ELECTRICIAN TRAINING
Contents
1. Modicon Skill Development Guide 8 K 01b Connect and Operate Programmer P230 PROGRAMMER 1 Identify the PLC unit number o Locate the PLC number on the Modbus Plus data highway chart See Figure 1 4 Bridge C Bridge Mux Node 9 1 Controller Figure 1 4 Example of the Modbus Plus Data Highway Chart o The Modbus Plus data highway chart is usually located next to the Machine Print taped on the work cabinet door 2 Power up the unit 3 Enter the Modsoft Directory o When the DOSSHELL screen appears tab over to the directory side and put the cursor on the Modsoft directory using the arrow keys 4 Enter the Modsoft program o Using the lt Tab gt key to toggle from the directory side of the screen to the file side of the screen move the cursor to the right side file side From the file listings move the cursor with the up and down arrow keys to select Modsoft exe and press lt Enter gt to select the file Electrician Training DUTY K PLC Modicon Skill Development Guide 9 K 01b Connect and Operate Programmer 5 Press lt Enter gt when the MODSOFT default screen is displayed See Figure 1 5 Utility Offline Combined Transfer Tools Quit OnT ine Select Program Direct to PLC Communication Parameters ADDRESS Protocol Routing Address Device Tab moves between the Menu Bar and the Editing Screen ALT H provides help on the menu item selected by the cursor Select Pr2. K 01b ELECTRICIAN TRAINING SKILL DEVELOPMENT GUIDE DUTY K PLC Modicon K 01b Connect and Operate a Programmer Issued 01 01 98 Task Preview Connect and Operate Programmer The Learner uses the P190 programmer mostly to communicate with the 184 and 384 series processors although the P190 is capable of communicating with all PLC types Connection of the P190 includes plugging in the data communications cable designed for the required PLC If required the Learner will hook up the P190 to the Modbus Plus Operating the P190 involves using the command keys software label keys numeric pad alphanumeric pad shift key and arrow keys as required by P190 program tapes This tape driven programmer requires that the Learner load a programmer tape to enable communication with the processor The P230 programmer is used to communicate with the 584 884 and 984 processors and is the only programmer that can perform online menu functions The Learner may need to use the online menu routing procedure and must use extreme caution when doing so Connecting the programmer to the wrong PLC when using the ONLINE menu routing procedure could result in a machine breakdown or personnel injury How your skills will be checked The Skill Check will require you to connect and operate a programmer All tools materials and resources will be available The Evaluator will verify that your demonstration meets the skill objective by observing or measurin
3. UNIT Back View O Figure 1 1 Data Communication Cable Hook up on the P190 Programmer Electrician Training DUTY K PLC Modicon Skill Development Guide 6 K 01b Connect and Operate Programmer 2 Power up the unit o The P190 has a toggle switch located at the right rear of the unit near the top when viewed from the front o When the prompt to Insert Tape appears the P190 is warmed up 3 Insert the tape See Figure 1 2 o When the Insert Tape prompt appears insert the required action tape o Insert the tape loader tape if loading program or backing up software o Insert the programmer tape if programming Figure 1 2 P190 Tape Drive Slot Electrician Training DUTY K PLC Modicon Skill Development Guide 7 K 01b Connect and Operate Programmer 4 Attach the unit o When the prompt appears on the software label keys enter the unit number assigned to the PLC on which you are working and press the lt Attach unit gt software label key See Figure 1 3 UNIT 001 DATE AR 00001 Attach 184 384 Evaluate Operations Tape Unit Operations Operations Operations SCREEN KEYBOARD A Figure 1 3 DH NETWORK MENU Screen 5 Load a program o Perform the procedure in Skill Development Guide K 03 Load Program to work with a PLC machine program Electrician Training DUTY K PLC
4. at the node closest to the P230 Your address should now read 12 5 9 1 o There should be a period between each connection o Following Figure 1 7 as an example the address from the P230 xxx processor to the A processor located at the 1 port of the bridge mux is 12 5 9 1 o Enter Modsoft From the Modsoft Main Menu select ONLINE Use the Select Program option to verify that the program is not already set up as a hot key This automatically enters the routing address if it is listed Select the Direct to PLC option Press lt Enter gt to find the available nodes on the network When the Communication Parameters window appears See Figure 1 8 at the bottom of the screen observe the following options and enter the information requested The information provided is from the previous example Utility Offline Combined Transfer Tools Quit OnT ine Select Program Direct to PLC Tab moues between the Menu Bar and the Editing Screen ALT H provides help on the menu item selected by the cursor Select Program loads a PLC specific program enuironment and program files Communication Parameters ADDRESS Protocol Routing Address Device Figure 1 8 Communication Parameters Window Electrician Training Skill Development Guide DUTY K PLC Modicon 13 K 01b Connect and Operate Programmer 1 ADDRESS 01 from example This is the address of the processo
5. ave difficulty answering a question review the Skill Development Guide or ask your Trainer for assistance 1 When loading a program on the P190 programmer the first tape you should use is the a Program Loader Tape b Tape Loader Tape c Programmer Tape d Backup Tape 23 If the machine program you are looking for is not listed from the Select Program screen in the Combined menu you should find the remote address and enter what menu to proceed a OFFLINE b Utilities c ONLINE d Routing 3 When using the Routing procedure you should write the number farthest away from your programmer when encountering a bridge a b True False Electrician Training Skill Development Guide DUTY K PLC Modicon 15 K 01b Connect and Operate Programmer 4 When entering a remote address the MEMORY PROTECT KEYLOCK should be in the ON position a True b False 9 The machine program is accessed and communication is established between the programmer and the PLC when what screen displays a Segment Status Display b Elements Edit Screen c Main Menu d Transferring Configuration to Panel prompt Answers 1 b 2 c 3 b 4 a5 a Next Step If you are ready to demonstrate the task now ask your Evaluator or Trainer to schedule the Skill Check However if you need to practice some of the steps first continue to the next section Electrician Training DUTY K PLC Modicon Skill Development Gui
6. de 16 K 01b Connect and Operate Programmer Practice The following practice will help prepare you for the Skill Check Ask your Trainer to set up the practice for you After you complete a practice ask your Trainer to check your work Practice 1 Locate all PLCs in the area Observe all Modicon PLC types 184 384 584 884 and 984 and learn where the data communication cable plugs into each processor Identify all the interfaces between the 984 and 184 384 484 and 584 Determine which processors are already connected to a programmer and which ones will need programmers supplied Practice Objective 1 You should have become familiar with the location of all PLC units in the area so that when called upon you will know if a programmer is required You should also have become familiar with the various types of Modicon PLCs in the area including the 184 384 584 884 and 984 You should be able to identify all the interfaces between the 984 and 184 384 484 and 584 Practice 2 Practice connecting and operating both types of programmers Connect a P190 on the job site with a Journeyman s supervision at a location in which a programmer is not already connected Attempt to connect the P190 to all PLC units so that you will be familiar with the communication cable required for each unit and the hook up locations for each unit Operate the programmer and verify that it is communicating with the processor Practice Objective 2 You s
7. g each task standard You must demonstrate safe work practices during the Skill Check Contact your Evaluator whenever you are ready for the Skill Check Electrician Training DUTY K PLC Modicon Skill Development Guide 2 K 01b Connect and Operate Programmer Skill Objective Upon notification of any task requiring communication with a PLC connect and operate either the P190 or P230 programmer Task Standards 1 Connection of the programmer results in communication between the programmer and the required PLC Communication is established when the unit number of the PLC is entered and the programmer prompt allows you to continue without an error message 2 Operation of the programmer results in your having access to the required machine program Access to the program is established when the Segment Status screen is displayed 3 You should be able to identify all the interfaces between the 984 and 184 384 484 and 584 Electrician Training DUTY K PLC Modicon Skill Development Guide 3 K 01b Connect and Operate Programmer What You Will Need This section contains the safety information tools and resources you will need before connecting and operating a programmer SAFETY FIRST DON T TAKE o Follow all Caterpillar Facility Safety Standards when performing this task in the plant o You will perform this task online Perform the steps carefully mistakes could result in injury to personnel or damage to the e
8. hould have been able to identify the different types of cables required to hook a P190 up to all PLCs Verify your connections by accessing the PLC program Be sure to leave the MEMORY PROTECT KEYLOCK in the ON position Electrician Training DUTY K PLC Modicon Skill Development Guide 17 K 01b Connect and Operate Programmer Practice 3 Identify a machine s processor that is not accessible from the programmer from which you are working Note the address for this machine s processor and call up this program from the ONLINE menu in MODSOFT on a P230 programmer Practice Objective 3 You should have been able to locate a remote address in the online mode for accessing machine programs Practice using the Routing process When the Segment Status Screen is displayed you have successfully communicated with the PLC Next Step Continue to practice until you are ready for the Skill Check When you are ready to demonstrate the task ask your Evaluator or Trainer to schedule the Skill Check Electrician Training DUTY K PLC Modicon Skill Development Guide 18 K 01b Connect and Operate Programmer
9. mmer o Ifthe name you want is not listed on the Combined Select Program menu then follow the routing procedure to communicate with a processor in a remote address Locate the processor address on the Modbus Plus Data Highway Chart See Figure 1 7 Bridge C Bridge Mux Node 9 1 Cl Controller Figure 1 7 Example of the Modbus Plus Data Highway Chart o Using the example in Figure 1 7 the desired processor you would want to find is Processor A communicating from Programmer xxx o Write the node number of the processor from Modbus Plus with a decimal to the left of the number Processor A is located at Port 1 of the bridge mux so the address is 1 from the example in Figure 1 7 o Trace from the processor back to your programmer o If the processor is connected to a bridge mux then include its number and the port number that the processor is connected The port number would be the processor number 1 o Enter the bridge mux number next At this point your address consists of 9 1 o Ifyou come to a bridge write the node number from side of bridge closest to programmer From the example the first bridge you encounter has the node 5 closest to the P230 Your address should now read 5 9 1 Electrician Training DUTY K PLC Modicon Skill Development Guide 12 K 01b Connect and Operate Programmer o The second bridge you encounter in the example has a 12
10. ogram loads a PLC specific program environment and program files Figure 1 5 MODSOFT Default Screen o The MODSOFT Main Menu screen should now be displayed See Figure1 6 Electrician Training DUTY K PLC Modicon Skill Development Guide 10 K 01b Connect and Operate Programmer Utility Commands Editors Config ASCII Save Quit Seg SFC Networks PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED Press lt ENTER gt to view the selected segment Figure 1 6 MODSOFT Main Menu with Menu Options 6 Access the machine program o Select COMBINED from the menu o Select the program name from the list of names provided o Ifthe program is listed then move the cursor to the program name and press lt Enter gt Proceed to step 8 to verify that communication is established o Ifthe program is not listed then go to the routing procedure in Step 7 7 Perform the routing process WARNING The routing procedure is dangerous if you enter the wrong address doing so could result in a wreck The MEMORY PROTECT KEYLOCK should be on Electrician Training DUTY K PLC Modicon Skill Development Guide 11 K 01b Connect and Operate Progra
11. quipment o Use caution when working around the PLC high voltage is present on the inside of the PLC cabinet door and near the I O chassis o Avoid having liquids near the programmer keyboard o P190 programmer Typically used with the 184 384 484 584 884 and 984 processors o P230 programmer Used with the 984 processors and the 184 384 484 584 and 884 processors in the P190 emulator mode o PLC communication cable o Tape Loader Tape and Program Loader Tape P190 only o Modicon Bus Plus Used with all processors Electrician Training DUTY K PLC Modicon Skill Development Guide 4 K 01b Connect and Operate Programmer Basic Help Keys available on programmer software o Modsoft Programmer User s Manual GM MSFT 001 Rev F o Ladder Diagram printout o Modbus Plus Data Highway Chart o Machine Print Electrician Training DUTY K PLC Modicon Skill Development Guide 5 K 01b Connect and Operate Programmer Task Steps Connect and Operate Programmer P190 PROGRAMMER 1 Connect the P190 programmer o You will need a data cord that will hook up with the type of processor you will be using o Locate the data cords o Connect the proper data communication cable to the programmer and the PLC Supply power for the P190 programmer unit See Figure 1 1 584 PLC Front View MODBUS PORT 2 MEMORY PROTECT KEYLOCK p90 m PROGRAMMER
12. r you are contacting 2 PROTOCOL MODBUS This is the typical protocol selection used 3 ROUTING ADDRESS 12 05 09 00 Notice that the last two digits are 00 and not 01 Enter this address twice 4 DEVICE Enter nothing here f Communication is being established when Transferring Configuration to Panel appears on the screen 8 Verify that you have accessed the program o When the Segment Status Display screen is displayed you have accessed the machine program See Figure 1 9 Utility Commands Editors Config ASCII Save Quit Seg SFC Networks PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED PROGRAMMED Press lt ENTER gt to view the selected segment Figure 1 9 Segment Status Display Screen Electrician Training DUTY K PLC Modicon Skill Development Guide 14 K 01b Connect and Operate Programmer Concept Check Connect and Operate Programmer Answer the following questions to check your understanding of connecting and operating a programmer Circle the correct answer in each question Then compare your responses with the answers at the bottom of this page Some of the questions may have more than one correct answer If you h
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