Introduction To Manufacturing: Automation and Robotics

Automation and Robotics
Flexible Manufacturing System
Introduction to Manufacturing
1-800-Lab-Volt
www.labvolt.com
38770-20
|3038770200000Q~
Job Sheets – Student

Automation and Robotics
Flexible Manufacturing System
Introduction to
Manufacturing
Job Sheets – Student
38770-20
A
AUTOMATION AND ROBOTICS
FLEXIBLE MANUFACTURING SYSTEM
INTRODUCTION TO
MANUFACTURING
by
the Staff
of
Lab-Volt Ltd.
Copyright © 2007 Lab-Volt Ltd.
All rights reserved. No part of this publication may be reproduced,

in any form or by any means, without the prior written permission
of Lab-Volt Ltd.
Legal Deposit – Fourth Trimester 2007
ISBN 978-2-89640-201-4
FIRST EDITION, OCTOBER 2007
Printed in Canada
November 2012
Foreword
The Lab-Volt Flexible Manufacturing System (FMS), Model 5901-1 or Model 5901-3,
is a modular system that allows students to experience challenges commonly
encountered in facilities. The system comes with the necessary equipment to
familiarize students with basic manufacturing applications such as:
• operating a flat belt conveyor;

• feeding and sorting parts into containers;
• configuring and wiring sensors, buttons, indicator lights, and other devices;
• PLC programming;
• installing pneumatic equipment;
• troubleshooting.
The difference between Model 5901-1 and Model 5901-3 is in their Programmable
Logic Controller. In Model 5901-1, the Allen-Bradley CompactLogix L32E (Model
5930-0) is used. With Model 5901-3, the Allen-Bradley CompactLogix L43 (Model
5930-A) is running the system. The L43 includes the functionalities of the L32E, but
with integrated motion instructions.
The Flexible Manufacturing System (Advanced Applications), Model 5901-2 (add-on

to 5901-01) or Model 5901-4 (add-on to 5901-3), is an add-on to the Flexible
Manufacturing System. It allows students to create more sophisticated applications
using the latest manufacturing technology such as: Servo Drive, Touch-Screen
Operated Control, Machine Vision System, Bar Code Reader, and Optical Encoder.
The fully automated Storage Unit option, Model 5940, is available as an add-on to
Model 5901-3 and 5901-4.
The sequence in which the curriculum must be completed is shown below, along with
the necessary equipment for each manual. The Introduction to Manufacturing
manual must be completed first. Human-Machine Interface, Machine Vision, and
Servo Control manuals can be completed independently, but are all prerequisites for
FMS Production Line. Finally, Storage Unit requires knowledge of all the other
subjects.
III
IV
Table of contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Job Sheet 1 Familiarization with the AC Drive . . . . . . . . . . . . . . . . . . . 1-1
Job Sheet 2 Ethernet Communication and PLC Programming

Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Job Sheet 3 Network Communications . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Job Sheet 4 PLC-Controlled Conveyor and Sensors . . . . . . . . . . . . . . 4-1
Job Sheet 5 Sorting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Job Sheet 6 Filling Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Appendices A Equipment Utilization Chart

B AC Drive – Quick Start Guide
C Changing the PLC IP address setting
D Hydraulics and Pneumatics Graphic Symbols
E Changing the node address of the DeviceNet devices
F Safety Procedures
G Troubleshooting
We Value Your Opinion!
V
VI
Introduction
The Job Sheets in this manual are designed for students already familiar with
electrical wiring, basic PLC programming, and manufacturing processes. These
topics are thoroughly covered in the reference textbook provided with the Flexible
Manufacturing System. A careful reading of the reference textbook is highly
recommended before proceeding with the Job Sheets.
The difficulty and complexity increase with each Job Sheet. First, the student
familiarizes himself with the AC Drive and uses his wiring skills to build a small
setup. Next, the student is introduced to PLC programming through four programs
written in four different languages. These programs are used to control the
push-button station. Each subsequent Job Sheet adds another level of complexity,
allowing the student to acquire skills in advanced ladder diagram, structured text,
sequential function chart, and block diagram programming. The student will also
experience several situations encountered in manufacturing plants, including typical
sensors applications, DeviceNet network configuration, quality control issues, and
troubleshooting. For each Job Sheet, the required programs are provided on both the
Lab-Volt Flexible Manufacturing System Resource Kit (student) CD-ROM used the
files corresponding to the right controller (L32E or L43). The latter includes complete
solutions to the programming exercises proposed in the Job Sheets. Videos of some
of the setups presented in the Job Sheets of this manual are also available on the
CD-ROMs.
Note: If the configuration files on the CD-ROM don’t have the same
versions as the softwares, you can go to the following address:
http://www.labvolt.com/downloads/download/FMS_CDROMs_Files.pdf.
Safety Considerations
Make sure that you are wearing appropriate protective equipment before performing
any of the Job Sheets in this manual. You should complete the basic safety
procedures listed in Appendix F of this manual whenever you begin a Job Sheet.
Remember that you should never perform a job if you have any reason to think that
a manipulation could be dangerous to you or your teammates.
The Flexible Manufacturing System is provided with the following reference material:
Reference Textbook
Stenerson, Jon. Fundamentals of Programmable Logic Controllers, Sensors, and

Communications, 3rd ed. New Jersey: Prentice Hall, 2004.
VII
Introduction
Lab-Volt Flexible Manufacturing System Resource Kit CD-ROM
• Allen-Bradley/Rockwell Automation reference guides:

– Programming Manual – Logix5000™ Controllers Common Procedures
– Quick Start – Logix5000 Controllers
– Quick Start – PowerFlex 40 Adjustable Frequency AC Drive
– Quick Start Manual – CompactLogix Controller Starter Kit
– Reference Manual – Logix5000™ Controllers General Instructions
– Technical Data – CompactBlock I/O for DeviceNet
– User Manual – Adjustable Frequency AC Drive
– User Manual – Compact™ I/O 1769-SDN DeviceNet Scanner Module
– User Manual – CompactLogix Controllers
– User Manual – DeviceNet Adapter
– User Manual – DeviceNet Modules in Logix5000™ Control Systems
• Lab-Volt material:
– PLC program files for each Job Sheet
– Videos of the Flexible Manufacturing System in action.
Appendices
Appendix A, Equipment Utilization Chart, indicates the components required to

complete each of the Job Sheets in this manual. The chart also provides the Lab-Volt
part number of each component.
Appendix B, AC Drive – Quick Start Guide, provides the information required to

operate the AC Drive.
Appendix C, Changing the PLC IP address setting, provides a step-by-step

procedure to change the PLC IP address setting.
Appendix D, Hydraulics and Pneumatics Graphic Symbols, lists common hydraulics

and pneumatics graphic symbols.
Appendix E, Changing the node address of the DeviceNet devices, provides a

step-by-step procedure to change the DeviceNet node address of the AC Drive and
Part Feeder.
Appendix F, Safety Procedures, lists the basic safety procedures to be performed

before you begin any of the Job Sheets in this manual.
Appendix G, Troubleshooting, lists common problems that can be encountered when

using the FMS and helps you to troubleshoot your setup.
VIII
1
FAMILIARIZATION WITH THE AC DRIVE
The conveyor provided with the Flexible Manufacturing System is equipped with a
three-phase motor. The applications studied with the FMS are complex and the
control of the conveyor speed is important. This is the function of the AC Drive.
The speed of ac motors is determined by the frequency of the ac source. To control

the speed of the motor, the drive adjusts the frequency of the ac source.
The ac drive provided with the FMS receives single-phase power and converts it to
three-phase power of the proper voltage and frequency. Note that it is not all
industrial drives that accept single-phase ac power, some only accept three-phase
power.
The process through which the power is transformed by the drive can be divided in
three steps. First, ac power is converted to dc power by a converter. Then, the
current coming out of the converter is smoothed by a low-pass filter to obtain a
constant voltage dc current. This dc current passes through an inverter which
converts the dc current to a three-phase ac current of the desired frequency and
voltage. Figure 1-1 below shows a simplified version of a Pulse Width
Modulation (PWM) circuit such as the one in the drive provided with the FMS.
As in Figure 1-1, the converter may be preceded by a transformer. This transformer

raises the voltage of the current before it enters in the converter.
INTRODUCTION TO MANUFACTURING 1-1

Figure 1-1. Pulse Width Modulation circuit.
Converter
The converter consists of a diode bridge that returns constant polarity

current (always positive) composed of half-cycle sine waves. Figure 1-2 shows the
sinusoidal current before and after it passes through the convertor.
1-2 INTRODUCTION TO MANUFACTURING

Figure 1-2. (a) Input current of the diode bridge (b) Output current of the diode bridge.
DC link
The DC link is a low-pass filter composed of an inductor and a capacitor. This filter
allows only the low frequencies to pass and it transforms the raw output of the
converter to an almost-smooth dc current as shown in Figure 1-3.

Figure 1-3. DC link output.
Inverter
The inverter shown in Figure 1-1 consists of six Insulated Gate Bipolar
Transistors (IGBT). A logic controller compares three reference sine waves to a
triangular wave. Figure 1-4 shows two reference sine waves compared to a
triangular wave. When the triangular wave intersects the sine wave, the IBGTs are
turned on or off to produce a signal such as the one presented in Figure 1-5 (a) and
Figure 1-5 (b). When combined together, these on-off sequences allow current to
build in the motor windings as if the current was a smooth sine wave as shown in
Figure 1-5 (c).
Figure 1-4. Two reference sine waves compared to a triangular wave.

Figure 1-5. Inverter action on the current from the dc link.

Figure 1-6 shows the amount of current built into the motor due to the on-off
sequences. The envelope formed by the hysteresis band has a sinusoidal form
similar to the reference sine wave used.
Varying the parameters of the PWM allows choice of the frequency and amplitude
of the three-phase current output of the drive, thus changing the speed of the motor.
Figure 1-6. Amount of current built in the motor.

1
OBJECTIVE
To configure the AC Drive and build a circuit to control the Flat Belt Conveyor.
Note: Some of the modules provided with the Flexible Manufacturing

System are equipped with fault switches to make troubleshooting
training easier. Make sure all fault switches are set at O (off) when
performing Job Sheets 1, 2, 3, 4, 5, and 7.
PROCEDURE
Note: Electrical connections between modules can be made using either

the banana jacks or the terminal screws available on each module. Ask
the instructor which of them you should use.
CAUTION!
When using terminal screws for wiring, make sure to use the
appropriate wire gauge. For 24-V dc signal wire, use 24 gauge
wires. For details on the minimum requirements for power wires,
refer to the manufacturer documentation provided on the Lab-Volt
Flexible Manufacturing System Resource Kit CD-ROM.
G 1. Perform the basic safety procedures listed in Appendix F of this manual.
G 2. Use Table 1-1 and Figure 1-7 to identify the components used in this Job
Sheet.
NAME MODEL DESCRIPTION/FUNCTION
Flat Belt Conveyor 5910 Flat belt conveyor driven by a 1/4-HP

three-phase motor.
AC Drive 5927-A 1/2-HP Allen-Bradley PowerFlex 40 AC drive

used to control the three-phase motor of the
Flat Belt Conveyor.
Wiring ducts (from the 5951 Plastic wiring ducts used to maintain a tidy
Accessories) setup.
Work Surface 46604 Perforated plate that can be slid into a

bench.
Table 1-1. Components used for Job Sheet 1.

Figure 1-7. Flat Belt Conveyor and AC Drive.
G 3. Affix the Flat Belt Conveyor and the AC Drive onto the Work Surface. The
AC Drive will be used to control the 1/4-HP three-phase motor of the Flat
Belt Conveyor.
CAUTION!
The Flat Belt Conveyor is heavy. Do not carry the Flat Belt
Conveyor alone.
G 4. Position the Flat Belt Conveyor on the Work Surface using the location pins
as shown in Figure 1-8.

Figure 1-8. Location pin used to position the Flat Belt Conveyor on the Work Surface.
Note: Use the push-lock fasteners to secure each module on the

perforated Work Surface.
G 5. Connect the equipment as shown in the wiring diagram presented in

Figure 1-9.
Figure 1-9. Familiarization with the AC Drive wiring diagram.
Note: Wiring ducts should be used appropriately to maintain a

tidy setup.

G 6. Once wiring is completed, the setup should look as shown in Figure 1-10.
Figure 1-10. Familiarization with the AC Drive setup.
Note: Refer to the AC Drive - Quick Start Guide in Appendix B to

obtain more information about the AC Drive. Read the general
precautions at the beginning of the guide before using the AC
Drive.
Resetting to factory defaults
G 7. The various parameters of the AC Drive can be viewed and edited using the
drive keypad. Before familiarizing yourself with the drive parameters, you
must reset all parameters to factory default. Follow the step-by-step
procedure below to do so.
Note: If you experience problems when manipulating the drive,

refer to the AC Drive - Quick Start Guide in Appendix B.
Once the drive is turned on, press Escape to display the group
parameter.
Press Escape again. The group menu letter will flash.

Use the up and down arrows to select the "P" group (Basic
Program Group).
Press Select or Enter . The parameter number should flash.
Use the up and down arrows to select the "041" parameter.
Press Select or Enter . The actual parameter (i.e. 0) value is

be displayed. The parameter P041 is the Reset to Defaults parameter.
Setting this parameter to 1 resets all the drive parameters to factory
defaults.
Use the up and down arrows to set the P041 parameter to 1.
Press Enter to confirm. Once the reset is complete, an F48 fault is

displayed. The F48 fault warns the user that the parameter values are reset
to factory defaults.
Press Stop to clear the F48 fault.
Displaying a Parameter value
G 8. Record the value of the following parameters (factory default) set on the AC
Drive. Refer to the Parameter Cross Reference Table in Appendix B to
determine the parameter numbers.
Motor nameplate voltage: V
Motor nameplate frequency: Hz
G 9. To display the value of a parameter, follow the steps below:
Press Enter to display the group parameter.
Use the up and down arrows to select the desired group.
Press Select or Enter .
Use the up and down arrows to select the desired parameter

number.
Press Select or Enter to display the parameter value.
Use the Escape key to go back and select another parameter.

Measuring the three-phase motor voltage and current
G 10. Record (in the table below) the value of the output current and output
voltage parameters when the frequency potentiometer is set at 20.0, 40.0,
and 60.0 Hz.
Use the Start key to start the motor and turn the
Potentiometer to adjust the frequency.
Note: If the motor does not start to rotate, make sure a jumper
connects terminals 11 and 01 on the AC Drive. If it is not the
output frequency that is displayed on the drive display, select
parameter d0001. Refer to the AC Drive - Quick Start Guide for
more details.
Frequency (Hz) Output Current (A) Output Voltage (V)
20.0
40.0
60.0
Note: The parameter numbers to display the output current and

voltage can be found in Table B-1 of Appendix B.
G 11. Press Stop to stop the AC Drive.
G 12. Adjust the maximum frequency of the AC Drive output at 40 Hz by setting

the maximum frequency parameter (Maximum Freq) to 40.
Note: Again, the parameter number can be found in Table B-1 of

Appendix B.
G 13. Verify the maximum output frequency setting as follows:
C Display the output frequency parameter

C Start the AC Drive
C Set the frequency potentiometer to the maximum position
If the displayed frequency is not 40 Hz after 10 seconds, repeat the output

frequency adjustment.
G 14. Stop the AC Drive.

G 15. Proceed as in step 7 to reset the parameters to default.
Verifying the acceleration time
G 16. Adjust the time it takes for the AC Drive to reach the frequency set by the
frequency potentiometer (Accel Time 1) to 20 seconds by setting the
acceleration time parameter to 20.
G 17. Verify the acceleration time setting as follows:
C Display the output frequency parameter

C Set the frequency potentiometer at the maximum position
C Start the AC Drive and use a stopwatch to measure the time taken to
reach the maximum frequency
If the time is not 20 seconds, repeat the acceleration time adjustment.
G 18. Familiarize yourself with the direction of rotation control by pressing the
Reverse key on the AC Drive keypad.
Determine if the Flat Belt Conveyor rotates in the clockwise (CW) or

counterclockwise (CCW) direction when the AC Drive is set to forward.
Direction of rotation:
G 19. Once familiar with the AC Drive, configure the drive according to Table 1-2.
PARAMETER VALUE
Motor nameplate voltage 208 V ac
Maximum allowable motor current 1.3 A
Acceleration time 0.1 s
Deceleration time 0.1 s
Table 1-2. Parameter values for the AC Drive.
G 20. Ask the instructor to check and approve your work.
Troubleshooting exercise
Note: Prior to this exercise, the instructor must insert a fault into
the circuit of the Flexible Manufacturing System.
G 21. Try to use the setup and determine whether if everything is working
properly.

G 22. If the system is not working properly, describe the symptom(s).
G 23. Use your troubleshooting skills to identify the malfunctioning module(s) and
isolate the problem(s).
G 24. Explain in detail your approach to isolating the problem.
G 25. Ask the instructor to check and approve the Troubleshooting Exercise.
Name: Date:
Instructor's approval:

2
ETHERNET COMMUNICATION AND
PLC PROGRAMMING LANGUAGES
Using the Emergency Switch Station
From now on, all setups made with the FMS must include the Emergency Switch
Station, Model 5926. The Emergency Switch Station has a red mushroom push
button similar to the emergency buttons found on most industrial equipment. This
mushroom push button allows the equipment to be stopped in case of an emergency
if the Emergency Switch Station is used as a 24-V dc and 120-V ac power source
for your setup.
Do not connect the FMS without the Emergency Switch Station in your setup. Some
of the equipment provided with the FMS involves high voltages, moving parts, or
pneumatically activated components. In case of an incident, manipulation error, or
malfunction, the user must be able to stop the system immediately using the
Emergency Switch Station.
The Emergency Switch Station is equipped with two 120-V ac power outlets and
a 24-V dc output that can be used to provide current to the FMS equipment. To be
able to use the 120-V ac power outlets, the Emergency Switch Station must be
connected to a wall outlet meeting the electric specification of the station. The 24-V
dc power is provided by the Programmable Logic Controller.
Refer to the wiring diagram provided with each Job Sheet to properly connect the
Emergency Switch Station to the equipment. The electrical circuit controlling the
Emergency Switch Station is printed on the module and is reproduced in Figure 2-1.
Figure 2-1. Emergency Switch Station electrical circuit.
How the Emergency Switch Station works
To activate the Emergency Switch Station, an output of the PLC (output 15) must be
connected to the yellow terminal of the station. The programs provided with the FMS
are designed to send a momentary 24-V signal through this output to activate the

Emergency Switch Station. This signal energizes the relay K, which has a three-pole
double-throw (TPDT) contact arrangement. When the relay is energized, the
contacts K-A, K-B, and K-C are closed and power is provided to the 120-V power
outlets and to the 24-V output connector (orange terminal).
Once the relay has been energized for a short period of time by the PLC, there is no
need to apply a 24-V dc signal continuously to the yellow terminal since the contact
K-A is closed and the 24-V source keeps the relay energized. This type of circuit is
known as a self-maintained contact.
Pressing the mushroom push button stops the current flow through the coil of the
relay which opens all contacts. Thus, the power to the relay is cut (K-A is open), the
power to any 24-V dc device connected to the 24-V output terminal (orange terminal)
is cut (K-B is open), and the power to both 120-V ac power outlets is cut (K-C is
open).
To reset the Emergency Switch Station if the mushroom push button has been
pressed, the mushroom push button must be turned clockwise and a 24-V dc signal
must be sent to the yellow terminal to re-energize the relay coil.
PLC programming languages
As manufacturing applications become more complex, programming these

applications becomes more difficult. Today's PLCs provide a wide variety of
programming tools to build simpler and more efficient programs. Most PLC
programming applications tend to follow the IEC 61131-3 standards. These
standards helped to give uniformity to ladder logic programming and introduced
new (and sometimes more efficient) programming languages. All programs in this
manual use one or more of the following programming languages from the
IEC 61131-3 standards: ladder diagram, sequential function chart, function block
diagram, and structured text.
Ladder diagram and PLC programming
Ladder logic was initially developed to make PLC programming easier for
electricians. Ladder logic uses electric symbols to represent the rules and conditions
in a program. A ladder diagram contains two uprights connected together by rungs.
Hence the name, ladder diagram. The uprights provide the power to the rungs; each
rung contains a series of electrical-symbol operators. When all conditions on a rung
are true, power can flow through that rung. The conditions on a rung are represented
by contacts such as normally open (NO or XIC) or normally closed contact (NC or
XIO). When all contacts on a rung are set so that current can flow, one (or more) coil
is turned on. Contacts are sometimes referred to as inputs and coils as outputs.
Note: Normally open and normally closed contacts are also called Examine If
Close (XIC) and Examine If Open (XIO) contacts respectively.
Let us look at an example to see how ladder logic works. For this, we will use the
circuit shown in Figure 2-2 (a) where a light is turned on when a normally-open push
button is pressed. The ladder logic version of this circuit is shown in Figure 2-2 (b).
In this example, the normally-open push button becomes a normally-open

contact (the input). The light is the output and is represented by the coil at the right
of the ladder diagram.
Figure 2-2. Push button and light ladder diagram.
Figure 2-3 shows how this circuit can be connected to a PLC. In this case, the push
button is connected to input 1 and the light is connected to output 3.
Figure 2-3. Connection of a push button and a light to the PLC.
The PLC takes care of the logical operations between the input and the output. Thus,
the system is no longer limited by the physical wiring. Figure 2-4 below shows two
different ladder diagram programs that can be used to interface the push button with
the light. The first ladder diagram controls the light as if it was connected as in
Figure 2-2, the light is turned on when the push button is pressed. The second ladder
diagram controls the same push button and light circuit in a completely different way.
The normally-open contact in the ladder diagram has been replaced with a normally-
closed contact. Hence, the light is always on, unless the push button is pressed.

Since the input element of the electrical circuit (the push button) is no longer
connected to the output element (the light), the system behavior is not limited to the
design of the physical connections.
Figure 2-4. Two ladder diagrams for the push button and light circuit with different behaviors.
As shown in the previous example, all the components used as input

devices (whether they are buttons, sensors, or switches) are connected to the 24-V
input module of the PLC. The output devices (lights, ac drives, actuators, etc.) are
connected to the output module and everything in between is taken in charge by the
PLC.
The ladder diagram instructions or symbols used in this Job Sheet are shown in
Table 2-1.
Instruction/Name Symbol Description
Examine if the data bit is

XIC (Examine If Closed)
set (on condition)
Examine if the data bit is

XIO (Examine If Open)
cleared (off condition)
The output data bit is set

OTL (Output Latch) until cleared with a OTU
instruction
If the output data bit is set,

OTU (Output Unlatch) the OTU instruction clears
this bit
Timer that accumulates

TON (Timer On Delay)
time when enabled
Execute a subroutine
JSR (Jump to Subroutine)
when enabled
Table 2-1. Ladder diagram instructions used in this Job Sheet.

Modern PLCs are no longer limited to ladder diagram programs. All PLC
programming languages can be mixed together in a program. This includes
sequential function chart, function block diagram, and structured text programming.
The sections below shows the main characteristics of the other programming
languages used in the FMS applications presented in this manual.
Sequential function chart
Sequential function chart programming is ideal for condition-dependant processes.

A sequential function chart is composed of steps and conditions. Steps are used to
accomplish an action while conditions determine if a step will be executed or not.
From the beginning of the chart, the steps depend on conditions to be executed.
When a condition is reached on the sequential function chart, the controller does not
proceed further with the evaluation of the chart, unless this condition is true. To
control complex processes, branches can be used and processes can be run
concurrently. Figure 2-5 shows a simple sequential function chart.
Figure 2-5. Sequential function chart program.
Function block diagram
Like ladder diagrams, function block diagram programming provides a graphical

programming interface inspired by electrical circuit blueprints. Each block in the
diagram is similar to an electric device connected to other devices with
wires (connection lines). A block receives input signals, treats them using different

operators, and returns output signals. In turn, these output signals can be used as
input signals for other blocks in the diagram. Figure 2-6 shows an example of a
function block diagram and Table 2-2 shows the function block instructions used in
this Job Sheet.
Figure 2-6. Function block diagram program.
Instruction/Name Description
BNOT (Boolean Not) Logic Not
BAND (Boolean And) Logic And
BOR (Boolean Or) Logic Or
Used Set or Reset inputs to control

RESD (Reset Dominant)
latched outputs (priority to reset)
Used Set or Reset inputs to control

SETD (Set Dominant)
latched outputs (priority to set)
TONR (Timer On Delay with Reset) Non-retentive timer
JKFF (JK Flip Flop) Logic JK Flip Flop
Table 2-2. Sequential function block instructions used in this Job Sheet.
Structured text
This high-level programming language can be used to create complex programs.

Structured text includes logical and arithmetic operators (not, and, +, =, <=, etc.),
conditional statements (if, then, else, case, etc. ), loops (repeat, for, do, while, etc.),
and other instructions commonly found in high-level programming languages. Its
structure is similar to the C and to the old Pascal programming language. Structured
text is often used in the actions of sequential function chart programs.
Addressing
The terminals on the PLC input and output modules are identified by addresses.
Each address has the following format: Location:Slot:Type.Member.SubMember.Bit.
For example, in the push button and light example above, the address of the push
button connected to input 1 is: Local:1:I.Data.1. Table 2-3 below details the different
parts of an address.

Stands for / Value: Example
Local if the module is on the same chassis as

Location the controller. If not, the adapter name is used Local:1:I.Data.1
instead.
Slot identification number of the input or output

Local:1:I.Data.1
Slot module (the smaller the identification number,
the closer the module is to the controller).
The type of data associated with the address: Local:1:I.Data.1

Type I (input), O (output), C (configuration), or
S (status).
Local:1:I.Data.1
Data if digital modules are used or a channel
Member
member if analog modules are used.
Local:1:I.Data.1
SubMember Specific data related to a Member. (there is no

submember in this
example)
Local:1:I.Data.1
The bit number of the physical input or output
Bit
on the module.
Table 2-3. PLC address structure.
As illustrated in Table 2-3 above, the address Local:1:I.Data.1 represents input

number 1 on the digital input module located in slot 1 of the controller chassis.
To make programming easier and more understandable, alias tags can be created
to replace the addresses assigned to inputs or outputs. If a red push button is
connected to input Local:1:I.Data.1, an alias such as red_button can be created.
Thus, instead of constantly referring to Local:1:I.Data.1, the more descriptive tag
red_button can be used. Figure 2-7 shows how an alias tag can replace an input
address in a ladder diagram.

Figure 2-7. An address replaced with an alias tag in a ladder diagram.
Tags can be edited and monitored using the options available in the Logic menu of
RSLogix 5000. Figure 2-8 shows how tags information are displayed in
RSLogix 5000.
Figure 2-8. RSLogix 5000 tags window.

Memory Map
An easy way to document how a PLC is connected to the real world devices is to
build a memory map of the PLC inputs and outputs. That is, to write down in a table
how I/O devices, physical inputs and outputs, PLC addresses, and alias tags are
related to each other in a given PLC controlled system. Intermediate variables can
also be written down in the memory map table since they can play an important role
in the understanding of the PLC program structure. Table 2-4 is an example of a
memory map, it is the memory map of the program used in this Job Sheet. All I/O
modules are digital modules and are located on the same chassis as the controller.
Function/Physical Device I/O number Address Alias Tag

Mushroom push button on the Emergency
Input 0 Local:1:I:Data.0 Emergency_Off
Switch Station, Model 5926
Start button / Green push button (NO) on
the Indicator Light/Push-Button Station, Input 1 Local:1:I:Data.1 Pushbutton_Start
Model 5925
Pause button / Yellow push button (NO)
Input 2
on the Indicator Light/Push-Button Local:1:I:Data.2 Pushbutton_Pause
Station, Model 5925
Stop button / Red push button (NC) on
the Indicator Light/Push-Button Station, Input 3 Local:1:I:Data.3 Pushbutton_Stop
Model 5925
Start indicator light / Green indicator light
on the Indicator Light/Push-Button Output 12 Local:2:O:Data.12 Light_Start
Station, Model 5925
Pause indicator light / Yellow indicator
Local:2:O:Data.13
light on the Indicator Light/Push-Button Output 13 Light_Pause
Station, Model 5925
Stop indicator light / Red indicator light on
Local:2:O:Data.14
the Indicator Light/Push-Button Station, Output 14 Light_Stop
Model 5925
Yellow terminal on the Emergency Switch
Output 15 Local:1:O:Data.15 Emergency_Reset
Station, Model 5926
Bit (boolean) indicating that the system is N/A
N/A Pause_Bit
paused
Timer N/A N/A tmr_pause
Table 2-4. Memory Map.

2
OBJECTIVE
To configure an Ethernet network for use with the PLC and to control the Indicator
Light/Push-Button Station with the PLC using four different programming languages.
PROCEDURE
G 2. Use Table 2-5 and Figure 2-9 to identify the new components used in this
Job Sheet.
Indicator Light/Push-Button 5925 Three push buttons (one normally-closed

Station and two normally-open) and three
indicator lights.
Emergency Switch Station 5926 Station featuring a mushroom-type push

button used to cut the power in case of
emergency.
Programmable Logic 5930 or Used to control the different modules of

Controller 5930-A the Flexible Manufacturing System.
Table 2-5. New components used for Job Sheet 2.

Figure 2-9. New components used for Job Sheet 2.
Note: A Personal Computer with RSLogix 5000 and RSLinx is

also required to complete this Job Sheet. For the following Job
Sheet you will also need to have RSNetWorx installed on your
computer.
Note: Refer to the Equipment Utilization Chart in Appendix A of

the manual to obtain the complete list of equipment required to
complete this Job Sheet.
Note: The Programmable Logic Controller shown in the picture is

Model 5930. If the Flexible Manufacturing System, Model 5901-3,
is used, the Model 5930-A will be provided. It looks a little bit
different but has the same form factor.
System setup

Figure 2-10.

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

Figure 2-10(b). PLC programming languages wiring diagram (Compact Logix L43).
G 4. Use the wiring ducts appropriately to maintain a neatly organized work

surface as shown in Figure 2-11.

Figure 2-11. Wiring ducts used appropriately to maintain a tidy setup.
G 5. Once completed, the setup should look as shown in Figure 2-12.
Figure 2-12. PLC programming languages setup.

G 6. Briefly describe how a coil relay works.
G 7. Identify if the buttons on the Indicator Light/Push-Button Station are XIC or

XIO push buttons.
XIC or XIO
Green push button
Yellow push button
Red push button
Ethernet configuration
G 8. In this Job Sheet, communications between the computer and the PLC use
the Ethernet/IP network protocol. Other types of network communication
protocols are introduced in the next Job Sheet. Before proceeding further,
make sure that your computer is not connected to another local area
network.
CAUTION!
If you do not want to use a wireless connection to

communicate with the PLC, jump immediately to the LAN
configuration section below.
Wireless network configuration
Note: This section is intended for those who want to use the
wireless feature of the router provided with the Flexible
Manufacturing System. Jump to the "LAN configuration" section
if you prefer to use a standard LAN configuration or if your
computer is not equipped with a wireless Ethernet card.
G 9. Make sure your computer is equipped with an operational wireless Ethernet

card and that the connections are as in Figure 2-10, with the exception of
the cable between the computer and the router since the connection will be
wireless.

G 10. From the computer Control Panel, open the Network Connections folder and
double-click on Wireless Network Connection to open the Wireless Network
Connection window (Figure 2-13). This is where you can change your
wireless network parameters.
Note: If there is more than one connection available in the

wireless network list, make sure to double-click on the connection
associated with the Ethernet card you want to use to
communicate with the wireless router connected to the PLC.
Figure 2-13. Wireless Network Connection window.
G 11. Click on the Change advanced settings task to display the Wireless Network
Connection Properties window (Figure 2-14).

Figure 2-14. Wireless Network Connection Properties window.
G 12. Double-click on the Internet Protocol (TCP/IP) item to open the Internet
Protocol (TCP/IP) Properties window.
G 13. Select Use the following IP address and enter 192.168.2.3 in the IP address
section and 255.255.255.0 in the Subnet mask section as shown in
Figure 2-15.

Figure 2-15. Internet Protocol (TCP/IP) Properties window.
Note: At this point, you will lose communications to equipment

that are not part of the Flexible Manufacturing System.
G 14. Once the IP address and subnet mask are entered, click OK to apply the
changes and close the Internet Protocol (TCP/IP) Properties window.
G 15. Click OK to close the Local Area Connection Properties window.
G 16. Double-click on belkin54g in the Wireless Network Connection window. If a

warning window similar to the one shown in Figure 2-16 is displayed, click
on Connect Anyway.

Figure 2-16. Wireless Network Connection warning window.
Note: The factory default setting of the wireless router does not
secure the wireless network against unauthorized access. Ask
your local network administrator if you want to secure your
wireless network.
G 17. Once the connection is established with the router, the connected icon
appears in the upper-right corner of the belkin54g network connection item
as in Figure 2-17.
G 18. The wireless network configuration is completed, jump to the RSLinx

configuration section below to configure the PLC software for
communication with the PLC through the wireless network.

Figure 2-17. Wireless Network Connection window.
LAN configuration
Note: This section is intended for those who do not want to use
the wireless feature of the router provided with the Flexible
Manufacturing System. If you have already
completed (successfully) the steps of the "Wireless network
configuration" section above, jump to the "RSLinx configuration"
section below.
G 19. Make sure the Ethernet connections on your setup are as in Figure 2-10.
G 20. From the computer Control Panel, open the Network Connections folder and
double-click on Local Area Connection to open the Local Area Connection

Status window (Figure 2-18). This allows you to change your LAN (Local
Area Network) parameters.
Note: If there is more than one connection available in the

Network Connections folder, make sure to double-click on the
Local Area Connection associated with the Ethernet card to which
the router is connected.
Figure 2-18. Local Area Connection Status window.
G 21. Click on Properties (Figure 2-19) to display the Local Area Connection
Properties window.

Figure 2-19. Local Area Connection Properties window.
G 22. Double-click on the Internet Protocol (TCP/IP) item to open the Internet
Protocol (TCP/IP) Properties window.
G 23. Select Use the following IP address and enter 192.168.2.3 in the IP address
section and 255.255.255.0 in the Subnet mask section as shown in
Figure 2-20.

Figure 2-20. Internet Protocol (TCP/IP) Properties window.
Note: At this point, you will lose communications to equipment

that are not part of the Flexible Manufacturing System.
G 24. Once the IP address and subnet mask are entered, click OK to apply the
changes and close the Internet Protocol (TCP/IP) Properties window.
G 25. Click OK to close the Local Area Connection Properties window.
G 26. Click Close to close the Local Area Connection Status window.
G 27. The network configuration is complete. Jump to the RSLinx configuration

section below to configure the PLC software for communication with the
PLC through the wireless network.

RSLinx configuration
G 28. Start RSLinx (Figure 2-21). This software links the devices of the Flexible
Manufacturing System to Microsoft Windows® applications.
Figure 2-21. RSLinx.
G 29. From the Communications menu, select Configure Drivers to open the
Configure Drivers window (Figure 2-22).

Figure 2-22. Configure Drivers window.
G 30. From the Available Driver Types drop-down list, select Ethernet/IP
Driver (Figure 2-23).

Figure 2-23. Available Driver Types drop-down list.
G 31. Click on Add New to display the Add New RSLinx Driver window shown in
Figure 2-24.
Figure 2-24. Add New RSLinx Driver window.
G 32. This window allows you to choose a name for the Ethernet/IP driver. Keep
the default name AB_ETHIP-1 and click OK.
G 33. The Configure driver: AB_ETHIP-1 window appears. Select the local subnet
with IP address 192.168.2.3. Click OK to accept the changes.

Figure 2-25. Configure driver: AB_ETHIP-1 window.
G 34. The added driver appears in the Configured Drivers list (Figure 2-26). Click
Close to close the Configure Drivers window.
Figure 2-26. Configure Drivers window.

G 35. Make sure the PLC is connected to the previously configured router.
G 36. Turn on the PLC.
G 37. If it is not already active, open the RSWho window in RSLinx (Figure 2-27).
To do so, select RSWho from the Communications menu.
Figure 2-27. RSWho window.
G 38. Click on the + symbol beside AB_ETHIP-1, Ethernet to expand the Network
tree and wait for the PLC to appear in the devices list (Figure 2-28). It can
take several seconds before RSLinx detects the new device.

Figure 2-28(a). Browsing the network devices using RSWho (Compact Logix L32E).

Figure 2-28(b). Browsing the network devices using RSWho (Compact Logix L43).
G 39. The factory default configuration for the PLC is shown in Figure 2-29.

Figure 2-29. PLC default configuration.
Note: If the PLC does not appear in the devices list, check the
physical connections between the PLC, the router, and the
computer. Check if the indicator lights are active on the router. If
all connections are correct and the PLC is still not detected by
RSLinx, follow the "Changing the PLC IP address setting"
procedure in Appendix C to make sure the PLC IP address is
correct.
G 40. When completely expanded, the AB_ETHIP-1, Ethernet network tree looks
as in Figure 2-30.

Figure 2-30(a). AB_ETHIP-1, Ethernet network tree (Compact Logix L32E).

Figure 2-30(b). AB_ETHIP-1, Ethernet network tree (Compact Logix L43).
G 41. From the File menu, select Exit to close the RSLinx window (the software
remains active). To open the RSLinx window again, click on the RSLinx
Communications Service icon located in the notification area of the
Windows taskbar.
G 42. The Ethernet network configuration is completed. You should be able to

communicate with the PLC using RSLogix 5000.
Running the program
G 43. Start RSLogix 5000 (Figure 2-31). This programming software offers four
different languages to develop programs for the PLC: ladder diagram,
structured text, sequential function chart, and block diagram. In this Job
Sheet, and all subsequent ones, the programs made with RSLogix 5000 are
used to control the various components of the Flexible Manufacturing
System.

Figure 2-31. RSLogix 5000.
Note: Make sure RSLinx is running on your computer before

trying to download the program to the PLC.
G 44. Open the RSLogix 5000 project file named intro_manu_stu2.acd, familiarize
yourself with the interface of RSLogix 5000, and browse through the main
program (Figure 2-32). The MainProgram is divided into six sections:
Note: Select the file from the directory corresponding to the right
controller.
Program Tags, where the details about the tags used in the program are
available.

MainRoutine, where the core of the program is located. A PLC program can
be written directly as a main routine or subroutines can be executed from
the MainRoutine section.
Lights_Activation_1, is a subroutine of the MainRoutine written using the

ladder diagram programming language.

sequential function chart programming language.

function block diagram programming language.
Lights_Activation_4, is a subroutine of the MainRoutine entirely written in

structured text.
Figure 2-32. Intro_manu_stu2 program.

G 45. Before the program can be downloaded, the controller with which
RSLogix 5000 communicates must be selected. To activate the PLC, select
Who Active from the Communications menu to display the Who Active
window (Figure 2-33).
Figure 2-33. Who Active window.
tree and select the PLC from the list (00, CompactLogix Processor...) as
shown in Figure 2-34.

Figure 2-34(a). Select 00, CompactLogix Processor... from the Network tree (Compact Logix L32E).

Figure 2-34(b). Select 00, 1768-L43... from the Network tree (Compact Logix L43).
G 47. Click on the Download button to download the program to the PLC.
Note: Make sure the PLC key is set to the REM position.
CAUTION!
Before running the program, make sure the connections are

as in Figure 2-10.
G 48. Once the program is running, the main routine jumps to a subroutine when
either input 4, 5, 6, or 7 is high. Each subroutine controls the Flexible
Manufacturing System in the same way but is written in a different
programming language. Use a banana-plug connection lead as a jumper to
activate input 4 (i.e. connect one end of the lead to a 24-V dc source and
connect the other end to input 4). This activates the ladder diagram
subroutine.

G 49. Does an XIC push button have to be associated with an XIC contact in a
ladder diagram?
G 50. Make sure the setup is working properly. You should be able to:
• Turn on the green light by pressing the green (start) button on the
Indicator Light/Push-Button Station;
• Turn on the red light by pressing the red (stop) button (all the other
lights turn off);
• Turn off the green light by pressing the yellow (pause) button and turn
on the yellow flashing light;
G 51. Repeat steps 46 and 47 with inputs 5, 6, and 7.
G 53. Try to use the setup and determine whether everything is working properly.

Programming exercise
Note: Make sure there is no fault from the troubleshooting

exercise left on the setup.
In the PLC program used for this Job Sheet, the four subroutines used are written
in four different programming languages. If the yellow push button is pressed when
this program is running on the PLC, the system pauses and the yellow light flashes.
Modify each of the subroutines of this program so that the yellow light flashes at a
slower rate when the yellow push button is pressed.
G 58. Once this exercise is complete, ask the instructor to check and approve your
work.
Name: Date:

3
NETWORK COMMUNICATIONS
Network communications
Plant communications can be divided in three main categories (levels) : information,

control, and device communication. At the information level, the network deals with
the communications between computers, the internet/intranet connections, and the
plant management applications. Below the information level is the control level. The
control level regroups the devices involved in the control of industrial applications
such as PLCs, ac drives, and I/O devices. The bottom level of communication in a
plant is the device level. The device level includes communications with devices
such as sensors, pneumatic valves, and actuators.
The choice of communication protocol in a plant depends on which network level is

favored. The information network level is widely associated with the Ethernet
protocol while the control network level is associated with ControlNet and the device
network level is associated with the DeviceNet protocol. Older networks or devices
may use serial communication, but the use of serial communication tends to be
replaced with other types of communication protocols. The communication protocols
used in the Flexible Manufacturing System Job Sheets are briefly described below.
Ethernet
The Ethernet protocol is integrated to a wide variety of network technologies. Most

industries use the Ethernet protocol to link computers and other devices (such as
printers) in a local area network (LAN). The Ethernet protocol is usually associated
with what is called the information network level. It is at this level that information is
shared between the computers connected to the LAN.
Ethernet protocol is the most used of the network communication protocols because
it is inexpensive, it supports internet/extranet connections, and it is usually
compatible with the computer network already present in the plant. Ethernet
connections can be used to link various devices to PLCs and to link PLCs to
computers. Figure 3-1 shows an example of a PLC connected to other devices using
Ethernet.

Figure 3-1. Ethernet network configuration.
As far as the Flexible Manufacturing System devices are concerned, Ethernet

communication is used only between the PLC and the computer.
DeviceNet
DeviceNet is another communication protocol used in industries but, instead of being

used for communication at the information or control levels, it is used mainly for
communications between devices. Connecting I/O devices of a plant using a
DeviceNet network prevents the use of hundreds of wires to physically connect these
devices to the PLC. This reduces both the initial and maintenance cost of the
equipment. In a DeviceNet configuration, the devices (sensors, valves, buttons,
motors, etc.) are connected to a bus which is a subsystem that transfers data
between the various devices and the controller.
The AC Drive and the Part Feeder provided with the Flexible Manufacturing System
have DeviceNet communication ports allowing connection to the PLC. Figure 3-2
shows a typical DeviceNet network configuration.

Figure 3-2. DeviceNet network configuration.
Serial
Some devices are equipped with an RS-232 port for serial communication. Even
though serial communication is giving way to Ethernet communication, it is still used
in industry.
The Programmable Logic Controller provided with the Flexible Manufacturing System
is equipped with an RS-232 port which can be used to configure the controller if a
problem occurs with the Ethernet connection. Refer to the Changing the PLC IP
address setting procedure in Appendix C for details.

3
OBJECTIVE
To control the Flat Belt Conveyor using the AC Drive, the Indicator Light/Push-Button
Station, and the Emergency Switch Station. To configure the system for DeviceNet
communication and to control the AC Drive through a DeviceNet link.
PROCEDURE
G 2. In this Job Sheet, the setups used in the two previous Job Sheets are put
together to build a bigger setup and to introduce DeviceNet networking.

PART 1 – STANDARD COMMUNICATION WITH THE AC DRIVE
System setup

Figure 3-3.

Figure 3-3(a). Network communications (part 1) wiring diagram (Compact Logix L32E).

Figure 3-3(b). Network communications (part 1) wiring diagram (Compact Logix L43).

Figure 3-4. Network communications setup.
G 5. Follow the Ethernet configuration procedure given in Job Sheet 2 to

configure the system for Ethernet communication.
G 6. Make sure the AC Drive is powered and turned on.
G 7. Configure the AC Drive using the settings given Table 1-2 of Job Sheet 1.
G 8. Set the value of the AC Drive Start Source parameter (P036) to 2 (2-Wire).
Note: Make sure that no DeviceNet cable is connected on the AC

Drive and that there is no jumper installed between the AC Drive
I/O terminals 01 and 11.
G 9. Open the RSLogix 5000 project file named intro_manu_stu3a.acd and

download the program to the PLC. Refer to the Running the programs
procedure given in Job Sheet 2 for details on downloading programs.

Note: Make sure RSLinx is running on your computer before

trying to download the program to the PLC.
• Start the Flat Belt Conveyor (clockwise rotation) using the green push
button on the Indicator Light/Push-Button Station;
• Stop the Flat Belt Conveyor using the red push button on the Indicator
Light/Push-Button Station;
• Start the Flat Belt Conveyor (counterclockwise rotation) using the yellow
push button on the Indicator Light/Push-Button Station;
• Observe that the red indicator light turns on when the system is
powered;
• Observe that the green indicator light turns on when the Flat Belt
Conveyor is rotating clockwise and that the yellow indicator light turns
on when the Flat Belt Conveyor is rotating counterclockwise;
• Shut the process down by pressing the emergency button on the

G 11. Ask the instructor to check and approve your work for this part of the Job
Sheet.
PART 2 – DEVICENET COMMUNICATION WITH THE AC DRIVE
In the first part of the current Job Sheet, the AC Drive has been connected to the
PLC using standard wires (or leads). In this second part, the DeviceNet connectivity
feature of the AC Drive is used to connect the drive to the PLC.

Figure 3-5. Once the setup is complete, the system must be configured for
DeviceNet communication. Follow the procedure below to configure the
Flexible Manufacturing System for DeviceNet.

Figure 3-5(a). Network communications (part 2) wiring diagram (Compact Logix L32E).

Figure 3-5(b). Network communications (part 2) wiring diagram (Compact Logix L43).
DeviceNet configuration
G 13. Make sure the AC Drive is connected to the PLC with a DeviceNet cable.
G 14. Make sure the AC Drive is powered and turned on.

G 15. Configure the AC Drive using the settings given in Table 1-2 of Job Sheet 1.
G 16. Set the value of the AC Drive Start Source parameter (P036) to 5 (Comm
Port).
Note: Make sure that the DeviceNet cable is connected on the

AC Drive and that there is a jumper installed between AC Drive
I/O terminals 01 and 11.
G 17. Start RSNetWorx for DeviceNet (Figure 3-6). This software is used to
configure and monitor devices connected to the DeviceNet network.
Figure 3-6. RSNetWorx for DeviceNet.
G 18. Click on the Online button to display the Browse for network
window (Figure 3-7).

Figure 3-7. Browse for network window.
tree until the Port2, DeviceNet item is reached. Select this item and
click OK (Figure 3-8).

Figure 3-8(a). Select the Port2, DeviceNet item (Compact Logix L32E).

Figure 3-8(b). Select the Port2, DeviceNet item (Compact Logix L43).
G 20. The message window shown in Figure 3-9 appears. Click OK to continue.
Figure 3-9. RSNetWorx for DeviceNet synchronization message window.

G 21. RSNetWorx for DeviceNet scans each of the 64 node addresses to find
devices (Figure 3-10). The PLC DeviceNet scanner card is located at node
address 00 and the AC Drive at node address 01.
Note: The node addresses are numbered from 00 to 63.
Figure 3-10. Browsing network window.
Note: If the browsing network sequence is very fast, there may be

a problem with your DeviceNet network. Make sure there is 24-V
dc power on your setup. Refer to the troubleshooting section for
details.
Note: If you experience problems communicating with the AC

Drive through your DeviceNet network, check if the node address
and the data rate switches of the AC Drive DeviceNet Adapter are
set to the factory default value of 11000001 (node
address: 01 / data rate: Autobaud). Refer to Appendix E for
details.
G 22. Once the DeviceNet network is scanned, the RSNetWorx for DeviceNet
window looks as in Figure 3-11. Both the scanner module and the AC
Drive (PowerFlex 40) are displayed on the Graph tab.

Figure 3-11. RSNetWorx for DeviceNet window.
G 23. Double-click on the scanner module icon to open the 1769-SDN Scanner
Module window (Figure 3-12).

Figure 3-12. 1769-SDN Scanner Module window.
G 24. Click on the Module tab. The Scanner Configuration Applet

window (Figure 3-13) appears.

Figure 3-13. Scanner Configuration Applet window.
G 25. Click on Upload.
G 26. On the Module tab, make sure CompactLogix is selected in the Platform
drop-down list and that the Slot is set to 3 as in Figure 3-14.

Figure 3-14. Module tab of the 1769-SDN Scanner Module window.

G 27. Click on the Scanlist tab (Figure 3-15).
Figure 3-15. Scanlist tab of the 1769-SDN Scanner Module window.
G 28. In the Available Devices list, select the AC Drive item (i.e. 01,
PowerFlex 40 1P 100...) and click on the left arrow button to move the
item from the Available Devices list to the Scanlist.
Note: Up to 63 devices can be connected to the Flexible

Manufacturing System DeviceNet network. Each device must be
in the Scanlist to be scanned by the scanner module.
G 29. Once the AC Drive is in the Scanlist, click on the Input tab (Figure 3-16). In
this tab you can see to which memory bits the AC Drive inputs have been
assigned. In the example below, the input bits of the drive are located at
Local.3:I.DataXX. Refer to the 22-COMM-D manual for details.

Figure 3-16. Input tab of the 1769-SDN Scanner Module window.

G 30. Click on the Output tab and note to which addresses (memory bits) the AC
Drive outputs have been assigned (Figure 3-17).
Figure 3-17. Output tab of the 1769-SDN Scanner Module window.
G 31. Click OK to close the 1769-SDN Scanner Module window. The Scanner
Configuration Applet asks if you want to download the changes to the
device. Click on Yes to download the changes (Figure 3-18).
Note: To be able to download the changes, the PLC key must be

set to REM.

Figure 3-18. Scanner Configuration Applet window.
G 32. From the File menu, select Save As to save the DeviceNet network
configuration on your computer hard drive. Save your configuration under
the name Networx_1st_Config (Figure 3-19). This file can be used to restore
the DeviceNet configuration later.
Figure 3-19. Save As window.
Running the program
G 33. Open the RSLogix 5000 project file named intro_manu_stu3b.acd and
Note: Make sure RSLinx and RSNetWorx for DeviceNet are

running on your computer before trying to download the program
to the PLC.

• Start the Flat Belt Conveyor (clockwise rotation) using the green push
• Stop the Flat Belt Conveyor using the red push button on the Indicator
• Start the Flat Belt Conveyor (counterclockwise rotation) using the yellow
push button on the Indicator Light/Push-Button Station;
• Observe that the red indicator light turns on when the system is
powered;
• Observe that the green indicator light turns on when the Flat Belt
Conveyor is rotating clockwise and that the yellow indicator light turns
on when the Flat Belt Conveyor is rotating counterclockwise;
• Reset the system using the red push button on the Indicator Light/Push-
Button Station;
• Shut the process down by pressing the emergency button on the

G 35. Ask the instructor to check and approve your work for this part of the Job
Sheet.


In the PLC program used for the second part of this Job Sheet, the Indicator
Light/Push-Button Station is used to control the Flat Belt Conveyor. The lights of the
Indicator Light/Push-Button Station turn on when the push buttons are pressed.
Modify the PLC program so that the green and yellow lights turn on when they
receive a feedback signal from the AC Drive.
This can be done when controlling the AC Drive through a DeviceNet connection.
Use the status of the AC Drive outputs 1 and 3 to turn on the green light when the
Flat Belt Conveyor is rotating in the clockwise direction and to turn the yellow light
when the Flat Belt Conveyor is rotating in the counterclockwise direction. The
addresses to access these output bits with the PLC are Local.3:I.Data[0].1
Local.3:I.Data[0].1 respectively. If required, refer to the AC Drive – Quick Start Guide
in Appendix B of this manual.

work.
Name: Date:

4
PLC-CONTROLLED CONVEYOR AND SENSORS
Sensors
Sensors are the eyes and ears of the PLC. Usually sensors are divided in two large
categories: contact and non-contact. Contact sensors require a physical contact with
the target to be triggered while non-contact sensors can sense the target without
touching it, as long as the target is within the sensing distance. Sensors used in the
Flexible Manufacturing System are non-contact sensors. The different types of
sensors used with the Flexible Manufacturing System are presented below.
Inductive sensor
Inductive sensors are designed to detect metal targets passing within their sensing
distance. The inductive sensors provided with the Flexible Manufacturing System are
identified as Inductive Proximity Switch, Model 6375-B. They are either mounted on
a flexible support or on another device such as the Pneumatic Sorting Device.
An inductive sensor generates a weak oscillating magnetic field at its end. When a
metallic target enters the magnetic field, eddy currents are induced at the surface of
the target, which results in a loss in the oscillation amplitude in the oscillator. In turn,
this loss in the oscillation amplitude causes a voltage drop in the sensor circuit. This
voltage drop triggers an "on" output signal.
Inductive sensors are composed of four essential parts (Figure 4-1):
• the coil, which generates the magnetic field;

• the oscillator which provides the oscillatory signal to the coil;
• the trigger circuit, which detects the energy drop in the oscillator circuit when
a metallic target interacts with the sensor magnetic field;
• the output circuit, which provides the on or off signal to whatever device is
connected to sensor.
Figure 4-1. Inductive sensor (courtesy of Allen-Bradley).

Figure 4-2 shows the change in the oscillator response and the resulting output
voltage as a metallic target approaches the sensor.
Figure 4-2. Effect of the target on the oscillator response and output voltage of an inductive
sensor (courtesy of Allen-Bradley).
The sensing distance of an inductive sensor is influenced by numerous factors. The

composition of the metallic target has a considerable influence on the sensing
distance. Most inductive sensors are optimized to detect mild steal targets. If the
target is made of another material, a correction factor must be applied to the sensing
distance. Large targets may be detected from a greater distance than small targets.
Round or irregularly shaped targets may reduce the sensing distance.
Polarized retroreflective sensor
Polarized retroreflective sensors are optical sensors. They detect objects without
physical contact by sensing the change in the intensity of the light emitted by a
known light source. The polarized retroreflective sensor provided with the Flexible

Manufacturing System is mounted on a flexible support and is identified as Polarized

Retroreflective Photoelectric Switch, Model 6374-B.
A polarized retroreflective sensor uses an LED (Light Emitting Diode) as a light

source. The LED emits light within a narrow band of wavelengths (usually infrared),
which is reflected by a special reflector. The reflected light is detected by a light
detector installed in the same housing as the light source. If an object gets between
the sensor and the reflector, the light beam is cut and the light detector senses the
difference. The appropriate output signal is then generated by the output circuit.
Since the light emitted by the sensor may also be reflected back to the light detector
by shiny objects, the light emitted by the sensor is polarized by a polarizing filter
placed in front of the sensor LED. The polarizing filter only allows the light having an
electric field (thus a magnetic field) oscillating in a specific direction in the plane
perpendicular to the direction of travel.
Figure 4-3 shows non-polarized light (incoherent radiation) passing through a

polarizing filter that allows only vertically polarized light to pass through.
Figure 4-3. Polarizing filter allowing only vertically polarized light to pass through.
If a polarizing filter allowing only horizontally polarized light to pass through is placed
in front of a vertically polarized light beam, what will get through? Nothing, since
vertically polarized light has no horizontal component. This is the secret behind the
polarized retroreflective sensors. A polarizing filter is placed in front of the light
source and another filter, perpendicular to the light source one, is placed in front of
the light detector (receiver). Thus, if the light from the light source is reflected by a
shiny object, nothing is detected by the detector. But, if the light bounces on the
special reflector, the light is depolarized and the receiver can detect a portion of the
reflected light. Figure 4-4 shows how a polarized retroreflective sensor works.

Figure 4-4. Target detection with a polarized retroreflective sensor (courtesy of Allen-Bradley).

Figure 4-5. Even shiny objects can be detected by a polarized retroreflective sensor.

Background-suppression diffuse sensor
Background-suppression diffuse sensors are also optical sensors but, unlike

retroreflective sensors, they do not require a reflector. The background-suppression
diffuse sensor provided with the Flexible Manufacturing System is mounted on a
flexible support and identified as a Background Suppression Photoelectric Switch,
Model 6373-B.
A background-suppression diffuse sensor uses an LED as a light source. When an

object passes in front of the sensor, the light from the LED is scattered and a small
portion of this light is detected by the light detector which is in the same housing as
the light source (Figure 4-6).
Figure 4-6. Target detection with a diffuse sensor (courtesy of Allen-Bradley).
To avoid confusing the background behind the target with the target itself, special
electronics suppress the background and allow objects to be detected even when
the background is reflective.
Capacitive sensor
Capacitive sensors use a change in capacitance to detect a target passing within the
sensing distance. The capacitive sensors provided with the Flexible Manufacturing
System are mounted on the Part Feeder hoppers.
A capacitive sensor generates a weak electrostatic field at its end. The sensor
oscillator stays inactive unless the target enters the electrostatic field. When a target
passes within sensing distance, an electric field is generated between the sensor
and the target and the oscillator starts to oscillate. When it does, the amplitude of the
oscillations in the circuit increases and so does the voltage in the oscillator. This
voltage change triggers an "on" output signal.
Capacitive sensors are composed of four essential parts (Figure 4-7):
• the coil, which generates the electrostatic field;

• the oscillator, which stays inactive unless a target interacts with the
electrostatic fields;
• the rectifier circuit, which rectifies the signal from the oscillator;
• the output circuit, which provides the on or off signal to whatever device is
connected to sensor.

Figure 4-7. Capacitive sensor (courtesy of Allen-Bradley).
Sensors wiring
The sensors mounted on flexible supports can be wired either as normally open or
normally closed switches. Make sure to check the wiring diagram in each Job Sheet
to wire the sensors correctly.
Pneumatics
Modern assembly lines are nearly impossible to imagine without pneumatics.

Sometimes it is the easiest and most efficient way to convert energy into actual work.
Pneumatics is thus an unavoidable topic when flexible manufacturing systems are
discussed.
The pneumatic circuits used in the Flexible Manufacturing System Job Sheets
contain the following elements: a source of compressed air, a pressure control
device, tubing, an actuator, and a directional control valve to control the operation
of the actuator. The sections below describe how the pneumatic equipment provided
with the Flexible Manufacturing System works.
Note: The Flexible Manufacturing System must have an adequate supply of

pressurized and relatively dry air. The compressed air can be obtained from an
adequate compressed air supply located in the classroom or from an air
compressor. The air supply must deliver at least 138 kPa (or 20 psi).
Push-in Tube Fittings
Flexible Manufacturing System components are equipped with push-in tube fittings
that allow one to quickly assemble and disassemble pneumatic circuits. To connect
tubing to a fitting, simply push the tubing in as far as it will go. To disconnect the
tubing, grasp the tubing near the fitting and push the tubing and collar of the fitting
in toward the component. Hold down the collar in one hand, and pull the tubing out
with the other hand.
The ends of the tubing will wear out with repeated use. Eventually, the tubing will not
seal properly in the fittings. When this happens, the worn tubing end must be
trimmed. Use a tube cutter to remove about 12 mm (or 1/2 in) of the worn tubing.

Pneumatic cylinders
Some of the applications presented in this Job Sheet and in the following Job Sheets
require that pneumatic cylinders extend and retract automatically. This is called
cylinder reciprocation. Cylinder reciprocation involves a change in direction of the
cylinder. Automatic reversal is achieved using the Directional Control Valve Station.
The shifts of the four directional valves of the station are triggered with signals from
the PLC. This allows extension or retraction of the cylinders according to the
information provided by the sensors and other devices.
Figure 4-8 below illustrates the flow of air through a simple pneumatic circuit, similar
to those used in the Flexible Manufacturing System. Compressed air from either an
air compressor or a pressurized air supply is sent to the Conditioning Unit which
controls the air pressure in the circuit. From the Conditioning Unit, air goes through
a Safety Valve which will purge the system if the electrical power is lost at the valve
solenoïd. From the Safety Valve, air passes through tubing and is directed to the
desired branch of the circuit by a control valve. This extends or retracts the cylinder
depending to which branch the air flow has been redirected.
Figure 4-8. Fundamental flow circuit.
Conditioning Unit
The Conditioning Unit consists of a main shutoff valve, a pressure regulator, a

Directional Valve, a filter, an outlet port, and a muffler as shown in Figure 4-9.

Figure 4-9. Conditioning Unit and Components.
• Main Shutoff Valve
The main shutoff valve opens and closes the air supply line between the air
supply and the circuit. The air supply line is on when the button is in the upper
position and is off when the button is in the lower position. When the button is
in the off position, the pressure in the regulator is exhausted to the
atmosphere.
• Pressure Regulator
Pressure regulators are used to limit and to maintain a constant pressure in

a circuit. They allow an operator to manually set the pressure in the circuit
downstream from the valve.
The operation of a simple pressure regulator is illustrated in Figure 4-10. Air

flows through the valve by entering the inlet port and leaving through the outlet
port. The spring exerts a downward force against the top of the diaphragm,
holding the poppet out of the way. An internal pilot passage allows pressure
to exert an upward force underneath the diaphragm. Full system flow will pass
through this valve as long as the poppet is not blocking the way.
When the pressure increases at the outlet port, the pressure works against the
spring and will move the poppet up, blocking the way to the inlet pressure.

Figure 4-10. Pressure Regulator.
Note: Your Conditioning Unit is equipped with a Directional Valve,

Double-Air-Pilot Operated indicating the pressure after the pressure regulator.
We will refer to this meter as a regulated pressure gauge.
• Pressure Gauge
Pneumatic pressure gauges measure the force applied by compressed air in

pneumatic circuits. They allow operators to monitor the pressure in a system
or in a branch circuit to ensure that the correct amount of work is being done
and that pressure is not high enough to damage the components.
Figure 4-11. Pressure Gauge.
The gauge design most commonly used in pneumatics is the bourdon tube
design. The internal parts of a bourdon tube gauge are shown in Figure 4-11.
The pressure line is connected to the fitting on the bottom of the bourdon tube
assembly. Pressure is directed through the fitting and into the bourdon tube.
When the air pressure inside the bourdon tube increases, the bourdon tube
has a tendency to straighten, communicating its movement through the gear
mechanism to the pointer indicator.
• Filter
Unfiltered compressed air contains contaminants. To remove these

contaminants, filters are installed in pneumatics systems. Figure 4-12 shows
a pneumatic in-line filter.

The pneumatic in-line filter used in your trainer is combined with the pressure
regulator. It removes dirt in two stages. In the first stage, air enters the inlet
port and flows through openings in the deflector plate. These openings cause
air to swirl around the inside of the filter in one direction. Centrifugal force
pushes dirt and liquids to the inside of the bowl wall, where gravity causes
them to travel to the bottom of the bowl.
The baffle creates a quiet zone in the filter bowl to permit dirt and moisture to
collect without being affected by the swirling air. The quiet zone prevents
contaminants from reentering the airstream. Dirt and liquids collected in the
bottom of the quiet zone are removed by opening the manual drain located at
the bottom of the bowl.
In the second stage, air flows through the filter element and then through the
outlet port. This filter element removes smaller particles not removed by
centrifugal force.
Figure 4-12. Pneumatic In-Line Filter.
In certain applications such as dentistry and other medical applications, food

processing, or paint spraying, coalescing filters may be used to remove
suspended oil and other aerosols that can pass through ordinary filters.
• Outlet port
The Conditioning Unit has one outlet port equipped with a quick connect fitting
to allow easy connection to the Directional Control Valve Station.
• Muffler
Pneumatic systems that use air as an energy-transmitting fluid, exhaust the

air back to the atmosphere after it is used. As this air returns to its free state,
it expands, converting some of the unused energy into high intensity sound
energy. To decrease the noise level created by expanding air, mufflers are
often used in pneumatic systems. In addition to providing adequate sound
attenuation, a properly selected muffler should have low resistance to air flow.

As shown in Figure 4-9, the muffler supplied with your Conditioning Unit is
located at the outlet port of the main shutoff valve. A quick fitting located
above the muffler allows the connection of any compressed air lines to be
exhausted to atmosphere through the muffler.
Directional Control Valves
Directional control valves (DCVs) are used to stop and control the direction of flow
in an air power branch circuit. They are classified according to the number of
positions, the number of ways, and the number of valve ports. There are two-way,
three-way, and four-way types. The number of ways corresponds to the number of
air port connections in one position of the valve. The number of positions
corresponds to the number of possible flow path configurations. As an example, a
two-way, two-position directional control valve is shown in Figure 4-13.
Figure 4-13. 2-Way, 2-Position Directional Control Valve.
The symbol for a directional control valve consists of a separate envelope for each
position. The number of ports, or ways, is shown by lines protruding from one of the
envelopes. The envelope with lines protruding or with ports identified by a letter or
a number shows the flow path through the valve in the normal, or at rest, position.
The Directional Control Valve Station provided with the Flexible Manufacturing
System consists of four directional control valves. Each valve is
a 5-port, 4-way, 2-position, directional control valve. The valve has five ports: one
pressure port, two actuator ports and two exhaust ports. The valve also has two
possible flow path configurations.
The operation of a 4-way, 2-position directional control valve is illustrated in

Figure 4-14. When the valve is in its normal position, port 1 is pressurized and
ports 2 is connected to exhaust 2 (atmosphere). When the spool is shifted, air flows
from pressurized port 1 and port 2 is pressurized.

Figure 4-14. 4-Way, 2-Position Directional Control Valve Operation.
The valves of the Directional Control Valve Station are solenoid-operated valves;
they have distinct advantages over pilot and manually operated valves that make
them an efficient means of actuating directional valves. Solenoid operated valves
react almost instantly to the electrical switching signal, while the response time of
pilot- operated valves depends on pilot pressure, tubing size, and tubing length.
The solenoid operated valves of the Directional Control Valve Station are of the
solenoid-pilot operated type. In this type of valve, the electric current flowing through
the solenoid coil produces a magnetic field that moves a plunger. Moving the plunger
opens a flow path and allows the pilot pressure to activate the actuator.
As shown in Figure 4-15, the solenoids are equipped with an indicator light and a
manual override that allows opening of the flow path without energizing the solenoid.
Figure 4-15. Directional valve solenoid.

Pneumatic Safety Valve
The Pneumatic Safety Valve is used to depressurize (purge) the system when an
electrical power interruption occurs. The Pneumatic Safety Valve is located between
the Conditioning Unit and the Directional Control Valve Station.
The Pneumatic Safety Valve is a single-solenoid, normally-closed, directional control

valve (3 ways, 2 positions), see Figure 4-16. When the solenoid is de-energized,
compressed air supply is blocked at inlet port P, and outlet port A is connected to
exhaust port. In this position, compressed air trapped in the circuit is exhausted to
the atmosphere. When the solenoid is energized, inlet port P is connected to outlet
port A and the circuit can be supplied with compressed air. In this position, the
exhaust port is blocked.
Figure 4-16. Pneumatic Safety Valve and Simplified Symbol.

4
OBJECTIVE
To familiarize yourself with the various sensors provided with the Flexible
Manufacturing System and measure their respective sensing ranges. To use the Flat
Belt Conveyor to drive a box from the Pneumatic Box Feeder to the sensor installed
in the middle of the conveyor.
PROCEDURE
G 2. Make sure the system is configured for Ethernet communication as

described in the Ethernet configuration procedure given in Job Sheet 2.
G 3. Make sure the DeviceNet network is configured according to the procedure

described in Job Sheet 3.
Note: Use the saved DeviceNet configuration file

(Networx_1st_Config) to speed up the DeviceNet configuration.
G 4. Use Table 4-1 and Figure 4-17 to identify the components that will be added
to the setup used in this Job Sheet.
Pneumatic Box Feeder 5911 Pneumatic activated feeder used to drop a box on the
conveyor.
Directional Control Valve Station 5914 Used to activate the Pneumatic Box Feeder.
Background Suppression 6373-B Sensor using invisible light to detect the presence of
Photoelectric Switch objects.
Inductive Proximity Switch 6375-B Proximity switch sensitive to ferrous metals used to detect
boxes on the conveyor.
Conditioning Unit 6411-A Used to provide the appropriate pressure to pneumatic

activated devices.
Tubing Set 6491-10 Polyethylene tubing used to make pneumatic connections.
Safety Valve 6494 Used to purge the system using an electrical signal.
Table 4-1. New components used in this Job Sheet.


System setup
G 5. Install the Inductive Proximity Switch in the middle of the Flat Belt Conveyor
G 6. On which electrical phenomenon do inductive sensors rely on to detect

metallic targets?

Figure 4-18. Installation of the Inductive Proximity Switch.
G 7. Install the Pneumatic Box, the Directional Control Valve Station, the Safety
Valve, and the Conditioning Unit (Figure 4-19 and Figure 4-20). Refer to the
diagram presented in Figure 4-21 to make the pneumatic connections.

Figure 4-19. The Pneumatic Box Feeder installed on the Flat Belt Conveyor.
Figure 4-20. Side view of the Pneumatic Box Feeder and Conditioning Unit.

Figure 4-21. Pneumatic connections diagram.
G 8. Whether using compressed air from a compressed air supply located in the
classroom or from an air compressor, make sure to adjust the pressure in
the circuit downstream from the valve of the Conditioning Unit
to 138 kPa (or 20 psi).
Note: The pneumatic cylinder installed on the Pneumatic Box

Feeder is equipped with two needle valves allowing control of the
air flow. Use these valves to adjust the speed at which the
Pneumatic Box Feeder reacts when activated.

Figure 4-22.

Figure 4-22(a). PLC-controlled conveyor and sensors wiring diagram (Compact Logix L32E).

Figure 4-22(b). PLC-controlled conveyor and sensors wiring diagram (Compact Logix L43).
G 10. Set the AC Drive parameters as in the second part of Job Sheet 3.
Note: Make sure the AC Drive "Start Source" parameter (P036)

is set to 5 (Comm Port).

Figure 4-23. PLC-controlled conveyor and sensors setup.
Running the program

to the PLC.
G 12. Before downloading the program to the PLC, restore the RSNetWorx
configuration made in Job Sheet 3. To do so, start RSNetWorx for
DeviceNet (if not already started).
G 13. From the File menu, select Open and open the file named
Networx_1st_Config (Refer to Job Sheet 3 for details).

G 14. Opening the Networx_1st_Config file restores the DeviceNet configuration

made in Job Sheet 3.
G 15. Open the RSLogix 5000 project file named intro_manu_stu4.acd and
• start the Flat Belt Conveyor (clockwise rotation) using the green push
• stop the Flat Belt Conveyor using the red push button on the Indicator
Light/Push-Button Station (pressing the green push button resumes the
manufacturing process simulation);
• cut off the power in case of emergency with the Emergency Switch
Station;
• drop another box using the yellow push button on the Indicator
• observe that the red indicator light turns on when the AC Drive is ready
and turns off when the Flat Belt Conveyor is rotating;
• observe that the green indicator light turns on when the Flat Belt
Conveyor is rotating clockwise;
• observe that once the Flat Belt Conveyor is rotating, a box is dropped
by the Pneumatic Box Feeder;
Button Station;
• observe that the Flat Belt Conveyor stops if a box is detected by the
Inductive Proximity Switch.
A video of the setup presented in this Job Sheet is available

on the Lab-Volt Flexible Manufacturing System Resource
Kit (student) CD-ROM.
G 17. Once you are sure the setup is working properly, press on the green button
to start the Flat Belt Conveyor.
G 18. Use the AC Drive potentiometer to adjust the AC Drive output frequency (i.e.
the conveyor speed) to 10 Hz.

G 19. Drop a box on the Flat Belt Conveyor using the yellow push button. The
conveyor should stop before the box reaches the sensor.
G 20. Measure the distance between the active face of the Inductive Proximity
Switch and the side of the box when the conveyor stops. This is the sensing
distance of the Inductive Proximity Switch for this setup. Write down the
sensing distance of the Inductive Proximity Switch below:
Inductive Proximity Switch sensing distance:
G 21. Replace the Inductive Proximity Switch with the Background Suppression
Photoelectric Switch. Use the same wiring as for the Inductive Proximity
Switch.
G 22. Proceed as for the Inductive Proximity Switch and write down the sensing
distance of the Background Suppression Photoelectric Switch below:
Background Suppression Photoelectric Switch sensing distance:


In this Job Sheet, a box is dropped on the conveyor by pressing the yellow button.
The conveyor stops when the sensor detects the box.
Modify the program so that the yellow light turns on if the operation described above
is performed five times in a row.
work.
Name: Date:

5
SORTING PROCESS
OBJECTIVE
To sort boxes in different trays using the Pneumatic Sorting Device.
PROCEDURE


Name Model Description/Function
Pneumatic Sorting Device 5913 Sorts the boxes in different trays.
Sorting Trays (from the Accessories) 5951 Used to collect boxes sorted by the
Pneumatic Sorting Device.

SORTING PROCESS


SORTING PROCESS
System setup
G 5. Install the Inductive Proximity Switch halfway across the Flat Belt Conveyor
Figure 5-2. Installation of the Inductive Proximity Switch.
G 6. Install a sorting tray at the end of the Flat Belt Conveyor as shown in
Figure 5-3.
Figure 5-3. Installation of the sorting tray at the end of the Flat Belt Conveyor.

SORTING PROCESS
G 7. Install the Background Suppression Photoelectric Switch at the end of the

sorting tray as shown in Figure 5-4.
Figure 5-4 Installation of the Background Suppression Photoelectric Switch.
G 8. Install two sorting trays, two Inductive Proximity Switches, and the
Pneumatic Sorting Device on the Flat Belt Conveyor as shown in Figure 5-5.
Make sure the two Inductive Proximity Switches are positioned at the end
of each sorting tray.

SORTING PROCESS
Figure 5-5. Installation of the sorting apparatus.

SORTING PROCESS
G 9. Make the pneumatic connections according to the diagram presented in

Figure 5-6.
Figure 5-6. Sorting process pneumatic connection diagram.
CAUTION!
Make sure to adjust the pressure in the circuit downstream

from the valve of the Conditioning Unit to 138 kPa (or 20 psi).
Note: Some of the pneumatic cylinders installed on the

Pneumatic Sorting Device are equipped with needle valves
allowing control of the air flow. Use these valves to adjust the
speed at which the pneumatic cylinders extend and retract.
A video showing how to adjust the needle valves on the

Pneumatic Sorting Device is available on the Lab-Volt
Flexible Manufacturing System Resource Kit (student)
CD-ROM.

SORTING PROCESS

Figure 5-7.
Figure 5-7(a). Sorting process wiring diagram (Compact Logix L32E).

SORTING PROCESS
Figure 5-7(b). Sorting process wiring diagram (Compact Logix L43).


SORTING PROCESS
Figure 5-8. Sorting process setup.
Note: Before running the program, always check that the sensors
are accurately positioned to detect the targets. An LED on the
sensor lights up when a target is within sensing distance.
Running the program

to the PLC.
G 12. Before downloading the program to the PLC, restore the RSNetWorx
configuration made in Job Sheet 3. To do so, start RSNetWorx for
DeviceNet (if not already started).

SORTING PROCESS

made in Job Sheet 3.
• Start the process by pressing the green push button;
• terminate a paused process by pressing the red push button;
• observe that the boxes are directed to Tray 1 by the Pneumatic Sorting
Device. If tray 1 is full, the boxes are directed to tray 2. If both tray 1 and
tray 2 are full, the boxes are directed to tray 3.
Button Station;


SORTING PROCESS

In this Job Sheet, boxes are successively dropped on the Flat Belt Conveyor. When
the boxes reach the end of the Flat Belt Conveyor they are sorted in three trays.
Modify the program so that the yellow light turns on if the Inductive Proximity Switch
installed halfway across the conveyer does not detect any box for more than five
seconds.
work.
Name: Date:

6
FILLING PROCESS
Part Feeder
The Part Feeder, Model 5912, is designed to handle the 1-inch diameter marbles
provided with the Flexible Manufacturing System. Figure 6-1 identifies the main
components of the part feeder.
Figure 6-1. Part Feeder.
How the Part Feeder works
Marbles are placed in the two hoppers at the top of the Part Feeder. At the bottom
of each hopper there is a disc with four holes in it. To drop a marble, a signal is sent
by the PLC to activate the small motor under one of the discs. When the disc rotates,
a marble is allowed to fall in the Part Feeder funnel. Figure 6-2 shows how it works.

FILLING PROCESS
Figure 6-2. Dropping a marble.
Two small motors control the rotation of the discs. To drop only a marble at a time,
the motor must be activated for a short period to rotate the disc for a quarter turn
only. To stop the rotation of the disc at the right moment, four metal positioners are
installed on each disc. An inductive sensor located under each disc detects the
positioners when they pass over their tip. Each time a positioner passes over the
sensor, the sensor sends a signal to the PLC. This signal is used to stop the motor
at the right position. Figure 6-3 shows the positioners and the inductive sensors
installed on the Part Feeder.

FILLING PROCESS
Figure 6-3. Positioners and inductive sensors.
Two capacitive sensors installed on the sides of the hoppers send a signal to the
PLC if the level of marbles drops below the sensor. As indicated in Table 6-1 below,
there is only one input for the two capacitive sensors. Thus, if the level of marbles
is low in one of the hoppers, a signal is sent to the PLC.
All sensors and motors are connected to a CompactBlock I/O module installed on
the Part Feeder. The PLC monitors the inputs to detect changes in the various
sensors. The hopper selection and the activation of the motor under the selected
hopper is made using the outputs on the CompactBlock I/O module. The detail of the
inputs and outputs of the module is given below.
CompactBlock I/O
The CompactBlock I/O module installed on the Part Feeder allows the placement of
I/O points close to sensors and other devices to reduce the amount of wiring
required. These devices are connected to the inputs and outputs of the I/O module.
The information is relayed to and from the PLC through a DeviceNet connection.
Figure 6-4 shows the back of the Part Feeder where the CompactBlock I/O module
is located and Table 6-1 resumes the function of the inputs and outputs.

FILLING PROCESS
Figure 6-4. CompactBlock I/O module.
CAUTION!
Do not modify any the connections on the CompactBlock I/O

module, all communications are made through a DeviceNet
connection.

FILLING PROCESS
Input/Output is connected to... Description
Input 0 Not Used N/A
Inductive sensor used to detect the

Input 3 Hopper 1 inductive switch metal positioner on the first hopper
disc
Inductive sensor used to detect the

Input 4 Hopper 2 inductive switch metal positioner on the second
hopper disc
Sends a signal to the PLC when any

Input 5 Capacitive Sensors of the capacitive sensors detects a
low level of marbles
Left-end limit switch of the Linear

Input 6 Left-end limit switch Guide [Used with the FMS
(advanced) only]
Right-end limit switch of the Linear

Guide [Used with the FMS
Input 7 Right-end limit switch
(advanced) only]
Start the motor of the selected

Output 0 Selected motor
hopper
Output 2 Motors switch Used to select one of the motors
Table 6-1. Part Feeder inputs and outputs.

6
FILLING PROCESS
OBJECTIVE
To fill boxes with marbles using the Part Feeder. To include quality control features
in the process to ensure the boxes are properly filled with four marbles.
PROCEDURE


Part Feeder 5912 DeviceNet-controlled part dispenser (filled

with marbles from the Accessories).
Polarized 6374-B Sensor using light to detect the presence of

Retroreflective objects.
Photoelectric Switch

FILLING PROCESS

System setup
G 5. Install the Part Feeder and the Polarized Retroreflective Photoelectric

Switch as shown in the front view and side view in Figure 6-6. Make sure
that the Polarized Retroreflective Photoelectric Switch turns on when a
marble is dropped by the Part Feeder.
Figure 6-6. Installation of the Polarized Retroreflective Photoelectric Switch under the Part Feeder.

FILLING PROCESS

Figure 6-7.
Figure 6-7(a). Filling process wiring diagram (Compact Logix L32E).

FILLING PROCESS
Figure 6-7(b). Filling process wiring diagram (Compact Logix L43).


FILLING PROCESS
G 7. Keep the pneumatic connections as in Job Sheet 5.
CAUTION!
Make sure to adjust the pressure in the circuit downstream

from the valve of the Conditioning Unit to 138 kPa (or 20 psi).
G 8. Fill the Part Feeder using marbles of two different colors, one color for each
hopper.
Note: To keep marbles from getting stuck in the Part Feeder

mechanism, do not overfill the hoppers.
G 9. Once complete, the setup should look as shown in Figure 6-8.
Figure 6-8. Filling process setup.

FILLING PROCESS
Adding the Part Feeder to the DeviceNet network
Note: Some of the elements in this procedure are similar to those

presented in the "DeviceNet configuration" section of Job Sheet 3.
Refer to Job Sheet 3 for details.
G 10. Start RSNetWorx for DeviceNet.

made in Job Sheet 3 (Figure 6-9).
Figure 6-9. RSNetWorx for DeviceNet.
G 13. Make sure the Part Feeder is linked to the AC Drive with a DeviceNet cable
G 14. Click on the Online button to display the Browse for network window.

FILLING PROCESS
tree until the Port2, DeviceNet item is reached. Select this item and
click OK.
G 16. Click OK, when the synchronization message appears.
G 17. RSNetWorx for DeviceNet scans each of the 64 node addresses to find
devices. The node address of the Part Feeder is factory set to 02.
G 18. Once the Part Feeder is detected, the Sink In/8 Source Out module is
displayed on the Graph tab (Figure 6-10). This module is the
CompactBlock I/O module installed at the back of the Part Feeder.
Figure 6-10. RSNetWorx for DeviceNet window.
G 19. Since a new module has been added to the DeviceNet network, it must be
added to the scanlist too to be scanned by the scanner module. The steps
below detail how this can be done.

FILLING PROCESS
G 20. Double-click on the scanner module icon to open the 1769-SDN Scanner
Module window.
G 21. Click on the Scanlist tab (Figure 6-11).
Figure 6-11. Scanlist tab of the 1769-SDN Scanner Module window.
G 22. In the Available Devices list, select the Part Feeder

item (i.e. 02, 1791D-8B8P 8 Sink I...) and click on the left arrow button to
move the item from the Available Devices list to the Scanlist.
G 23. Once the Part Feeder is in the Scanlist, click on the Input tab (Figure 6-12).
In this tab you can see to which memory bits the Part Feeder inputs have
been assigned. In the example below, the input bits of the drive are located
at Local.3:I.DataXX.

FILLING PROCESS
Figure 6-12. Input tab of the 1769-SDN Scanner Module window.
G 24. Click on the Output tab and note to which addresses the output bits of the
AC Drive have been assigned.
G 25. Click OK to close the 1769-SDN Scanner Module window. The Scanner
Configuration Applet asks if you want to download the changes to the
device. Click on Yes to download the changes.
Note: To be able to download the changes, the PLC key must be

set to REM.
G 26. From the File menu, select Save As to save your DeviceNet network
configuration on your computer hard drive. Save your configuration under
the name Networx_2nd_Config.

FILLING PROCESS
Running the program

to the PLC.
• include the features of the setup presented in Job Sheet 5;
• observe that each box is filled with 4 marbles. The quality control (i.e.
counting the marbles) is made by the Polarized Retroreflective
Photoelectric Switch;
• observe that the boxes are directed to Tray 1 by the Pneumatic Sorting
Device. If tray 1 is full, the boxes are directed to tray 2. If both tray 1 and
tray 2 are full, the boxes are directed to tray 3.
• observe that if no marble falls from the distributor, the program tries to
drop another one;
• observe that if the level of marbles is low in the Part Feeder, the yellow
indicator light is flashing on the Indicator Light/Push-Button Station.

FILLING PROCESS
Figure 6-13. Sorted boxes.


FILLING PROCESS

FILLING PROCESS

In this Job Sheet, boxes are filled with four marbles (two marbles from the first
hopper and two marbles from the second hopper). Add a recipe selector subroutine
to the PLC program so that the user can choose between two recipes by switching
a bit on or off. For example, the first recipe can be two red marbles and two blue
marbles in each box and the second recipe can be three red marbles and one blue
marble in each box.
work.
Name: Date:

Appendix A
Equipment Utilization Chart
COMPONENT PART JOB SHEET

NAME NUMBER 1 2 3 4 5 6
Flat Belt Conveyor 5910 1 1 1 1 1 1
Pneumatic Box Feeder 5911 1 1 1
Part Feeder 5912 1
Pneumatic Sorting Device 5913 1 1
Directional Control Valve Station 5914 1 1 1
Indicator Light/Push-Button Station 5925 1 1 1 1 1
Emergency Switch Station 5926 1 1 1 1 1
AC Drive 5927-A 1 1 1 1 1
Programmable Logic Controller 5930 or -A 1 1 1 1 1
RSLogix5000 Lite Edition 5935 1 1 1 1 1
RSNetWorx for DeviceNet 5936 1 1 1 1 1
Accessories 5951 1 1 1 1 1 1
Background Suppression Photoelectric Switch 6373-B 1 1 1
Polarized Retroreflective Photoelectric Switch 6374-B 1 1
Inductive Proximity Switch 6375-B 1 3 3
Conditioning Unit 6411-A 1 1 1
Tubing Set 6491-1 1 1 1
Pneumatic Safety Valve 6494 1 1 1
Work Surfaces 46604 3 3 3 3 3 3
Personal Computer 1 1 1 1 1
Table A-1. Equipment Utilization Chart.
INTRODUCTION TO MANUFACTURING A-1

Equipment Utilization Chart
COMPONENT PART JOB SHEET

NAME NUMBER 1 2 3 4 5 6
Grey Leads 24987-08 * * * * *
White Leads 24987-09 * * * * *
Black Leads 24989 * * * * *
Red Leads 24989-02 * * * * *
Hex Key 28755 1 1 1 1 1 1
Handle 30856-01 1 1 1 1 1 1
Red Leads 31720-02 * * * * *
Ethernet Cable 34118 1 1 1 2
Red Boxes 36925 * * *
White Boxes 36925-01 * * *
Black Marbles 37259 *
Red Marbles 37259-02 *
Green Marbles 37259-05 *
Blue Marbles 37259-06 *
Wiring Ducts 37271-01 * * * * * *
Wiring Ducts 37271-02 * * * * * *
Trays 37276 2 2
Tray 37277 1 1
Hex Key 38294 1 1 1 1 1 1
Wireless Router 39969 1 1 1 1 1
Black Wire 70280 * * * * * *
Brown Wire 70280-01 * * * * *
Red Wire 70280-02 * * * * *
Orange Wire 70280-03 * * * * *
Blue Wire 70280-06 * * * * *
Power Bar 77540 1 1 1 1 1 1
Red Lead 93668-02 * * * * *
Table A-2. Equipment required from the Accessories, Model 5951.
* Use as many as required.
A-2 INTRODUCTION TO MANUFACTURING

Appendix B
AC Drive – Quick Start Guide
Fault switches
If the operation of the AC Drive is erratic, or if it does not operate, make sure the four
fault switches are set at the O position.
Default Parameters
To reset the Basic Program Group Parameters to defaults, perform the following
steps:
C stop the AC Drive by pressing the O button,

C set the Reset to Defaults, parameter P041, to 1 (Factory Reset).
INTRODUCTION TO MANUFACTURING B-1

PARAMETER CROSS-REFERENCE TABLE

DISPLAY GROUP BASIC PROGRAM GROUP ADVANCED PROGRAM GROUP
Output Freq (1) d001 Motor NP Volts (4) P031 Digital In1 Sel A051 Comm Loss Action A105
Commanded Freq d002 Motor NP Hertz (5) P032 Digital In2 Sel A052 Comm Loss Time A106
Output Current (2) d003 Motor OL Current (6) P033 Digital In3 Sel A053 Comm Format A107
Output Voltage (3) d004 Minimum Freq P034 Digital In4 Sel A054 Language A108
DC Bus Voltage d005 Maximum Freq (7) P035 Relay Out Sel A055 Anlg Out Setpnt A109
Drive Status d006 Start Source P036 Relay Out Level A056 Anlg In 0-10V Lo A110
Fault 1 Code d007 Stop Mode P037 Opto Out1 Sel A058 Anlg In 0-10V Hi A111
Fault 2 Code d008 Speed Reference P038 Opto Out1 Level A059 Anlg In 4-20mA Lo A112
Fault 3 Code d009 Accel Time 1 (8) P039 Opto Out2 Sel A061 Anlg In 4-20mA Hi A113
Process Display d010 Decel Time 1 (9) P040 Opto Out2 Level A062 Slip Hertz @ FLA A114
Control Source d012 Reset To Defalts (10) P041 Opto Out Logic A064 Process Time Lo A115
Contrl In Status d013 Voltage Class P042 Analog Out Sel A065 Process Time Hi A116
Dig In Status d014 Motor OL Ret P043 Analog Out High A066 Bus Reg Mode A117
Comm Status d015 Accel Time 2 A067 Current Limit 2 A118
Control SW Ver d016 Decel Time 2 A068 Skip Frequency A119
Drive Type d017 Internal Freq A069 Skip Freq Band A120
Elapsed Run Time d018 Preset Freq 0 to 7 A070 Stall Fault Time A121
Testpoint Data d019 to Analog In Loss A122
Analog In 0-10V d020 A077 10V Bipolar Enbl A123
Analog In 4-20mA d021 Jog Frequency A078 Var PWM Disable A124
Output Power d022 Jog Accel/Decel A079 Torque Perf Mode A125
Output Power Fctr d023 DC Brake Time A080 Motor NP FLA A126
Drive Temp d024 DC Brake Level A081 Autotune A127
Counter Status d025 DB Resistor Sel A082 IR Voltage Drop A128
Timer Status d026 S Curve % A083 Flux Current Ref A129
Stp Logic Status d028 Boost Select A084 PID Trim Hi A130
Torque Current d029 Start Boost A085 PID Trim Lo A131
Break Voltage A086 PID Ref Sel A132
Break Frequency A087 PID Feedback Sel A133
Maximum Voltage A088 PID Prop Gain A134
Current Limit 1 A089 PID Integ Time A135
Motor OL Select A090 PID Diff Rate A136
PWM Frequency A091 PID Setpoint A137
Auto Rstrt Tries A092 PID Deadband A138
Auto Rstrt Delay A093 PID Preload A139
Start At PowerUp A094 Stp Logic 0-7 A140
Reverse Disable A095 to
Flying Start En A096 A147
Compensation A097 Stp Logic Time 0-7 A150
SW Current Trip A098 to
Process Factor A099 A157
Fault Clear A100 EM Brk Off Delay A160
Program Lock A101 EM Brk On Delay A161
Testpoint Sel A102 MOP Reset Sel A162
Comm Data Rate A103 DB Threshold A163
Comm Node Addr A104
(1) Output frequency (4) Motor nameplate voltage (7) Maximum frequency (10) Reset to defaults
(2) Output current (5) Motor nameplate frequency (8) Acceleration time
(3) Output voltage (6) Maximum allowable motor current (9) Deceleration time
Table B-1. Parameter cross-reference table.
B-2 INTRODUCTION TO MANUFACTURING























Appendix C
Changing the PLC IP address setting
You may need to change the IP address setting on the PLC. This may be required
if you want the PLC to be part of an existing network having specific IP address
requirements. You may also need to change the PLC IP address setting if you are
unable to communicate with the PLC using an Ethernet connection. This can occur
if the PLC IP address has been accidently changed, or if you do not remember which
IP address has been set on the PLC.
If you are unable to communicate with the PLC using an Ethernet connection, you
will need a DB9/DB9 Female/Female serial cable to manually change the PLC IP
address setting.
If you are still able to communicate with the PLC using an Ethernet connection, skip
the Serial Connection section below and jump immediately to the Changing the IP
address setting section.
Serial Connection
Note: This example was performed with Compact Logix L32E

controller. Perform the same procedure for a Compact Logix L43.
Note: To communicate with the PLC through a serial connection,

a DB9/DB9 Female/Female serial cable is required. Your
computer must be equipped with a serial communication port.
G 1. Connect the PLC to the computer using a DB9/DB9 Female/Female serial

cable.
G 2. Turn on the PLC.
G 3. Start RSLinx (Figure C-1).
INTRODUCTION TO MANUFACTURING C-1

Figure C-1. RSLinx.
G 4. From the Communications menu, select Configure Drivers to open the

Configure Drivers window (Figure C-2).
C-2 INTRODUCTION TO MANUFACTURING

Figure C-2. Configure Drivers window.
G 5. From the Available Driver Types drop-down list, select RS-232 DF1 devices.
G 6. Click on Add New to display the Add New RSLinx Driver window.
G 7. Choose a name for the RS-232 driver and click OK.
G 8. The Configure RS-232 DF1 Devices window appears (Figure C-3).

Figure C-3. Configure RS-232 DF1 Devices window.
G 9. From the Comm Port drop-down list, select the serial COM port associated
with your computer serial port.
G 10. From the Device drop-down list, select Logix 5550 / CompactLogix.
G 11. Click on the Auto-Configure button. If the auto configuration is a success,

a message appears in the text box beside the Auto-Configure button.
Note: If the Auto configuration fails, check the serial cable

connection and make sure the right communication port is
selected in the Comm Port drop-down list.
G 12. Click OK to close the Configure RS-232 DF1 Devices window.

G 13. The added driver appears in the Configured Drivers list. Click Close to close
the Configure Drivers window.
Changing the IP address setting
G 14. Open the RSWho window in RSLinx, if it is not already active. To do so,
select RSWho from the Communications menu.
G 15. Click on the + symbol beside AB_DF1-1, DF1 to expand the Network
tree (Figure C-4). It can take several seconds before RSLinx detects the
devices.
Figure C-4. Browsing the network devices using RSWho.
G 16. Right click on the 01, 1769-L32E Ethernet Port, 1769-L32E Ethernet Port to
bring up the contextual menu.
G 17. Select Module Configuration from the contextual menu to open

the 1769-L32E Configuration window.
G 18. Click on the Port Configuration tab (Figure C-5).

Figure C-5. 1769-L32E Configuration window.
G 19. Change the PLC IP address setting as desired. The factory default IP
address and the subnet mask are:
IP Address: 192.168.2.4
Subnet mask: 255.255.255.0
Note: The IP address for the PLC is different from the IP address
set for the computer Ethernet card, which is 192.168.2.3. If you
change the PLC IP address setting, make sure to change the
computer Ethernet card address accordingly. If you experience
problems with the Ethernet network configuration, ask your local
network administrator for help.
G 20. Once the IP address and subnet mask are modified, click OK.
G 21. The ControlLogix Gateway Tool window appears. Click Yes to confirm the
PLC IP address change (Figure C-6).

Figure C-6. ControlLogix Gateway Tool window.

Appendix D
Hydraulics and Pneumatics Graphic Symbols
Figure D-1. Hydraulics and pneumatics graphic symbols.
INTRODUCTION TO MANUFACTURING D-1

Hydraulics and Pneumatics Graphic Symbols
Figure D-1. Hydraulics and pneumatics graphic symbols (cont’d).
D-2 INTRODUCTION TO MANUFACTURING

Appendix E
Changing the node address of the DeviceNet devices
Each device connected to a DeviceNet network is identified by a number called a
node address. The node address of a device is usually set manually on the device.
Below are two procedures describing how to change the node addresses of the AC
Drive and of the CompactBlock I/O module (installed on the Part Feeder). The
default node address of the AC Drive is 01 while the node address of the
CompactBlock I/O module is factory set to 02.
Changing the AC Drive node address
The AC Drive node address can be changed using the dip switches installed under
the drive protective cover as shown in Figure E-1.
Figure E-1. AC Drive dip switches.
It is not necessary to unscrew the drive protective cover to change the dip switch
settings. Make sure to set the dip switches in the right order. The switches are
identified by numbers, Table E-1 shows the functions of the eight dip switches.
INTRODUCTION TO MANUFACTURING E-1

Dip switches
Description Factory Default value
number
1 Bit 0 of the node address1 1

2 Bit 1 of the node address 0
6 Bit 5 of the node address2 0
7 Bit 0 of the data rate1 1
8 Bit 1 of the data rate2 1
1
Least Significant Bit (LSB)
2
Most Significant Bit (MSB)
Table E-1. Functions of the dip switches of the AC Drive.
To change the node address of the AC Drive you must change the position of the
first six dip switches (i.e. dip switches 1 to 6) so that they represent the new node
address number (between 0 and 63). Make sure to choose a node address that is
not already used by another DeviceNet device.
To select the node address using the dip switches, they must be set so that they
represent the node address number in the binary numeral system. The dip switches
can be set either to on (1) or off (0). Setting the six dip switches to either 1 or 0 gives
a six digit binary number (for example: 101101).
Binary numerical system
Binary numbers are written using a base-2 number system. That is, each digit in the
number can take only two different values: 0 or 1. By comparison, the decimal
numerical system used in every day life is a base-10 number system, each digit in
a number can take 10 different values (0, 1, 2, 3, 4, 5, 6, 7, 8, 9).
As in the decimal numerical system, the rightmost digit of a binary number

represents the smallest unit. This digit is called the least significant bit, it is the bit 0.
If the value of the least significant bit is 1 the binary number is odd and if its value
is 0 the binary number is even.
To represent a number greater than or equal to 2, more than one digit must be used.
The second digit in a binary number has a decimal value of 2. Thus, 2 is written 10
using binary number (i.e. 1 x 2 + 0 x 1) and 3 is written 11 (i.e. 1 x 2 + 1 x 1).
To calculate the decimal value of a digit in a binary number, one can use the position
of the digit as the power of 2 (the least significant bit being at position 0). For
example, the fourth bit (bit 3) of a binary number has a value of 23 = 8. Table E-2
gives the value of the first six digits of a binary number.
E-2 INTRODUCTION TO MANUFACTURING

Bit position 2 to the power... Decimal value

0 20 1
1 21 2
2 22 4
3 23 8
4 24 16
5 25 32
Table E-2. First six digits of a binary number.
To represent a number in the binary numerical system, the digits must be set to 0
or 1 so that the sum of the values of the digits set to 1 equals the number to be
represented. For example, the base-10 number 21 is written 10101 in the binary
numerical system, that is:
(1 x 16) + (0 x 8) + (1 x 4) + (0 x 2) + (1 x 1) = 16 + 0 + 4 + 0 + 1 = 21
Because only six dip switches are available to represent the node address, the
address value must be set between 0 (i.e. all switches off) and 63 (i.e. all
switches on).
Dip switches 7 and 8 are used to set the data rate used on the DeviceNet network.
It is factory set to 11 (both switches 7 and 8 set to on) which is the Autobaud mode.
In this mode the network data rate is automatically detected.
Note: To learn more on the AC Drive node address and baud rate setting,
refer to the manufacturer's documentation available on the Lab-Volt
Flexible Manufacturing System Resource Kit CD-ROM.
Changing the node address of CompactBlock I/O module
The CompactBlock I/O module is installed at the back of the Part Feeder as shown
in Figure E-2.

Figure E-2. CompactBlock I/O module installed at the back of the Part Feeder.
The CompactBlock I/O module node address can be changed using two rotary
node-address switches. To access these switches, open the plastic cover using a
small flat screwdriver as shown in Figure E-3.

Figure E-3. Opening the plastic cover protecting the rotary node address switches.
Turn the two rotary switches to set the desired node address. For example, to set the
node address to 53, set the MSB rotary switch to 5 and the LSB rotary switch to 3
as shown in Figure E-4.

Figure E-4. Changing the node address of the CompactBlock I/O module.

Appendix F
Safety Procedures
This appendix lists basic safety procedures. You should complete these safety
procedures whenever you begin a Job Sheet.
G You are wearing safety glasses.
G You are wearing insulated safety shoes.
G You are not wearing anything that might get caught such as a tie, jewelry, or
loose clothes.
G If your hair is long, tie it out of the way.
G The working area is clean.
G The floor is not wet.
G Your sleeves are rolled up.
Photocopies of this appendix can be used to serve as a checklist when performing

the safety procedures.
INTRODUCTION TO MANUFACTURING F-1

F-2 INTRODUCTION TO MANUFACTURING
Appendix G
Troubleshooting
Table G-1 lists common problems that can be encountered when using the FMS and
helps you to troubleshoot your setup.
Problem/Symptom Possible cause Solution
Check that the AC Drive is properly

connected.
Fault F003 or F004 is displayed There is no input power on
on the AC Drive display. the AC Drive.
Check that power is provided by
the Emergency Switch Station.
Check that the AC Drive node

address is set to 01.
Fault F081 is displayed on the AC
Communication problem.
Drive display.
Check the connection with the
PLC.
Check that the part feeder is

detected by RSNetWorx for
The Part Feeder does not work DeviceNet.
Communication problem
and error 78/02 is displayed on
with the Part Feeder.
the DeviceNet scanner display. Check that the Part Feeder node
address is set to 02 on the remote
I/O module.
There are too many

No marble is falling when output 0 Empty the Part Feeder hoppers,
marbles in the hoppers and
of the remote I/O module is and check if a marble is blocking
the mechanism of the Part
activated. the mechanism.
Feeder is stuck.
Check that the pressure at the

The pneumatic cylinder is not
Pressure problem. output port of the Conditioning Unit
working properly.
is set to 20 psi.
Unscrew the needle valves on the

pneumatic cylinder and adjust the
Cylinder reciprocation is too slow Bad adjustment of the
needle valve to reduce the input air
or too fast. needle valves.
flow as desired. Adjust one needle
valve at a time.
Check if all the DeviceNet

Error 75 and/or 79 are displayed No messages equipment is in the scanlist.
on the DeviceNet scanner received/transmission
display. failure. Check that DeviceNet Cables are
connected correctly.
Table G-1. Troubleshooting tips.
INTRODUCTION TO MANUFACTURING G-1

Troubleshooting
Check that the device is

connected. If you do not need
this device, remove it from the
scanlist.
The number XX
Error 78/XX is displayed on
indicates which device If the node address of the
the DeviceNet scanner
the DeviceNet scanner DeviceNet devices have not
display.
cannot detect. been modified, the AC Drive
should be at the node address
01 and the node address of the
Part Feeder (i.e Remote I/O
module) should be 02.
Turn the key of the PLC to RUN

Error 80 is displayed on the
The PLC is in idle mode. or set the PLC to the Remote
DeviceNet scanner display.
Run mode using RSLogix 5000.
There is now 24-V dc power.

Check that the mushroom push
button of the Emergency Switch
Error 92 is displayed on the Station is not pressed. Reset
No DeviceNet power.
DeviceNet scanner display. the Emergency Switch Station if
required.
Check the 24-V dc connections.
Check for error in the PLC

program using RSLogix 5000.
Turn the PLC key from PROG

The OK LED flashes on the Error in the PLC
to RUN two times to clear the
PLC. program.
error and reboot the controller
(clearing the error message
does not correct the error in the
PLC program).
The PLC outputs are turned Check that the VDC1 and
VDC connection
on but no power is detected on VDC2 outputs are connected
problem.
the output terminals. correctly.
The inputs cannot be activated Check that the grounds on the

Ground problem.
even if there is 24 V dc. PLC are connected correctly.
When the AC Drive is not set to

3-Wire control, a jumper must
be present between inputs 1
and 11. If there is no 24-V dc
The AC Drive does not start. Coast to stop activated.
power on input 1 (i.e. no
jumper) or if power is removed,
the power to the motor is cut
and the motor coast to stop.
Table G-1. Troubleshooting tips (cont’d).
G-2 INTRODUCTION TO MANUFACTURING

Troubleshooting
Disconnect the AC Drive from

The AC Drive keypad does not The AC Drive is
the DeviceNet to use the
work. connected to DeviceNet.
keypad for manual control.
The Start Source

The AC Drive cannot be Set the parameter P036 of the
parameter is not set to
started using the keypad. AC Drive to 0.
Keypad.
The AC Drive cannot be The Start Source

Set the parameter P036 of the
controlled through the parameter is not set to
AC Drive to 5.
DeviceNet network. Comm Port.
Check the physical connection.
Check that the router receives

signals from the computer
(some of the lights of the router
should flash if this is the case).
Communication problem
If not check the network
between the computer
Cannot connect to the PLC configuration of the computer.
and the router or
using Ethernet.
between the router and
Make sure the IP address
the PLC.
setting of the computer and
PLC are correct. Refer to the
Changing the PLC IP address
setting procedure in
Appendix C if required.
Make sure the PLC key is set to

Cannot download a program The PLC is not in remote
REM or PROG when trying to
to the PLC. mode or program mode.
download a program.
There is no 24-V dc power.

Check that the mushroom push
button of Emergency Switch
RSNetworx for DeviceNet
Station is not pressed. Reset
browses the DeviceNet No 24-V dc power.
the Emergency Switch Station if
network very fast.
required.
Check the 24-V dc connections.
Changes cannot be
RSNetworx for DeviceNet
downloaded to the PLC if the
cannot download changes to The PLC is not in remote
PLC key is set to RUN, make
the PLC DeviceNet scanner mode.
sure the PLC key is set to REM
module.
or PROG.
Table G-1. Troubleshooting tips (cont’d).
INTRODUCTION TO MANUFACTURING G-3

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Automation and Robotics

Flexible Manufacturing System

Job Sheets – Student

Copyright © 2007 Lab-Volt Ltd.

All rights reserved. No part of this publication may be reproduced,

Legal Deposit – Fourth Trimester 2007

FIRST EDITION, OCTOBER 2007

• operating a flat belt conveyor;

The Flexible Manufacturing System (Advanced Applications), Model 5901-2 (add-on

Job Sheet 1 Familiarization with the AC Drive . . . . . . . . . . . . . . . . . . . 1-1

Job Sheet 2 Ethernet Communication and PLC Programming

Job Sheet 3 Network Communications . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Job Sheet 4 PLC-Controlled Conveyor and Sensors . . . . . . . . . . . . . . 4-1

Job Sheet 5 Sorting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Job Sheet 6 Filling Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Appendices A Equipment Utilization Chart

We Value Your Opinion!

Stenerson, Jon. Fundamentals of Programmable Logic Controllers, Sensors, and

Lab-Volt Flexible Manufacturing System Resource Kit CD-ROM

• Allen-Bradley/Rockwell Automation reference guides:

Appendix A, Equipment Utilization Chart, indicates the components required to

Appendix B, AC Drive – Quick Start Guide, provides the information required to

Appendix C, Changing the PLC IP address setting, provides a step-by-step

Appendix D, Hydraulics and Pneumatics Graphic Symbols, lists common hydraulics

Appendix E, Changing the node address of the DeviceNet devices, provides a

Appendix F, Safety Procedures, lists the basic safety procedures to be performed

Appendix G, Troubleshooting, lists common problems that can be encountered when

The speed of ac motors is determined by the frequency of the ac source. To control

As in Figure 1-1, the converter may be preceded by a transformer. This transformer

INTRODUCTION TO MANUFACTURING 1-1

Figure 1-1. Pulse Width Modulation circuit.

The converter consists of a diode bridge that returns constant polarity

1-2 INTRODUCTION TO MANUFACTURING

INTRODUCTION TO MANUFACTURING 1-3

Figure 1-3. DC link output.

Figure 1-4. Two reference sine waves compared to a triangular wave.

1-4 INTRODUCTION TO MANUFACTURING

Figure 1-5. Inverter action on the current from the dc link.

INTRODUCTION TO MANUFACTURING 1-5

Figure 1-6. Amount of current built in the motor.

1-6 INTRODUCTION TO MANUFACTURING

Note: Some of the modules provided with the Flexible Manufacturing

Note: Electrical connections between modules can be made using either

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

NAME MODEL DESCRIPTION/FUNCTION

Flat Belt Conveyor 5910 Flat belt conveyor driven by a 1/4-HP

AC Drive 5927-A 1/2-HP Allen-Bradley PowerFlex 40 AC drive

Work Surface 46604 Perforated plate that can be slid into a

Table 1-1. Components used for Job Sheet 1.

INTRODUCTION TO MANUFACTURING 1-7

Figure 1-7. Flat Belt Conveyor and AC Drive.

1-8 INTRODUCTION TO MANUFACTURING

Note: Use the push-lock fasteners to secure each module on the

G 5. Connect the equipment as shown in the wiring diagram presented in

Figure 1-9. Familiarization with the AC Drive wiring diagram.

Note: Wiring ducts should be used appropriately to maintain a

INTRODUCTION TO MANUFACTURING 1-9

Figure 1-10. Familiarization with the AC Drive setup.

Note: Refer to the AC Drive - Quick Start Guide in Appendix B to