. This allows you to change
any information entered for a selected object.
To edit information for an object, do the following:
1.
Select Ladder | Object Properties.
OR
Click the Object Properties button.
2.
Click the Activation button of the rung with the
object to be edited.
3.
Click on the object to be edited.
The Object Properties dialog box, or a function box
dialog box opens.
4. Edit the appropriate fields using the on-screen
keyboard.
5.
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Click OK.
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Show Grid
Shows the active grid area in a ladder diagram.
To view the active grid area in a ladder, do the following:

Select Ladder | Show Grid.
OR

Click the Show Grid button.
The grid appears in the ladder diagram.
Add Rung
Activates the add rung function. To add a rung do the
following:
1.
Select Ladder | Add Rung.
OR
Click on the Add Rung button.
2.
Click on one of the Rung Activation buttons.
A rung will be added above the rung you selected.
Compile
Compiles and converts the ladder diagram into an Allen
Bradley ASCII import file, or a simulation Instruction List.
To compile a completed ladder diagram, do the following:
1.
Select Ladder | Compile.
OR
Click on the Compile button.
2.
If you are prompted to save the ladder diagram,
click yes.
A check mark will appear on the button if the ladder
was compiled successfully. If the ladder was not
compiled successfully, an “X” will appear on the
button, and a red dot will appear on the grid where
the first error occurs. For more information on
compiling a ladder diagram, see the section
Creating a Ladder with PLC Editor.
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3.2.4. Help Menu
The Help menu contains commands for viewing the software version
information as well as the software licensing options.
About
Opens the About PLC Editor dialog box containing the
current software version information.
Registration
Opens the Registration dialog box enabling you to
perform various registration options, such as obtain
and retrieve your software license by Intelitek’s web
site, e-mail, or fax or phone.
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3.3. Creating a Ladder with
PLC Editor
The Ladder menu and the button tool bar are used for ladder editing in PLCMotion.
To begin editing a ladder diagram, select File | New or File | Open.
3.3.1. Editing Tools
To edit a rung of the ladder, do the following:
1.
Click the Activation button next to the rung to be edited.
2.
Click on Relay (or other) button.
3.
Click on the rung where the input or output is to be placed.
4. Enter information in the appropriate dialog box.
3.3.2. Using the Activation Button
Activation Button
Activates the corresponding rung.
Clicking the Activation button a second time will deactivate
the corresponding rung.
Editing a rung is possible only after it is activated. Click on
the activation button for the rung to become active. An
active rung is bold.
3.3.3. Using the Submenus
3.3.3.1. Relay Contact Submenu
The Relay submenu allows you to enter relays or inputs into a
rung.
These relays are translated by the Allen Bradley controller as
instructions.
In order to insert any input instruction, you must give it an
address or other information.
To enter an address or other information, use the on-screen
keyboard in the appropriate dialog box. See the section
Using the PLC Editor Dialog Boxes.
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Normally Open contact
Inserts a normally open input into a rung. You must give the
input an address. You may also enter a comment.
This is also referred to as the Examine if Open (XIO)
instruction.
Normally Closed
contact
Inserts a normally closed input into a rung. You must give the
input an address. You may also enter a comment.
This is also referred to as the Examine if Closed (XIC)
instruction.
Label
Inserts a label into a rung. A label marks a place a place in a
rung as a reference for an output Jump. You must give the
label an address. You may also enter a comment dialog box.
One Shot Rising
Inserts the One Shot Rising (OSR) instruction. This
instruction generates a short pulse upon activation of the
instruction. The OSR instruction is true only for one cycle. It
is not true again until the conditions for the instructions
preceding it change.
ESC
Cancels the Relay Contact submenu without adding and
input.
See Chapter ‎6 for more information on the above instructions.
3.3.3.2. Coil Contact Submenu
The Coil submenu allows you to enter coils or outputs into a
rung.
These coils are translated by the Allen Bradley controller as
instructions.
See Chapter ‎6 for more information. In order to insert any
output instruction, you must give it an address or other
information.
To enter an address or other information, use the on-screen
keyboard in the appropriate dialog box. See the section
Using the PLC Editor Dialog Boxes.
Coil Output contact
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Inserts a Coil output contact into a rung. You must give the
output an address. You may also enter a comment. This is
also referred to as the Output Energize (OTE) instruction.
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Output Latch
Inserts an output latch into a rung. You must give the output
an address. You may also enter a comment.
Jump to Label
Inserts a Jump to Label instruction into a rung. The Jump
instruction causes the program to jump to the rung with the
specified label.
Reset a Timer/Counter
Inserts a reset timer or counter instruction into a rung. This
instructs the program to restart a specified timer or counter
to zero.
Output Unlatch
Inserts an output unlatch into a rung. You must give the
output an address. You may also enter a comment.
Master Control
Inserts the master control instruction into a rung. This
instruction instructs the program to skip a specified rung.
ESC
Cancels the Coil Contact submenu without adding an output.
See Chapter ‎6 for more information on the above instructions.
3.3.3.3. Box Submenu
The Box submenu allows you to enter special instructions
into a rung.
These instructions are inserted inside of a function box.
To program an instruction, use the on-screen keyboard in the
appropriate dialog box. See the section Using the PLC Editor
Dialog Boxes for more information.
TON
Inserts the [Timer On Delay] instruction into the function
box.
TOF
Inserts the [Turn Off Delay] instruction into the function box.
RTO
Inserts the [Retentive Timer On Delay] instruction into the
function box.
CTU
Inserts the [Count Up] instruction into the function box.
CTD
Inserts the [Count Down] instruction into the function box.
EQU
Inserts the [Equal] instruction into the function box.
NEQ
Inserts the [Not Equal] instruction into the function box.
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MEQ
Inserts the [Masked Comparison for Equal] instruction into
the function box.
GEQ
Inserts the [Greater Than or Equal To] instruction into the
function box.
LEQ
Inserts the [Less Than or Equal To] instruction into the
function box.
GRT
Inserts the [Greater Than] instruction into the function box.
LES
Inserts the [Less Than] instruction into the function box.
ADD
Inserts the [Addition] instruction into the function box.
SUB
Inserts the [Subtraction] instruction into the function box.
MUL
Inserts the [Multiply] instruction into the function box.
DIV
Inserts the [Divide] instruction into the function box.
AND
Inserts the [Logical AND Operation] into the function box.
OR
Inserts the [Inclusive OR operation] into the function box.
XOR
Inserts the [Exclusive OR Operation] into the function box.
NOT
Inserts the [Logical NOT Operation] into the function box.
NEG
Inserts the [Negate] instruction into the function box.
CLR
Inserts the [Clear] instruction into the function box.
MOV
Inserts the [Move] instruction into the function box.
MVM
Inserts the [Masked Move] instruction into the function box.
BSR
Inserts the [Bit Shift Right] instruction into the function box.
BSL
Inserts the [Bit Shift Left] instruction into the function box.
See Chapter ‎6 for more information on the above instructions.
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3.3.4. Using the PLC Editor Dialog Boxes
Instructions in PLCMotion must have addresses or other information. A dialog box appears each time an
instruction is inserted into a rung. Each dialog box includes fields to enter information. Data is entered into the
fields using an on-screen keyboard found in the dialog box.
3.3.4.1. Assigning Addresses
The Object Properties, or an instruction specific dialog box opens when you insert an instruction into a ladder
diagram.
To assign an address or other information, do the following:
1.
Click in the Address field.
2.
Enter an address using the on-screen keyboard, or your computer keyboard.
3.

Enter the input or output word number.

Enter a slash (/).

Enter the bit number.
Click on the comment field.
4. Use the on-screen keyboard, or your computer keyboard to enter a comment. (Optional).
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Each word begins with a file type and number separated by a colon. The following table describes the file types
used in PLCMotion.
File # or File Type
File Description
O:
Output. This file stores the state of an output.
I:
Input. This file stores the state of an input.
S2:
Status. This file stores information useful for troubleshooting.
B3:
Bit. This file contains internal relay logic. It is used for bit instructions other than
inputs or outputs. For example, the One Shot Rising (OSR) instruction.
T4:
Timer. This file contains timer accumulators and preset values.
C5:
Counter. This file contains the counter accumulators and preset values.
R6:
Control. This file contains the length, pointer position and status for specific
instructions.
N7:
Integer. This file is used to store numeric values.
Each of these file types is available by clicking a button found in the on-screen keyboard.
When selecting the file types, T4, C5 or R6, an internal bit must be selected. Select an internal bit from the Bit box
found in the middle of the dialog box.
The following are the internal bit instructions found in PLCMotion:
Internal Bit
Description
Use With File Type:
CD
Count down
C5
CU
Count up
C5
DN
Done
T4, C5, R6
EN
Enable
T4, R6
ER
Error
R6
FD
Found
R6
OV
Overflow
C5
TT
Timer Active
T4
UL
Unloaded unit
R6
UN
Underflow
C5
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3.3.4.2. Entering Information for Instructions in Function Boxes
Instructions in function boxes also have addresses. See the section, Assigning Addresses for more information.
Depending on the specific instruction, additional information is also entered into specific fields (See dialog box
examples below). This information varies. Therefore, each instruction has a different dialog box. The following are
examples of some of the dialog boxes used to enter this information.
See Chapter ‎6 for further information on specific instructions.
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4.
PLC Simulator
4.1. Overview
PLC Simulator allows you to view PLC ladders created with the PLC editor. Ladders can be viewed online, using a
PLC logic controller, or in simulation mode, using a file created with the Human Machine Interface (HMI).
4.1.1. Activating the PLC Simulator Window
To open the PLC Editor window, do one of the following:

Double click the PLC Simulator icon from the PLCMotion program group
folder,
OR

From the Start menu, select Programs | PLCMotion | PLC Simulator.
The PLC Simulator window opens at the top of the screen:
The System menu (that is displayed by right-clicking the title bar) contains the
usual controls for sizing and closing the application screen as well as an
additional option enabling you to display the interface on top at all times.
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4.1.2. Quitting PLC Simulator
To exit PLC Simulator, do the following:

Select File | Exit.
OR

Press [Alt] F4.
4.2. PLC Simulator Menus
4.2.1. File Menu
The file menu contains the Windows functions used to open close and print files. New
files must be created first using PLC Editor.
Open
Opens a saved ladder diagram.
Close
Closes the active window without exiting the program.
Close All
Closes all open windows.
Print Preview
Shows how a file will look when printed.
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Print Setup
Opens the Page Setup dialog box. Sets margins, paper size,
page orientation, paper source, and other layout options for
the active file.
Print
Opens the Print dialog box. Allows you to print the active
file.
Properties
Opens the Properties window.
The properties window has the name of the active ladder
diagram. It contains the following information:
Exit
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
Author

Comments

I/O list
Closes the PLC Simulator, while prompting you to save files.
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4.2.2. View Menu
The View menu contains the commands for the viewing modes available in the PLC
Simulator.
Memory Map
Opens a memory map. The memory map shows the status of
the memory addresses used in the ladder diagram. For
information on using the Memory Map, see Map Menu
below.
Ladder Diagram
Opens the active ladder diagram when the Memory Map is
active.
Refresh
Updates the HMI file when the simulator ladder is changed.
The active ladder diagram must correspond to the active
HMI module. For more information on using the simulator
with an HMI module, see Chapter ‎5.
4.2.3. Simulate Menu
The Simulate menu allows you to choose how to operate the software. You can work
online with a PLC panel and controller, offline, or in simulation mode.
On-Line
Activates PLCMotion communication with a PLC logic
controller. You can use the software to control PLC devices
in this mode.
Select this option again to go off-line.
Simulation
Activates PLCMotion simulation mode for the active HMI
window. Select this option again to stop the simulation.
The active ladder diagram must be associated with the active
HMI file.
Single Step
Activates the active PLC ladder instructions one at a time.
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4.2.4. Window Menu
The Window menu allows you to define how the windows containing circuit diagrams
are displayed on the screen.
Cascade
The usual Windows control for resizing and layering open
windows so that each title bar is visible.
Tile Horizontal
Arranges open windows one above the other.
Tile Vertical
Arranges open windows side by side.
4.2.5. Map Menu
The Map menu contains the commands used for viewing a Memory Map. The Memory
Map shows the status of the memory addresses. The Map menu is available only when
a Memory Map is open.
Red, Green
Displays the status for each bit by color. The box is red when
the status is false, and green when the status is true.
0,1
Displays the status for each bit by number. The box displays
the number 0 when the status is false, and displays 1 when
the status is true.
Hexidecimal
Displays the value of the word in hexidecimal numeric form.
Decimal
Displays the value of the word in decimal numeric form.
Octal
Displays the value of the word in octal numeric form.
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4.2.6. Help Menu
The Help menu contains commands for viewing the software version information
as well as the software licensing options.
About
Opens the About PLC Simulator dialog box containing
the current software version information.
Registration

Opens the Registration dialog box enabling
you to perform various registration options,
such as obtain and retrieve your software
license by Intelitek’s web site, e-mail, or fax or
phone.
4.2.7. Working with the Memory Map
The Memory Map displays the status of memory addresses for an active PLC ladder. Each row has 16 boxes. Each
box displays one bit, and each row represents one word. See the above Figure for a description of the Memory
Map. Placing the mouse on a box displays the address at the bottom of the screen. The address values can be
manually edited or automatically monitored with the Memory Map.
4.2.7.1. Manually Changing the Status of Addresses in the Memory Map
To change the status of a bit:

Click on the bit.
To change the value of a word:
1.
Click on the word value in the second column.
The Memory Value dialog box will open.
2.
Enter the new memory value in the field.
3.
Click OK.
4.2.7.2. Automatically Monitoring the Status of Addresses in the Memory Map
To monitor the status of a PLC program, do the following:
1.
Open the Memory Map.
2.
Click the Simulation button or Select Simulate | Simulation.
The status of the bits will change in coordination with the active PLC ladder.
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5.
Working with HMIs
5.1. Overview
The PLC modules allow you to work with the simulator and several Human Machine Interfaces (HMI). The HMIs
were created using Flash, and then programmed to integrate with the PLC Simulator software.
When working with an HMI, the PLC Simulator window opens on the top of the screen and the HMI opens at the
bottom.
This section will relate in particular to the HMI PLC Line, although the information regarding how to work with the
HMI is relevant to all HMIs supplied with the product.
To open the HMI PLC Line, do one of the following.

Double click the HMI PLC Line icon from the PLCMotion program group folder.

From the Start menu, select Programs | PLCMotion | HMI PLC Line.
OR
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The PLC Simulator and HMI PLC Line windows open:
PLC Simulator will work in conjunction with the HMI PLC Line. The switches and other devices on the panel will
operate according to the active ladder in the simulator. To open a ladder and run the operations in PLC Simulator,
see Chapter ‎4.
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5.2. Human Machine Interfaces (HMIs)
Some of the HMIs described in this chapter are only available through LearnMate courses and not directly through
the Windows Start menu.
5.2.1. PLC Line HMI
The HMI PLC Line, shown in the figure below, is a graphic display of the PLCLine hardware panel.
5.2.1.1. Panel Buttons
The bottom of the HMI PLC Line contains buttons that activate commands used when working with the HMI PLC
Line simulation.
Show All
Hide All
Reset
PLC Motion User Manual
Turns the labels on the HMI PLC Line on or off. The labels
show the addresses of the Panel components.

Resets the nut on the motor to the initial (left)
position.
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5.2.2. Sorting System HMI
In the Sorting System HMI, small and large objects travel on a moving conveyor, which is fitted with a sensor and
a solenoid. The sensor is part of a "testing station", whose task is to detect and then remove large objects from
the conveyor; while allowing small objects to continue along their path.
The sorting system components include:

A motor-driven conveyor

A toggle switch

A sensor fitted above the conveyor

A solenoid
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5.2.3. Three Conveyor HMI
In the Three Conveyor HMI, three motors drive three separate conveyors, each of which is fitted with its own
encoder. To ensure accurate production, the three motors must each run at the same speed.
The Three Conveyor HMI enables students to design ladder diagrams that monitor the output from each of the
three encoders and inform the system operator of the status of the average speed of each motor.
In addition to the conveyors and encoders, the HMI contains two lamps - red and green, which reflect the system
status.
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5.2.4. Rotating Disk HMI
The rotating Disk HMI enables the user to program a ladder diagram to prevent the accidental activation of a
machine in a production line.
When periodic maintenance is performed, the machine is stopped to enable maintenance personnel to attend to
it. While the maintenance procedure is performed, a slight risk exists that someone, unaware of the men at work,
will start up the machine. The rotating part of the machine could injure the workers and cause damage to other
parts of the machine.
To ensure that the machine will not operate during maintenance work, a solenoid is installed next to the
machine's wheel and a hole is drilled in the wheel's periphery. Before servicing the machine, maintenance
personnel will activate a safety toggle switch that will extend the solenoid into the hole in the wheel's periphery,
locking the machine and thereby securing the area.
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5.2.5. Gate HMI
The Gate HMI enables users to simulate ladder diagrams that control an entrance gate, which is opened and
closed by an electric motor that drives one of the gate's wheels. The electric motor is controlled by two push
button (PB) switches installed in the gatekeeper's booth: OPEN PB and CLOSE PB.
Assuming the gate is initially closed, the gate is opened as follows:

Pressing the OPEN PB starts the motor, and the gate opens.

The gate continues to open, even if the OPEN PB is released.

Once the gate is fully open, a sensor is activated and the motor stops.
The gate-closing procedure is as follows:

Pressing the CLOSE PB starts the motor in the opposite direction and the gate begins to close.

The gate continues to close, even if the CLOSE PB is released.

The motor stops once the sensor detects that the gate is fully closed.
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5.2.6. Platform Lift HMI
The Platform Lift HMI enables users to simulate a platform lift system. The platform lift system works as follows:

Initially, the platform is at ground level and the two solenoids are de-energized.

Pressing the "UP" button energizes one of the solenoids. The pistons extend, raising the platform to the
upper station. Upon the platform reaching the upper station, the solenoid is de-energized and the
platform stops.

The platform stays at the upper station until the "DOWN" button is pressed.

Pressing the "DOWN" button energizes the other solenoid. The pistons retract, thereby lowering the
platform to the ground floor. When the platform reaches the ground floor, the solenoid is de-energized
and the platform stops.
The platform stays at the lower station until the "UP" button is pressed again.
The platform lift system is comprised of the following components:

Two double acting hydraulic cylinders that lift or lower the platform.

A two-solenoid hydraulic control valve that controls the flow of oil to the cylinders

An encoder fitted on one of the axes. The encoder produces 30 pulses while traveling between the two
stations.

Two PBs - "Down" and "Up".
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5.2.7. Ice Cream Filling Station HMI
The Ice Cream Filling Station HMI simulates the control of an ice cream filling process.
The station includes the following components:

A filling valve.

A cup (to be filled with ice cream).

A PB switch that activates the system.

Two sensors:

Sensor A indicates when a cup is under the valve outlet.

Sensor B indicates when the cup is full.
The simulated control system works as follows:
1.
When an empty cup is placed under the valve outlet (indicated by Sensor A) AND the PB is pressed, the
ice cream valve is opened.
2.
When the cup is full (indicated by Sensor B), the filling valve closes.
3.
When the ice cream flow is too slow (for example, if the ice cream viscosity is too high), a red warning
lamp is activated to warn the system operator.
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5.2.8. Oven Conveyor HMI
The Oven Conveyor HMI enables users to simulate control of an oven conveyor system, typical of industrial baking
applications.
Oven conveyor systems are used in many applications where objects placed on a conveyor need to be heated to a
pre-set temperature. Objects are placed on a conveyor, which moves them through the oven at a predefined,
constant speed. Essential to proper system operation is that the objects placed on the conveyor travel through
the oven at a constant speed. Therefore, it is important to monitor the number of objects moved into the oven at
any one time.

If too many objects are moved into the oven at once, the heat energy will be distributed to more objects
and the temperature in the oven will drop.

Conversely, if the number of objects moved into the oven is too few, the heat energy will be distributed
to fewer objects and the temperature in the oven will rise.
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5.2.9. Pneumatic HMI
The Pneumatic HMI is used throughout the PLC Technology 3:
PLC-controlled Pneumatic Systems module to enable users to build ladder diagrams that can electrically control
pneumatic components.
The Pneumatic HMI comprises the following components:

Cylinder A - a double-acting cylinder with magnetic switches

5/2 sol-sol valve controlling Cylinder A

Cylinder B - a double-acting cylinder with magnetic switches

5/2 sol-sol valve controlling Cylinder B

Cylinder C - a double-acting cylinder with magnetic switches

5/2 sol-spring valve controlling Cylinder C

2 Electrical PBs

2 Lamps
Initially all three pistons are retracted, all solenoids are not energized, the PBs are not pressed and the lamps are
off.
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5.2.10.
Hydraulic HMI
The Hydraulic HMI is used throughout the PLC Technology 4:
PLC-controlled Hydraulic Systems module to enable users to build ladder diagrams that can electrically control
hydraulic components.
The Hydraulic HMI comprises the following components:

Cylinder A - a double-acting cylinder with magnetic switches

5/2 sol-spring valve controlling Cylinder A

Cylinder B - a double-acting cylinder with magnetic switches

5/2 sol-sol valve controlling Cylinder B

Cylinder C - a double-acting cylinder with magnetic switches

5/2 sol-sol valve controlling Cylinder C

2 Electrical PBs

2 Lamps
Initially all three pistons are retracted, all solenoids are not energized, the PBs are not pressed and the lamps are
off.
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6.
Allen Bradley (AB™) Controllers Instruction List
6.1. Overview
This chapter describes the instructions used for an Allen Bradley controller. For information on how to insert
instructions into your PLC ladder, see Chapter ‎3.
6.1.1. Address Organization
Allen Bradley PLC instruction addresses are made of words. Each word is made up of 16 bits, numbered from 0 to
15. Each group of addresses is located in a memory file. Each file contains 256 words, numbered from 0 to 255.
For an explanation of which file types to use with which type of instruction see, Chapter ‎3.
6.2. Instruction Descriptions
6.2.1. Relay Type Instructions
6.2.1.1. OSR: One Shot Rising
The OSR is a conditional input instruction that triggers a one time. Use the OSR when an event must start as soon
as the state of the rung changes from false to true, as triggered by a push button. An example would be to use the
OSR to freeze rapidly displayed LED values.
Place the OSR on the rung immediately before the output instruction. Then reference the output as the one-shot
in your program. The address that you give to the OSR input instruction is where the previous state of the rung is
retained.
Use the bit address B3 for the OSR instruction. This address is not used for any other instruction in PLCMotion.
6.2.1.2. OTE: Output Energize
When this is true, the output will be energized.
6.2.1.3. XIO: Examine if Open
This instruction functions as an input or storage bit.
If the corresponding memory bit is a “1” (on), this instruction will not allow rung continuity and any outputs on its
rung will be de-energized.
6.2.1.4. XIC: Examine if Closed
This instruction functions as an input or storage bit.
If the corresponding memory bit is a “1” (on), this instruction will allow rung continuity and outputs will be
energized.
6.2.2. Computational Instructions
6.2.2.1. ADD: Addition
When rung conditions are true, this output instruction adds Source A to Source B and stores the result at the
destination address. Source A and Source B can be either values or addresses that contain values; however,
Source A and Source B cannot both be constants.
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6.2.2.2. CLR: Clear
This output instruction sets all the bits in a word to (0) when rung conditions are true. The destination must be a
word address.
6.2.2.3. DIV: Divide
When rung conditions are true, this output instruction divides Source A by Source B and stores the result in the
destination and the math register. The value stored in the destination is rounded. The value stored in the math
register consists of the non-rounded quotient (placed in the most significant word) and the remainder (placed in
the least significant word).
Source A and Source B can be either constant values or addresses that contain values; however, Source A and
Source B cannot both be constants.
6.2.2.4. MUL: Multiply
Use the MUL instruction to multiply one value (source A) by another (source B) and place the result in the
destination. Source A and Source B can be either constant values or addresses that contain values; however,
Source A and Source B cannot both be constants.
6.2.2.5. NEG: Negate
The NEG instruction changes the sign of the source and places it in the destination when rung conditions are true.
The source and destination parameters must be word addresses.
6.2.2.6. SUB: Subtraction
The SUB output instruction subtracts Source B from Source A and stores the result in the destination when rung
conditions are true. Source A and Source B can be either values or addresses that contain values; however, Source
A and Source B cannot both be constants.
6.2.3. Program Control Instructions
6.2.3.1. JMP: Jump
When the rung condition is true, the processor jumps in the program to the rung with the specified label. Jumping
forward to a label saves program scan time by omitting a program segment until needed. Jumping backward lets
the controller execute program segments repeatedly.
6.2.3.2. LBL: Label
A label marks a place in a rung as a reference for a Jump instruction. This instruction has no control bits. It is
always evaluated as true or logic 1.
6.2.4. Timer and Counter Instructions
6.2.4.1. CTD: Count Down
This output instruction counts down for each false-to-true transition of conditions preceding it in the rung and
produces an output when the accumulated value reaches the preset value. Rung transitions might be activated by
a limit switch or by parts traveling past a sensor.
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6.2.4.2. CTU: Count Up
This output instruction counts up for each false-to-true transition of conditions preceding it in the rung and
produces an output when the accumulated value reaches the preset value. Rung transitions might be activated by
a limit switch or by parts traveling past a sensor.
6.2.4.3. RTO: Retentive Timer on Delay
An RTO function is the same as a TON except that once it has begun timing, it holds its count of time even if the
rung goes false or a fault occurs. By retaining its accumulated value, retentive timers measure the cumulative
period during which rung conditions are true.
6.2.4.4. TOF: Turn Off Delay
Use the TOF instruction to turn an output on or off after its rung has been off for a preset time interval. This
output instruction begins timing (at either one second or one hundredth of a second intervals) when its rung goes
false. It waits the specified amount of time (as set in the PRESET), keeps track of the accumulated intervals which
have occurred (ACCUM), and resets the DN (done) bit when the ACCUM (accumulated) time equals the PRESET
time.
The Accumulated value is reset when rung conditions go true regardless of whether the timer has timed out.
6.2.4.5. TON: Timer on Delay
Use the TON instruction to turn an output on or off after the timer has been on for a preset time interval. This
output instruction begins timing (at either one second or one hundredth of a second intervals) when its rung goes
true. It waits the specified amount of time (as set in the PRESET), keeps track of the accumulated intervals which
have occurred (ACCUM), and sets the DN (done) bit when the ACCUM (accumulated) time equals the PRESET
time.
As long as rung conditions remain true, the timer adjusts its accumulated value (ACC) each evaluation until it
reaches the preset value (PRE). The accumulated value is reset when rung conditions go false, regardless of
whether the timer has timed out.
6.2.5. Compare Instructions
6.2.5.1. EQU: Equal
This input instruction compares two sources. If Source A equals Source B the output will be true. It allows rung
continuity if the two values are equal.
6.2.5.2. GEQ: Greater Than or Equal To
This input instruction compares two sources. If Source A equals or is greater than Source B it allows rung
continuity. The rung will go true and the output will be energized.
6.2.5.3. GRT: Greater Than
This input instruction compares two sources. If Source A is greater than Source B it allows rung continuity. The
rung will go true and the output will be energized.
6.2.5.4. LEQ: Less Than or Equal To
This input instruction compares two sources. If Source A equals or is less than Source B it allows rung continuity.
The rung will go true and the output will be energized.
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6.2.5.5. LES: Less Than
This input instruction compares two sources. If Source A is less than Source B it allows rung continuity. The rung
will go true and the output will be energized.
6.2.5.6. MEQ: Masked Comparison for Equal
This conditional instruction compares 16-bit data of a source address to 16-bit data at a reference address through
a mask. If the values match, the instruction is true. This instruction allows portions of the data to be masked by a
separate word.
6.2.5.7. NEQ: Not Equal
This instruction tests whether two values are not equal. Source A and Source B can be values or addresses.
6.2.6. Logical Instructions
6.2.6.1. AND
When rung conditions are true, sources A and B of this output instruction are stored in a specified destination.
Sources A and B can be either word addresses or constants; however, both sources cannot be a constant. The
destination must be a word address.
AND Truth Table
SOURCE A
SOURCE B
DEST
0
0
0
0
1
0
1
0
0
1
1
1
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6.2.6.2. NOT
When rung conditions are true, the source of the NOT instruction is stored in the specified destination.
The source and destination must be word addresses.
NOT Truth Table
SOURCE
DEST
0
1
0
1
1
0
6.2.6.3. OR
When rung conditions are true, Sources A and B of the OR instruction are stored in the specified destination.
Sources A and B can be either word addresses or constants; however, both sources cannot be a constant. You can
enter a constant or a word address for either source parameter. The destination must be a word address.
OR Truth Table
SOURCE A
SOURCE B
DEST
0
0
0
0
1
1
1
0
1
1
1
1
6.2.6.4. XOR
When rung conditions are true, Sources A and B of the XOR instruction are Exclusive stored in the specified
destination. Sources A and B can be either word addresses or constants; however, both sources cannot be a
constant.
XOR Truth Table
SOURCE A
SOURCE B
DEST
0
0
0
0
1
1
1
0
1
1
1
0
6.2.7. Move Instructions
6.2.7.1. MOV: Move
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.
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6.2.7.2. MVM: Masked Move
When rung conditions are true, the MVM instruction moves data from a source location to a destination, and
allows portions of the destination data to be masked by a separate word. Data at the source address passes
through the mask to the destination address. As long as the rung remains true, the instruction moves the same
data each scan.
6.2.8. Shift Register Instructions
6.2.8.1. BSL: Bit Shift Left
On each false-to-true transition, this output instruction loads a bit of data into a bit array, shifts the pattern of
data through the array to the left, and unloads the end bit of data.
An example of the use of this instruction might be for tracking bottles through a bottling line where each bit
represents a bottle.
6.2.8.2. BSR: Bit Shift Right
On each false-to-true transition, this output instruction loads a bit of data into a bit array, shifts the pattern of
data through the array to the right, and unloads the end bit of data.
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7.
Online Operation
7.1. Overview
The PLCMotion software is configured to work online with a PLC controller. To connect the controller to the PLC
components, consult the manual provided with your controller.
7.2. Connecting a Controller to a PC
7.2.1. Allen Bradley (AB) SLC-500 or Micrologix PLC
To connect the controller to the computer, do the following:

Connect an RS232 cable from the RS232 port on the controller to an open COM port on the computer, or

Connect an RS232 cable from the RS232 port on the controller to an RS232 – USB adapter and connect
the adapter to an open USB port on the computer.
7.3. PC-Controller Communication
7.3.1. Configuring Communication Settings
If there is no communication between the PC and the controller, the communication settings must be configured.
Ensure that the TESTPLC.exe application is closed before continuing.
To configure the communication settings:
1.
Run SERVCFG.exe from the C:\Intelitek\PLCMotion\ folder.
2.
Ensure that the correct Com Port is selected.
If you are using a RS232 – USB adapter identify the Com Port number from Windows Device Manager.
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3.
Configure the Communications settings as required.
4. Click Apply, and then Close.
Run TESTPLC.exe as described in the steps in the Testing Communication section below to test if communication
has been enabled between the PC and the controller.
7.3.2. Testing Communication
For most PCs configuration is not required in order to facilitate communication with the controller.
To test whether the PC communicates with the PLC:
1.
Run TESTPLC.exe from the C:\Intelitek\PLCMotion\ folder.
1.
In the Data field, insert a number between 1 and 63.
2.
Click Write.
The number will appear in binary form in the Outputs field.
If communication is successful:

The word “SUCCESS!” will appear in the Result field.

The corresponding output LEDs on the controller for the binary number will light-up.
For example: If you insert the number 5 in the Default field, since 5 is equal to 101 in binary, the first and third
LEDs will light-up.
101000 =
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If communication is unsuccessful, an error will appear in the result field (see the example error message in the
image below). If this occurs, the PLC communication settings must be configured.
IMPORTANT: If communication is successful, the controller must be returned to its default state after performing
the test. To do so, insert the number “0” and click Write. Then close the program.
To confirm that there is communication between the PC and the PLC:
1.
From the Start menu, select Programs | PLCMotion | PLC Simulator.
2.
Open the PLCLINE4.LAD ladder diagram located in the C:\Intelitek\PLCMotion\AB_work\Solutions\
folder.
3.
Click the On-Line
icon followed by the Simulation
icon.
PLC Line activity should be reflected in the ladder diagram. If there is still no communication, contact technical
support.
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8.
Software Licensing
For information regarding software licensing, refer to the Intelitek Software Licensing Guide in the Books folder
on the installation CD.
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