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We will use Modbus TCP Ethernet to connect and program the XGB PLC to the Machine Simulator
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Easy Transfer line. The Machine Simulator Easy PLC software suite is a comprehensive package with HMI, PLC
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and Machine Simulator software. It features a Machine Simulator, or MS, that allows virtual communication with many programmable
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logic controllers, or PLCs, in a 3D world with real-time graphics and physical properties
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Our PLC programming example will follow the five steps to PLC program development
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We will use the Simulator's pre-built Easy Transfer line machine to learn PLC programming
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We will develop ladder logic, connect via Modbus TCP, and test our program using the
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free XG5000 PLC programming software and XGB PLC. Let's begin. Detailed information contained in this video can be found at accautomation.ca
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A link has been put in the description below. If you have not watched the other videos yet, there will be links in the description below
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that will start you with video 1. There will be links to the rest of the videos in this series as well
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Step 1. Define the Task The first step of PLC programming development
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is to define the task to determine what must be done. The Machine Simulator or Easy PLC software suite contains the Easy Transfer line example
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in the Machine Simulator. This is just one of many machines with the software so you can learn and develop your
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PLC programming skills. Launch Machine Simulator 4 and access the Machine's menu
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The 01 Easy Transfer Line option will be seen on the pre-configured machines
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We will program this machine. As you move your mouse around the machine picture, you can select the icon on the top
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right side. This will show you the machine description. The photocell detects high boxes and sends them to the second conveyor, using the pneumatic pusher
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Conveyors are activated with digital output 1. They will also include the panel control
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The green start light will be on when the system is ready to run
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When the start is pressed, the stop light will be on to indicate how the system is to
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be stopped. Pressing the emergency stop button will turn off both lights and stop the sequence
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The Machine Simulator has a demo mode for this built-in machine. Select Close from the machine description window
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Select the demo mode for the Easy Transfer Line. This mode shows you the operation so you can better understand what needs to be accomplished
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Press the control buttons in the simulator to operate the machine. Take some time to explore the 3D virtual environment using the navigation menu at the top of the window
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The default selection allows you to move freely without colliding into any components, while
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the first-person and third-person modes provide different perspectives. Exploring the demo mode will help you understand how the Easy Transfer Line operates
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This will help you develop the PLC program to control the machine's actions effectively
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Once we understand the task and have familiarized ourselves with the easy transfer operation
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we can proceed to the next step in developing the XGB PLC program using the XG5000 programming software
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By following these steps and gaining hands-on experience with the Machine Simulator Learning
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Suite and the XGB, you'll be well on your way to mastering PLC programming and applying
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your knowledge to real-world scenarios. So let's continue our journey and move on to the next step in the process
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Step 2 – Define the Inputs and Outputs The written version specifies that we will require 4 digital outputs and 5 digital inputs
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for our Easy Transfer Line. Inputs are signals or data received by the PLC, while outputs are signals or data sent
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by the PLC to control external devices. By understanding the inputs and outputs, you can develop a program that reads the status
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of the inputs and activates the appropriate outputs. While still in demo mode, select the UIO to display the inputs and outputs required for
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this machine. These PLC IOs are for the machine's physical running and do not include the additional
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bits or registers that may be required for programming. This will show you the digital outputs on the left side of the screen and the digital
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inputs on the right side. If you are unsure what an output or input is doing, start the Easy Transfer Line machine
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in Start Mode. Select View I.O. along the top of the Easy Transfer Line Machine Simulator window
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You can manually run the Easy Transfer Line without any control or PLC connection
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Select the outputs on the left to turn on and monitor the inputs on the right
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Defining the inputs and output establishes the communication between the PLC and external devices
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This allows the PLC program to monitor the inputs and continuously decide based on their status
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The program can then activate the appropriate outputs to control the Easy Transfer Line operation
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It is important to note that PLC programs operate cyclically, meaning they continuously
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read the inputs and set the outputs. This ensures that the program is responsive to system changes and can adapt accordingly
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By understanding the inputs and outputs and their relationship to the overall system
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you can develop a logical sequence of operation for the Easy Transfer Line PLC program
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This is our next step. Step 3. Develop the Logical Sequence of Operation
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A flowchart or sequence table is used to understand the processes that need to be controlled thoroughly
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It must also answer questions like the following. What happens when electrical power and or pneumatic air is lost
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What happens when inputs and output devices fail? Do we need redundancy
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Knowing all these answers up front is vital in developing the PLC program
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This is the step where you can save a lot of work by understanding everything about the operation
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It will help prevent you from continuously rewriting the PLC program logic
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Here is a sequence table for the Easy Transfer Line. You read the input conditions and then look to the right hand side for the outputs that
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will be set. The following line will then look for the input conditions again
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As a programmer, it is vital to have a comprehensive understanding of the machine's sequence
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and operation before starting the programming process. This can be achieved by asking questions or reviewing existing documentation to ensure
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a clear understanding of the logical steps involved. This step sets the foundation for the subsequent development of the XGB PLC program which will
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be covered in the next section. Step 4. Develop the PLC Program
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Writing the ladder logic code for the PLC example will be the next step in our program development
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Start the XG5000 programming software and start a new project. This can be done by selecting the new project under the Project tab on the main menu, using
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the shortcut CTRL-N, or the New Project icon on the main ribbon
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We will name the project and select XGB PLC for our program
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Comments can be added for future reference
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Select OK. Our scanned program will be displayed. Under the LS PLC that we selected the program, select Global, Direct Variables
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We can now enter the variables for our machine simulator easy transfer line
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To aid in setting the variables, you can see that once an address is entered, we can
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highlight it, click and drag to populate the other variables below it
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The Modbus addresses that we will use will match the settings for the communication to
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the XGB PLC. Here is the map. These addresses will be written when we set up the communication and Modbus server
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As we program, remember to save your work often. Select the Scan Program tab
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We can now create our ladder logic program using the inputs and output icons on the menu bar
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As we enter the instructions, we can select the variables. Starting and stopping the conveyor is done with the set and reset instruction
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When the emergency stop is activated, both lights are turned off. This indicates to the operator that the emergency stop must be reset
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When the photocell sees the high boxes, this activates the pneumatic pusher
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When the pusher reaches the extended position, it will reset the pneumatic pusher
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An end statement will indicate that this is where the program ends and to repeat the scan
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Save your program. It is important to always save your program during programming
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Double click on the internal FENet or Fast Ethernet network port. This will call up the standard settings for the port
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Under the Basic tab, we can assign the IP address and settings to work with our network
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Select the Smart Server for the server mode. This will include the Modbus server
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Select the Modbus Settings button. Change the default Modbus address settings to those we have selected for our program
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Select OK. We can now connect and transfer the program to our XGB PLC
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If you are unsure of the connection to the XGB, we can use the network browsing to discover
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the IP address. Once the PLC is discovered on our network, we can select OK
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You can now select OK or connect from the Connection Settings window
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You can also use the Connect from the main menu. The bottom bar of the XG5000 programming software will turn green indicating that the PLC is
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connected and in Run mode. Select Write from the Online option in the main menu
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You will then stop the PLC and transfer the program and settings like Modbus into the controller
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We now have the PLC ready to test. Step 5. Test the program
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To ensure the functionality and accuracy of the XG PLC practice program for an EZ-Transfer
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line machine, it is essential to test the program thoroughly. Utilizing Machine Simulator or MS is an effective way
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Using the MS you can simulate the operation of the EZ-Transfer line machine without needing
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physical hardware, minimizing the risk of damage during the testing phase. You will use Modbus TCP on our LS XGB PLC to communicate with the EZ-PLC machine simulator
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Call up the EZ-Transfer line machine simulator in Start mode. The status of the machine simulator will be at the bottom of the screen
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Currently we have no PLC connected. Select I0 Drivers on the top middle of the screen
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The Machine Simulator I0 number will be displayed. Here we select more I0 than is required for the EZ-Transfer line machine
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The EZ-PLC driver is selected by default. Under the driver pulldown, select Modbus driver
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This driver will communicate Modbus TCP or Ethernet in Modbus RTU serial
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Select the configure button. We can now enter the information for our Modbus driver
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Select TCP IP. This means that the Ethernet port on the computer will communicate with the XGB PLC
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The digital inputs from MS to the XGB PLC will be MX3216 to MX3219
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Digital outputs from the MS to the XGB PLC will be MX6416 to MX6420
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Select the OK button. You will now see the inputs and outputs specified for the Modbus driver
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You can now manually assign the driver outputs to the PLC inputs and then the driver inputs
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to the PLC outputs. However, the automatic assignment works well and will save you time
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Select automatic assignment from the driver option in the main menu. This will automatically assign the PLC simulator I0 to the machine simulator I0
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Select Start Driver and exit from the main menu. On the bottom left side of the window, the driver communicates with the XGB PLC with
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a green light. Select View I0 to see the machine simulator's input and output status
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Ensure that the XGB PLC is in Run mode. We can now operate the Easy Transfer Line machine
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The inputs and outputs of the MS will correspond to the PLC controller
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Using Machine Simulator or MS to test the program will ensure that our program works
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Troubleshooting is quickly done without any damage to physical hardware. This testing phase is critical in ensuring the safe and reliable operation of our Easy
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Transfer Line machine. You can practice your modification and debug by modifying the Easy Transfer Line machine
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operation in the following way. Add a counter for the large box conveyor to show the total
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The control panel will need a reset button for this count. Calculate the rate of these boxes and boxes per hour
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Let me know how you made out in the comments below. If you enjoyed this video, please hit the like button below
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If you have any questions about the video, please leave a comment below and I'll do my best to answer it
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If you want more information about us, or you want our free ebooks on numbering systems
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or robust data logging, please click on the link in the description below to get it
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Thanks so much for watching. I'll see you next time. Stay safe
