6723-10.1, Process Configuration and Operation Software ...ucc.colorado.edu/allen-bradley/6723101.pdf · Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,

Quick Startfor theNew User

ProcessConfigurationand OperationSoftware forWindowsTM

(Cat. No. 6723�PCO)

Allen�Bradley

Allen-Bradley

https://industrialautomation.co/product-category/allen-bradley/page/3947/

Because of the variety of uses for the products described in thispublication, those responsible for the application and use of this controlequipment must satisfy themselves that all necessary steps have beentaken to assure that each application and use meets all performance andsafety requirements, including any applicable laws, regulations, codesand standards.

The illustrations, charts, sample programs and layout examples shown inthis guide are intended solely for purposes of example. Since there aremany variables and requirements associated with any particularinstallation, Allen-Bradley does not assume responsibility or liability (toinclude intellectual property liability) for actual use based upon theexamples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,Installation, and Maintenance of Solid State Control (available from yourlocal Allen-Bradley office), describes some important differencesbetween solid-state equipment and electromechanical devices that shouldbe taken into consideration when applying products such as thosedescribed in this publication.

Allen-Bradley publication ICCG-9.11, Software Licensing Agreement,provides the licensing terms for the use of this software as both adeveloper’s tool and a Runtime package. All software that is part of thispackage is covered by the license including:

FIX, Factory Link, and RSView code/screens PLC (ladder) functions PanelView screens

Reproduction of the contents of this copyrighted publication and software,in whole or in part, without written permission of Allen-Bradley Company,Inc., is prohibited.

Throughout this manual we use these notes to make you aware ofsafety considerations:

ATTENTION: Identifies information about practices orcircumstances that can lead to personal injury or death, propertydamage or economic loss.

Attention statements help you to:

identify a hazard avoid the hazard recognize the consequences

Important: Identifies information that is critical for successful applicationand understanding of the product.

Important User Information

Quick Start QS

Publication 6723�10.1 � August 1996

Process Configuration andOperation Software forWindows�(Catalog Number 6723-PCO)

This Quick Start introduces experienced PLC-5 processor users,6200 software users, and new Process Configuration and Operationsoftware users to installing and using PCO software.

Note: You can also use AI software. However, for the purposes ofthis Quick Start, we will be using 6200 software.

This document shows you how to set up a system using a typicalconfiguration. For the purposes of this Quick Start, we will use theapplication example of a forced-air grain-drying system to illustratethe procedures you will use to develop a process control system withPCO software.

This application example will show you how to:

• understand and define your process so that you can determineyour control requirements

• develop PLC code for use with PCO

• create Jump-to-Subroutine (JSR) instructions and Data Table files

• configure your process functions and load the appropriateinformation about these configurations into your PLC processor

This Quick Start includes:

• basic information needed to start using the PCO applicationquickly and effectively; we do not cover all PCO features

• high-level procedures with cross-references to other publicationsfor more detail

Refer to the Process Configuration and Operation Software UserManual (publication 6723-6.5.1) for more specific information onPCO functions and features.

Introduction

Allen-Bradley


Process Configuration and Operation Software for Windows�2


Hardware Requirements

PCO supports any combination of hardware from this list.

Requirement: Options:

Computer IBM PC Compatible 386/486/586 (Pentium), with at least 8 mb RAM and 14 mb Hard Drive space available.

Note: If you are running the PCO software tools and an MMI on this system, we highly recommend that you use at least 16mb RAM.

PLC Processors PLC�5/30 series A and later

PLC�5/40 series B and later

PLC�5/60 series B and later

PLC�5/80 series C and later

I/O Module(s) 1771�NBRC High�resolution Isolated Analog(RTD Input; 4�20mA Output)

1771�CFM Configurable Flowmeter

1771�NBTC High�resolution Isolated Analog(TC/mV Input; 4�20mA Output)

1771�IFE Analog Input

1771�NBVC High�resolution Isolated Analog(+5V Input; 4�20mA Output)

1771�IL Isolated Analog Input

1771�NIS High�resolution Isolated Analog (4�20mA Input) 1771�IR RTD Input

1771�NIV High�resolution Isolated Analog (+5V Input) 1771�IXE Thermocouple

1771�NIVR High�resolution Isolated Analog (+5V Input) 1771�IXHR High�resolution Thermocouple

1771�NIVT High�resolution Isolated Analog(+5V Input; TC/mV Input)

1771�QRD Pulse

1771�NOC High�resolution Isolated Analog (4�20mA Output) 1771�OFE Analog Output

1771�NOV High�resolution Isolated Analog (+10V Output) 1771�NR High�resolution Isolated Analog (RTD Input)

1771�NT1 High�resolution Isolated Analog (TC/mV Input)

PanelView Terminal(optional)

2711 Series (keypad version only)

Note: PLC-5/11 and -5/20 processors may also be used under somecircumstances. While use of these processors for PCO is somewhatlimited by memory considerations, their use may still be feasible,depending on your applications and the number of PCO functionsyou need. Use the sizing spreadsheet to determine if you will be ableto run your applications with these processors.

Note: There are many other build-to-order N-Series modules thatmay be compatible with this software that are not listed here. Checkwith your Allen-Bradley representative to determine compatibility.

Software Requirements

You need this software to run PCO.

Requirement: Options:

operating system Windows� 3.x or Windows� 95

operator interface Factory�Link�, FIX�, or RSView� MMI system1

application software Microsoft Excel� 5.0 or Microsoft Excel� for Windows 95pp

INTERCHANGE� 6.1.0 or later (cat. no. 9351�WKTSR)

PanelBuilder� Software (cat. nos. 2711�KA1, �KC1, �ND1, �TA1,and �TC1) if you plan to use PanelView screens

PLC�5 Programming Software1 (6200 Series, AI, or WinLogic))1 Contact your local Allen�Bradley representative for a list of other compatible operator interface and PLC

processor programming software packages.

System Requirements

Process Configuration and Operation Software for Windows� 3


Throughout this Quick Start, we will focus on the development of agrain-drying application. By following this example through fromstart to finish, you will be able to get a feel for the development of atypical process control application. In the interest of clarity, we willkeep this example as simple as possible.

Grain-drying applications are used to dry grain for storage before itsuse. In these applications, it is very important that the control systemhave the ability to control air and temperature loops independently;proper drying temperature must be maintained despite changes in theambient temperature in unheated buildings or variations in drying airflow. Furthermore, temperature or heat must be applied to the air toensure that moisture is removed by the time the grain reaches the endof the dryer, or the storage bin.

Air flow must also be maintained above a minimum level so as toensure complete moisture removal and avoid hot spots that couldbrown the grain, but not exceed a high flow that would blow grainoff the line.

HS103

FT100

FE100

FIC100

TT101

TE101

TIC101

TY101

conveyor M

SCR

2 Regulatory Loops

� Flow loop (100)

� Temperature loop (101)

2 Analog in (4�20 mA)2 Analog out (4�20 mA)

Conveyor control (103)� Auto/Manual

Interlocks� Temperature loop

FY100

For the purposes of this application example, we can assume thefollowing specific control requirements:

• Loop control must include complete Auto/Manual control (e.g.bumpless mode transfers, anti-reset windup, alarms on PV,setpoint ramping, etc.).

• Process measurement and control equipment is 4-20 mA.

The temperature loop must be interlocked with air flow to preventbrowning (or, in the worst case, a fire) if the air flow is less than aspecified minimum, or if the temperature is greater than aspecified maximum.

• Conveyor control is On/Off control, and is normally controlledfrom the PLC logic.

In addition, the operator must be able to control the motors in aManual mode from the supervisory station.

Overview of the Forced�AirGrain�Drying ApplicationExample

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This Quick Start describes how you can easily apply standard PLCprocessors in a process control application, using standarddevelopment tools. Here’s how easy it is to use the PCO program:

1. Install the PCO program onto your hard drive on your PC.

PCOSoftware

2. Use the PCO Sizing Spreadsheet to determine the systemrequirements necessary for your specific control application.

PLC based Process application system sizing

3. Use the PCO Library Manager to create PLC code for use withyour application.

4. Use 6200 programming software to create the JSRs and DataTable files necessary for your application.

5. Use the PCO Function Configurator to configure your processfunctions, and then download the function configurations into thePLC processor.

6. Use the faceplates to monitor and control your application.

What You'll Be Doing inThis Quick Start



As we will note throughout the Quick Start document,INTERCHANGE software plays an important role in the properfunctioning of your PCO application.

Important: If you are using the PCMK card, you should useINTERCHANGE Version 6.1.0 or later.

Configuring INTERCHANGE For Use With PCO Software

Before you use PCO software to download or upload, you should runthe INTERCHANGE Device Configuration Utility, located in theRockwell Software program group. When you run the utility, theINTERCHANGE Device Configuration screen appears.

From this screen, you have several configuration options.

If you are using a memory manager, click on the Advanced... button.From that screen, click on Load Drivers High and select theappropriate memory manager.

Using INTERCHANGE WithYour PCO Software

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If you are using the 1784-KT or -KTX card on DH+:

Highlight the appropriate card (1784-KT on DH+ or 1784-KTX onDH+) in the list of Available Drivers and click on the Add Devicebutton.

The 1784-KT on DH+ device configuration dialog box appears.

This is also called the pushwheelnumber or Port ID, not to beconfused with the serial com port.This is a software ID that representsyour network interface; you can havePort ID 1 associated with com port 2.

This is an arbitrary name you assign.

This is the DH+ number youassign to your computer.

This address should match the dip switchsettings on your KT card. A bad setting ofthe card address is often the cause of amalfunctioning network.

You set this interrupt on your KT cardusing the appropriate dip switches(refer to your KT card documentation).This is the most common source ofmalfunctioning communications.Always make sure that the interruptnumber you enter here matches theKT card settings, and that theinterrupt is not being used by anotherhardware card.

Important: Each configured device must have a unique port ID(1-8). You will need to know this ID when using theExcel spreadsheets to configure your functions.

Select the appropriate options and click on OK.

If you are using DF1:

Highlight that option in the list of Available Drivers and click on theAdd Device button.

The DF1 on COM Port Device Configuration dialog box appears.

Select the appropriate options and click on OK.



If you are using the 1784-PCMK card:

With the PCMK card, you must also set the PCMK enabler.

From the INTERCHANGE Device Configuration screen, click onthe Advanced button. The INTERCHANGE Advanced DeviceConfiguration dialog box appears.

In the PCMK Enabler Selection section, select one of the following:

• If you are using the Windows 95 Plug-n-Play driver (RSIPCMK),or if you are using Cardware, Cardsoft, etc. and PCMKINIT,choose Specific and click on OK.

• If you are using Cardware and PCENABLE, choose Generic andclick on OK.

The INTERCHANGE Device Configuration screen returns.

If you choose Specific, when you click on the Add Device button,the 1784-PCMK on DH+ dialog box appears as follows. You mustenter the Socket # on this screen.

Important: Rockwell Software currently refers to sockets by azero-based socket number, while Windows 95 beginsnumbering at 1. Therefore, specifying socket number 0in Interchange actually refers to the socket thatWindows 95 recognizes as socket 1.

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If you choose Generic, when you click on the Add Device button, the1784-PCMK on DH+ dialog box appears as follows. You must enterthe memory address and the IRQ value on this screen.

INTERCHANGE Compatibility

The following diagram illustrates the software packages that relate torunning PCO software on a single computer through onecommunication interface (either DH+ or DF1), along with 6200, AI,and RSView software.

RSView

PCO Excel�basedApplication Configuration

Software WINLinx V4.50 or later

INTERCHANGE V6.1.0 or later*

6200 Series Software

* You must have INTERCHANGE 6.1.0 for Windows 95 Plug�n�Play 1784�PCMK support.

Tip: Pick the INTERCHANGE to DH+�1

Channel configuration option

6723�PCO

AI



PCO software consists of six sub-components that you can installindividually:

• PCO Configurator

• PCO Library Manager

• PanelView screens

• FIX screens

• Factory Link screens

• RSView screens

Note: Refer to Appendix F of the Process Configuration andOperation Software User Manual (publication 6723-6.5.1) for adetailed listing of the files installed on your hard drive during thePCO software installation process.

Before You Begin

Before you install your PCO software, be sure that you have thefollowing software components installed:

• Allen-Bradley INTERCHANGE DH+ and/or DF1 drivers

Important: PCO uses INTERCHANGE software;INTERCHANGE must be installed and runningwhenever you attempt to communicate with thePLC processor. Refer to the end of thisdocument for tips on running and configuringINTERCHANGE if you do not already have itset up on your system.

• Microsoft Excel 5.0 or Excel 95

• OLE2 DLL files

PCO installs these files automatically if it does not find them onyour system, or if it finds an older version of them.

• 6200 Series Import/Export executable files

These files are stored in the target directory if PCO setup does notfind them there. Normally, these files come with your 6200Series software.

Note: You can also use AI software. However, for the purposesof this Quick Start, we will be using 6200 software.

Refer to the Process Configuration and Operation Software UserManual (publication 6723-6.5.1) for more information on thepurpose of each of these software components.

1. Insert disk 1 into drive A.2. Select Run from the appropriate

menu, depending on your version ofWindows.

3. Type a:\setup.4. Choose the PCO components you

wish to install.5. Choose the directory where you wish

to install PCO software.6. Enter the directory where your MMI

software is installed. (PCO uses thisdirectory to store Autotuningexecutable files.)

Basic steps

Installing PCO Software

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Installing the Software

Follow this flowchart to install PCO software:

START

Type a:\setup .

If you elected to install FIXfaceplates, PCO promptsyou to enter the directory

where FIX is installed.(e.g. C:\WDMACS)

DONE

For Windows 3.1: From theProgram Manager File

pull�down menu, select Run.

Insert disk 1 of thePCO 6723�PCO

software into drive a.

Click on the checkboxes toselect the PCO components

you wish to install (all areoptional).

Click on Continue.

Do you wish toinstall PCO in thedefault directory?

NO

YES

Click on the ChangeDirectory button and enter

the directory where you wishto install PCO.

If you elected to installFactory Link faceplates, PCO

prompts you to enter thedirectory where Factory�Link

is installed.(e.g. C:\FLWIN)

For Windows 95: Clickon the Start button and

select Run.

If you elected to installRSView faceplates, PCOprompts you to enter the

directory where RSView isinstalled.

(e.g. C:\RSI)

Note: To complete the stepsoutlined in this document, you mustinstall the PCO Excel Configuratorand the Library Manager.



To run the PCO application:

1. Run Windows.

2. From Program Manager, double-click on the 6723-PCO programgroup.

3. Double-click on the PCO Startup icon.

The PCO Startup Screen appears.

Note: The buttons on this screen appear in the order in whichyou will develop your process applications.

1. Run Windows.2. Double�click on the 6723�PCO

program group.3. Double�click on the PCO Startup icon.

Basic steps

Running the PCO Software Application

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The first button on the PCO Startup Screen is the PCO SizingSpreadsheet button. By clicking on this button, you can use thesizing spreadsheet included with your PCO software to determine thecontrol requirements needed for your application(s).

The Sizing Spreadsheet can help you understand your processrequirements. You may wish to have your P&ID diagrams handy, asthey can help you in the process of sizing PCO.

To use the Sizing Spreadsheet to determine your requirements:

1. From the PCO Startup screen, click on the PCO SizingSpreadsheet button.

This button launches Microsoft Excel, which opens automaticallyto the Sizing Spreadsheet.

2. Using your P&IDs or loop diagrams for reference, fill in thenumber of inputs and outputs per module category.

The Sizing Spreadsheet calculates the quantity of modules (pertype) required for your application.

For the grain-drying example, there are 2 analog inputs, FT100and TT101, and 2 analog outputs, FY100 and TY101. In thisexample, we will assume that the inputs and outputs are N-Serieschannels. Therefore, in the No. of Points column, you shouldenter 2 inputs (4-20 mA) and 2 outputs (4-20 mA).

3. Using your P&IDs or loop diagrams for reference, fill in thenumber and type of PCO functions required.

The grain-drying application in our example requires one PIDfunction for each of the regulatory loops (one flow loop, FIC100,and one temperature loop, TIC101). Therefore, you should entera 2 in the “Regulatory Loops (PID)” row.

1. From the PCO Startup screen, clickon the PCO Sizing Spreadsheetbutton.

2. Enter the number of input points andoutput points on the spreadsheet.

3. Enter the number and type of controlfunctions required for your application.

4. If you wish, print out the results thatappear on the spreadsheet.

5. Save the spreadsheet under a namewhich is meaningful for thisapplication.

Basic steps

Determining YourApplication'sRequirements



The grain-drying application in our example also requires thecontrol of a conveyor motor (HS102), which is a two-state,discrete device. You can use the DD2 function to control it. Youshould enter a 1 in the “DD2 Device Drivers” row.

You can assume that the motor is controlled by one PLC output.State 1 (output closed) turns the motor on, and state 0 (outputopen) turns the motor off. This is the output of the DD2 function.

You can also assume that the motor provides one feedback signal,attached to one PLC input, FB0. When FB0 is set to 1, itindicates that the motor is rotating; when FB0 is set to 0, themotor is not rotating. This is the feedback input of the DD2function. In the grain drying example, you will not use DD2’sFB1 input.

Keep the following items in mind when filling out this section:

• Regulatory (PID) loops count as one function; cascade loopscount as two functions.

• You can determine zero-state, two-state/three-state devicedrivers by counting all the digital valves, motors, etc. presentin your application.

• PCO comes configured for one PanelView per PLC processor(racks 6 and 7).

Once you have entered the number of PCO functions, the SystemSummary section of the Sizing Spreadsheet will provide you withthe following information:

• the number of JSRs required for your application

Every JSR represents one instance of the function. In ourexample, then, you should write one JSR for the DD2function, two JSRs for the PID function, and one JSR for theN-Series function (to handle all eight channels at once).

• the total PLC memory required for your application

The grain-drying example requires:

– 16.5K of program and data file memory

– 30.5 ms of scan time

– 375 tags, if you are using the RSView MMI system

This example shows that a PLC-5/30 processor might be largeenough to fit the application, as long as your own custom logicdoes not exceed 15.5K (i.e. 32K minus 16.5K, as required bythe grain-drying application).

• the calculated execution time, based on non-STI PLC-5/60,series C

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4. If you wish to print out the results of this sizing, choose Printfrom the File menu.

The Print dialog box appears.

5. Select the printer options you wish to use and click on .

6. From the File menu, choose Save As to save your spreadsheetunder a new name.

The Save As dialog box appears.

7. Choose the appropriate drive and directory where you want yourworksheet to be stored, type the file name you would like it saved

as, and click on .

For the purposes of this example, we have used the file namepcosampl.xls.



The second button on the PCO Startup Screen is the PCO LibraryManager button. By clicking on this button, you can use the LibraryManager tool to help you create your control logic.

The Library Manager helps you to develop your PLC code byenabling you to easily select, convert, and integrate PCO functionswith your PLC-5 application. The Library Manager manages thememory conflicts that can result from this integration process.

To use the PCO Library Manager, click on the PCO Library Managerbutton on the PCO Startup screen. The PCO Library Manager screenappears.

Once you have the PCO Library Manager up and running, you willuse it to complete the following tasks:

1. Select your PLC processor type.

2. Define the PCO application file directory.

3. Create your PCO application files.

4. Integrate the PCO application files with your application.

For additional help on using the PCO Library Manager, refer to thePCO Library Manager online help system.

Creating the PLC Code

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Select Your PLC Processor Type

Before you do anything else, you must define the PLC processortype that your application will be using.

1. From the Configure menu, choose PLC Type.

The PLC type configuration dialog box appears.

If you get an error message instead, it could be that your PCOApplication Files window is not empty. If this is the case, selectall the files listed in the window and press DEL to delete thecontents of this window. Then repeat step 1.

2. Enter your PLC processor Model, Series, and Rev informationappropriate for your processor.

For the grain dryer application example, we will use thePLC-5/60, Series C, Rev C processor.

3. Click on .

This saves your inputs and closes the PLC type configurationdialog box.

You cannot alter the PLC type configuration information if the PCOApplication Files window (in the upper right corner of the PCOLibrary Manager screen) is not empty. You must delete all filesbefore you can enter new PLC type configuration information.

1. From the Configure menu, choosePLC Type.

2. Enter the appropriate information foryour processor type.

3. Click on OK.

Basic steps

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Define the PCO Application File Directory

Next, you can configure the directory where you store your PCOapplication files. These files are the PC5 converted forms of thePCO functions. This PC5 form complies with the PC5 format orimport/export ASCII format used by 6200 Series, AI, and WinLogicproducts. PCO then uses these files to merge with your PLCapplication.

Refer to the procedure on the following page for instructions on howto create these application files.

1. From the Configure menu, choose Directory.

The PCO Application files directory config dialog box appears.

2. Select Use Default Directory.

You can also choose Use Custom Directory if you want the PCOLibrary Manager to store the PCO application files in a directoryyou specify, but for the purposes of this example, we will use thedefault directory (C:\PCO\LIBMGR\PC5).

3. Click on .

This validates your inputs and closes the PCO Application filesdirectory config dialog box.

1. From the Configure menu, chooseDirectory.

2. Select Use Default Directory.3. Click on OK.

Basic steps

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Allen-Bradley




Create Your PCO Application Files

The PCO Library Manager allows you to create a new program fileor merge selected PCO functions with your existing applications bymanaging PLC address conflicts, relocating PCO addresses, andsparing you the task of manually importing/exporting ladder files.

Important: If the PLC Data & Prog config dialog box appears inthe top center of your PCO Library Manager mainscreen, proceed with step 2. If it is not the activewindow, proceed with step 1.

1. From the Configure menu, choose PLC Data & Prog.

The PLC Data & Prog config dialog box appears.

2. From the PCO Library Functions window, click on the functionsyou want to add to your application.

You can select more than one function to be converted at a time.If you want to select functions that are adjacent to one another,simply click on a function and then drag up or down to includethe others. If the functions you want to add are not adjacent toone another, click on one, hold down the CTRL key, and click onthe other(s). Each function you click on will be converted.

For the purposes of our example, you should choose the NS, PID,and DD2 functions.

3. Choose Default for your memory allocation scheme.

You can also choose Custom if you wish to define specialmemory areas for the Class program and data memories, but forthe purposes of this example, we will use the default option.With this option, the PCO Library Manager will generateapplication files that are allocated in default memory locations.In other words, PCO programs will be located in files 2 through54, and PCO data will be located in files 3 through 124.

1. Make sure that the PLC Data & Progconfig dialog box appears in the topcenter of the Library Manager screen.

2. From the PCO Library Functionswindow, click on the functions youwant to add to your application.

3. Select Default.4. Click on Create Appl files.5. Click on Generate Memory Map.

Basic steps

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4. Click on .

The PCO Library Manager converts the PCO functions youselected to PCO application files, which appear in the PCOApplication Files window (upper right corner of the main LibraryManager window).

Note: The PCO Library Manager automatically installs the filesPCO_MAIN, DIGITAL_IN, PLC_ALMS, and CUSTOM_ALM.You can selectively delete these files.

Refer to Chapter 3 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for informationon deleting these files.

The PCO functions are relocated to the specified memorylocations, and are ready to be integrated into your application, aslong as it does not conflict with any memory within thepreviously allocated areas. If your application does happen to usememory within these areas, the PCO Library Manager willdisplay warnings for all the addresses that create conflicts. If theutility finds even one address conflict, you will be given theoption to overwriting the conflict, or cancelling the merge. If youchoose to cancel, your original application will not be altered.

5. Click on .

The PCO Library Manager generates a memory map of the PCOapplication files. This memory map displays all of the PLCprogram and data addresses used by the PCO application files.

Refer to Chapter 3 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for an example ofa memory map.

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Integrate the PCO Application Files With Your Application

Now that you have created the PCO application files, you can mergethem with any existing or new PLC application.

1. From the Configure menu, choose Application.

The User Application configuration dialog box appears.

2. Select the PLC Application Type with which you are working.

With this programming tool: with this file format: select this option: The PCO Library Manager:

WinLogic 5 or AI X5 WinLogic5, AI (X5 format) • Exports your X5 application to PC5 format

• Merges the PCO application files with the PC5 file

• Imports the PC5 file back into your X5 application

IPDS 6200 AF5 IPDS 6200 (AF5 format) • Exports your AF5 application to PC5 format

• Merges the PCO application files with the PC5 file

• Imports the PC5 file back into your AF5 application

Other PC5 Imp/Exp Text (PC5 format) Merges the PCO application files to the PC5 file.

The PCO Library Manager assumes that your PLCprogramming tool is able to generate a PC5 format (usuallyvia an import/export utility) and reprocess it after the mergeis performed.

3. In the User Application File text box, type the directory path andname of your application.

If you are using: Enter this:

WinLogic5 or AI the name of an existing application file with theX5 extension

(e.g. C:\RSI\WL5\PLANT.X5)

IPDS 6200 the name of an existing application file with theAF5 extension

(e.g. C:\IPDS\ARCH\PLC5\PLANT.AF5)

Imp/Exp Text the name of an existing application file with thePC5 extension

(e.g. C:\IPDS\TEXT\PC5\PLANT.PC5)

1. From the Configure menu, chooseApplication.

2. Select the PLC Application Type.3. Enter the directory path and name of

your application.4. Click on Merge.5. Click on Show Import LOG file

(optional)6. Click on Show Export LOG file

(optional).7. Click on Generate Mem. Map

(optional)8. Click on OK.

Basic steps



For the purposes of this example, we assume that you are using6200 software, installed in the IPDS directory, and that you arenaming your application USER. We also assume that USER doesnot already exist; if you have a PLC application named user, youshould choose another name to use with this example.

Select the AF5 format button, and type the name of the userapplication file: C:\IPDS\ARCH\PLC5\USER .

4. Click on .

Since USER is a new application, there is no Export activity toperform. The Library Manager will simply create a new PC5 filecalled USER.PC5, and then import this file into AF5 format sothat it is compatible with 6200 software.

Note: Import and Export activities are carried out using the 6200Import/Export DOS executables. You should be able to see theImport process in a DOS window session.

All processing activities and any errors that occur are displayed inthe “Display” window.

The Import Utility screen appears.

Important: The merge process only works on offline files inthe X5, AF5, or PC5 format; it does not loadyour application from or download yourapplication to the PLC processor. If yourup-to-date application resides in the PLCprocessor, you must upload it before you initiatethe merge. If you fail to do so, the mergeprocess will integrate the application files towhatever X5, AF5, or PC5 version it finds onthe disk.

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5. Click on the Show Import LOG file button if you wish to displaya report of the PC5 to AF5 import process.

The Import function generates this report, and you can use it totroubleshoot any errors reported by the merge process.

Refer to Chapter 3 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for an example ofan import log file and for conditions under which import errorscan occur.

Note: In this example, there is no Export activity because USERdid not exist at the time that the merge was performed.

6. Click on the Generate Mem. Map button to generate a memorymap of your application.

The Memory Map exports your X5 or AF5 application to PC5, ifnecessary, before it scans the resulting PC5 file. Use this functionto display the PLC Program and Data file allocations of yourapplication. By doing so, you can choose the correct addresseswhere the PCO application files should go. This preventsmemory conflicts between the PCO application files and yourPLC application.

In this example, check that:

• PID is located in program file 32

• NS is located in program file 24

• DD2 is located in program file 36

Refer to Chapter 3 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for an example ofa memory map.

7. Click on .



The third button on the PCO Startup Screen allows you to start yourPLC programming tool. When your PCO software is shipped to you,this button is configured to launch the IPDS 6200 software from theC:\IPDS directory. By clicking on this button, you can use 6200Series software to create the JSR instructions and data table files thatwill complete your PLC code.

With 6200 software, you can create these steps in one session.

1. From the PCO Startup screen, click on the IPDS 6200Programming Tool button.

The 6200 Series Software main screen appears.

2. Press F4 - Offline Configr.

3. Highlight the USER application and press F1 - Offline

Program.

The USER PLC application appears..

4. Press F1 - Proc. Functions.

5. Press F6 - Create Lad Fl.

6. Enter a file number. For purposes of this example, type 55.

7. Press F10 - Change Fl. Name.

8. Type a new name for the ladder file.

9. Press F8 - Monitor File.

10.Press F10 - Edit.

1. From the PCO Startup screen, clickon the IPDS 6200 Programming Toolbutton.

2. Add JSR instructions for each of thefunctions you merged with thisapplication

3. Enter data table file information foreach of the functions you merged withthe application.

4. Save the program.5. Download the application to the PLC

processor.

Basic steps

Creating JSR Instructionsand Data Table Files

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Creating the JSR Instructions

11.Press F4 - Insert Rung.

12.Press F4 - Insert Instr.

13.Type the instruction type, program file number, and the necessaryinput parameters for this function instance.

For our grain-drying application, you will enter this informationfor the N-Series function instance and for both instances of thePID function.

In the case of the N-Series function, type JSR 24 200 0.

14.Press ENTER 3 times.

This validates the JSR parameters.

15.Press ENTER to validate the rung.

16.Press F10 - Accept Rung to complete the instruction for the

N-Series function.

17.Repeat steps 11 through 16 for each of the PID functioninstances.

Use JSR 32 202 0 and JSR 32 204 0 for your parameters.

18.Press ESC.

19.Press F4 - Program Directory.

Creating the Data Table Files

20.Press F6 - Memory Map.

21.Press F6 - Create DT File.

22.Enter the integer and floating point addresses of the PCO functioninstances.

For the purposes of this example, use the following values for theN-Series and PID functions:

• For the N-Series function, use N200:209 and F201:209.

• For the flow loop (PID function), use N202:92 and F203:92.

• For the temperature loop (PID function), use N204:92 andF205:92.



23.Press ESC.

24.Press F2 - Save/Merge.

25.Press F2 - Save & Contnue.

26.Press F1 - Save Edits.

27.Press F3 - Return to Menu.

Downloading the Application to the PLC Processor

28.Press F1 - Online Program.

29.Press F2 - Save/Restore.

30.Press F3 - Restore Program.

31.Highlight the USER application and press F1 - Begin Restore.

Your program is then downloaded to the PLC processor.

32.Press F10 - Exit System.

Allen-Bradley




The fourth button on the PCO Startup Screen is the PCO FunctionConfigurator button. By clicking on this button, you can use PCO’sExcel-based Function Configurator tool to configure your PCOfunctions.

The Configurator tool provides you with pre-defined spreadsheetsthat help you select and enter the data required for each PCOfunction. Once the data for a function or group of functions iscomplete, you can then load that configuration data into the assignedinstance data table. Each dedicated Excel spreadsheet has built-infeatures that help you:

• configure each of the function’s parameters

• upload/download entire application configurations

• handle PCO function configuration errors

To use the PCO Function Configurator, click on the PCO FunctionConfigurator button on the PCO Startup screen. This launchesMicrosoft Excel. When this application begins, it loads the PCOmacros and displays an empty workbook. (You can also tell theapplication to open a specific workbook.) The Configurator alsocustomizes the Excel environment by adding the PCO toolbar andPCO menu.

The first time you launch the PCO Excel configurator, all existingtoolbars become hidden. You can recall them if necessary byclicking with your right mouse button above the toolbar section andchoosing Toolbars from the menu.

Refer to Chapter 4 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for more informationon PCO menus and the PCO toolbar.

Once you have the PCO Function Configurator up and running, youwill use it to complete the following tasks:

1. Display a configuration worksheet.

2. Configure channels.

3. Configure nodes.

4. Configure function parameters.

5. Download configurations.

6. Upload configurations.

For additional help on using the PCO Function Configurator, refer tothe PCO Function Configurator online help system.

Configuring Your ProcessFunctions

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Displaying a Configuration Worksheet

Use the PCO configuration worksheets (or spreadsheets) to configureyour PCO functions.

1. Click on .

A list of PCO functions appears.

2. Select the function you want to configure.

The PCO Configurator inserts a new worksheet in the activeworkbook. If no workbook is currently active, a new one iscreated. Each time a new workbook is created, the PCOConfigurator also inserts a Channel Configuration worksheet anda Node Configuration worksheet.

Note: If your workbook does not contain a ChannelConfiguration worksheet and/or a Node Configuration worksheet,you should add them. To do this, click on the Insert ChannelConfiguration WS and Insert Node Configuration WS optionsunder the PCO menu.

3. Repeat step 2 for every function you want to add to thisworkbook.

For the purpose of the grain-drying application, you will chooseNS and PID. A worksheet will be created for each function.

You only need to add one worksheet for each function type. Forexample, even if you know that your application requires two PIDfunctions, you only need to add one PID worksheet to the activeworkbook. You can then configure multiple instances of afunction on the same worksheet.

Refer to page 7-17 and page 9-2 of the Process Configuration andOperation Software User Manual (publication 6723-6.5.1) forsamples of the N-Series and PID configuration worksheets,respectively.

4. From the File menu, choose Save As.

In the Save As dialog box, type the name of the current workbook

and click on .

In naming your workbooks, consider the following:

• You can double click on a worksheet’s name to rename it.

• Be careful not to duplicate any names already in use; thesefiles will be overwritten if you do.

• Save all related files in the same directory.

1. Click on the PCO Functions Listbutton.

2. Select a PCO function.3. Repeat step 2 for additional functions.4. Save the workbook under a new

name.5. Move the sizing spreadsheet into the

active workbook (optional).6. Save the workbook again.

Basic steps

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5. You can also move your Sizing Spreadsheet for this applicationinto the active workbook. To do this:

a. Open the sizing spreadsheet that applies to this application.

b. From the Edit menu, choose Move.

The Move or Copy dialog box appears.

c. Select the name of the workbook to which you wish to add thesizing spreadsheet (this should be the name you chose in step4.), the position in the workbook where you wish to add it, and

click on .

6. From the File menu, choose Save As.

In the Save As dialog box, type the name of the current workbook

and click on .

Refer to Chapter 4 of the Process Configuration and OperationSoftware User Manual (publication 6723-6.5.1) for information onthe layout of the PCO configuration worksheet.



Configuring Function Parameters

Once you have added the appropriate worksheets to your workbook,and ordered them to your liking, you can go on with configuringyour functions.

1. From the function bar at the bottom left side of your workbook,click on the PCO function you want to configure.

The worksheet for that function becomes active.

2. Position the active cell in the column you want to configure, andat the line corresponding to the appropriate parameter.

3. Enter the appropriate value in the cell, or choose from a list ofvalid options.

Click on or double-click on a cell to access a list of allowed

symbols or values for a given field. If there is such a listavailable for this field, it will appear as a dialog box on yourscreen, from which you can then choose the desired value.

Refer to the PCO Function Configurator online help system forassistance in configuring your functions. Each parameter foreach function is described in detail there.

4. Continue entering values until the entire column is configured.

The data you enter configures the function for the needs of yourspecific application.

5. Repeat steps 2 through 4 for each function instance.

For example, in our grain-drying application, there are two PIDfunction instances. This means that you must configure twocolumns in the PID worksheet - one for the flow loop (FIC100)and one for the temperature loop (TIC101).

You can simplify and speed up function configuration byduplicating a function that you have already configured. To doso, simply click on the column reference row to highlight theentire column, and choose Copy from the Edit menu. Then selectan empty column and choose Paste. This duplicates the entirefunction instance, and you can then modify the parameters thatare different from the original configuration.

6. Repeat steps 1 through 5 for each PCO function in yourworkbook.

For example, for our grain-drying application, we need toconfigure both the N-Series function and the PID functions.

7. From the File menu, choose Save and click on .

The PCO Function Configurator saves the entire workbook.

1. Click on the PCO function you want toconfigure.

2. Position the active cell in the columnyou want to configure, and at the linecorresponding to the appropriateparameter.

3. Enter the appropriate value in the cellor choose from a list of valid options.

4. Continue entering values until theentire column is configured.

5. Repeat steps 2 through 4 for eachfunction instance.

6. Repeat steps 1 through 5 for eachPCO function in your workbook.

7. Save your configurations.

Basic steps

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Configuring Channels

The channel configuration worksheet allows you to configure thenetwork types of the attached PLC processor(s).

1. From the function bar at the bottom left side of your workbook,click on the Channels worksheet.

The channel configuration worksheet becomes active.

2. Enter the network type either by typing it in the appropriate cell,or by double-clicking on the cell to display the list of availableoptions from which you can choose.

3. For every network type you configure, enter the driver type thatconnects your computer to the network.

The PCO Function Configurator accesses these drivers throughthe INTERCHANGE software package.

4. Enter the number of messages the Configurator should send.

Note: This function is not currently supported, so you can eitherleave this cell blank, or enter a value between 1 and 10.



Configuring Nodes

The node configuration worksheet allows you to configure thenames, types, and addresses of PLC processors to which yourcomputer is attached. You can configure up to 20 different nodes.

1. From the function bar at the bottom left side of your workbook,click on the Nodes worksheet.

The node configuration worksheet becomes active.

2. Enter the node name (e.g. PLC5_1).

3. Enter the node type (e.g. PLC5).

4. Enter the channel number.

For the purposes of this example, enter the number 1 to refer tothe channel configured above.

5. Enter the station address (i.e. the DH+ addresss of your PLCprocessor).

6. Enter the communication timeout.

7. Enter the enable status.

Note: This function is not currently supported, so you can eitherleave this cell blank, or enter “Enable.” The PCO Configuratorwill always consider the node to be enabled.



1. Click on the Channels worksheet.2. Enter the network type.3. Enter the driver type.4. Enter the number of messages the

Configurator will send.5. Save the workbook.

Basic steps

1. Click on the Nodes worksheet.2. Enter the node name.3. Enter the node type.4. Enter the channel number.5. Enter the station address.6. Enter the communication timeout.7. Enter the enable status.8. Save the workbook.

Basic steps



Downloading Configurations

When you finish configuring a function or a series of functions, aswell as the nodes and channels, you can download the functioninstances to the PLC processor.

1. Make sure that:

• the active cell is in the column you wish to download

• you have configured the PLC node name in the nodeconfiguration worksheet

• the channel and node configuration worksheets reference yournetworked PLC node

• the Integer Data Address references one of the data tables thatyou created in the PLC processor

You can download several adjacent columns on a worksheet atonce by stretching the selection to highlight more than onecolumn at a time.

2. Click on .

A dialog box appears that lets you choose between downloadingthe selected column(s) or the entire worksheet. If you choose theentire sheet, then the PCO Function Configurator downloads allcolumns of the sheet until it finds a column with an empty nameor until it encounters an error.

3. If you receive an error, select and correct the erroneous field(s).

All fields must contain valid entries, even if they are notapplicable to your application.

You can access errors reported by the download function by

clicking on the buttons. These buttons enable you to

scroll through and correct all of the errors in your configuration.

4. Repeat steps 1 through 3 until there are no more errors.

Important: The Download functionality requires theINTERCHANGE driver in order to operate properly.INTERCHANGE software should be installed on yourdisk, and the INTERCHANGE driver should beactivated prior to the execution of the ExcelConfigurator. If INTERCHANGE is not properlyloaded and running, any attempt to download or uploadconfigurations will result in an error message.

1. Make sure that you have completedall of the required steps up to thispoint.

2. Click on the Download to PLC button.3. Correct any errors, as necessary, and

repeat steps 1 and 2 again.4. Repeat until the configuration

downloads without error.

Basic steps

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Uploading Configurations

You can also upload a PCO configuration from the PLC processor.

Important: When you upload a configuration from the PLCprocessor, the PCO Configurator fills the selectedcolumn(s) with the new data, and all previous data isoverwritten. Therefore, we recommend that you notupload and overwrite a function that you have alreadyconfigured and tested. Instead, move to a new column,copy or create a new header, and then upload.

1. Position the active cell in the column you wish to upload.

You can upload several adjacent columns on a worksheet at onceby stretching the selection to highlight more than one column.

2. Make sure the header of the function you wish to upload iscorrectly configured in your Excel spreadsheet.

3. Click on .

A dialog box appears that lets you choose between uploading theselected column(s) or the entire worksheet. If you choose theentire sheet, then the PCO Function Configurator uploads allcolumns of the sheet until it finds a column with an empty nameor an incorrect configuration.

The Upload function populates the columns in your spreadsheetwith the data found in your PLC processor.

Errors reported by the Upload procedure are much fewer thanthose reported by Download. At upload, all the PCOConfigurator does is read the data table and store the data inappropriate cells in the selected column(s). The Configuratoralso tries to convert the integer values it reads to a symbol if thefield allows a symbol value. If the value is out of range, theConfigurator simply stores the value as is. Most errors reportedby the Upload procedure concern the function header section.

4. If you receive an error, select and correct the erroneous field(s).

You can access errors reported by the download function by

clicking on the buttons. These buttons enable you to

scroll through and correct all of the errors in your configuration.

Important: The Upload functionality requires the INTERCHANGEdriver in order to operate properly. INTERCHANGEsoftware should be installed on your hard disk, and theINTERCHANGE driver should be activated prior to theexecution of the Excel Configurator. IfINTERCHANGE is not properly loaded and running,any attempt to download or upload configurations willresult in an error message.

1. Select the column(s) you want to upload.2. Check that the header is correctly

configured in your worksheet.3. Click on the Upload from PLC button.4. Correct any errors, as necessary, and

repeat steps 1 through 3 again.5. Repeat until the configuration uploads

without error.

Basic steps

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You can use the PCO faceplates to monitor configured I/O interface,process control, and discrete control functions.

For additional information about monitoring and controlling yourprocess functions through the faceplates, refer to Chapter 5 andAppendices C, D, and E of your Process Configuration andOperation Software User Manual (publication 6723-6.5.1).

In this Quick Start, you have completed the steps necessary to:

• define your process and control requirements

• develop your PLC code for use with PCO software

• create JSR instructions and Data Table files

• configure your process functions

• download the appropriate information into your PLC processor

Use the techniques that you learned here to configure your ownapplications for use with PCO software.

Using the Faceplates toMonitor and Control YourProcess Functions

Summary

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Allen�Bradley, a Rockwell Automation Business, has been helping its customers improveproductivity and quality for more than 90 years. We design, manufacture and support a broadrange of automation products worldwide. They include logic processors, power and motioncontrol devices, operator interfaces, sensors and a variety of software. Rockwell is one of theworlds leading technology companies.

Worldwide representation.

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Allen�Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382�2000 Fax: (1) 414 382�4444

Publication 6723�10.1 � August 1996 PN 955125�92Copyright 1996 Allen�Bradley Company, Inc. Printed in USA

Documents

6723-10.1, Process Configuration and Operation Software ...ucc.colorado.edu/allen-bradley/6723101.pdf · Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,