3800 tt4 Fundmtl

Technical Training
Turbotronic™ 4 Fundamentals
Student Workbook
Course No. 3800
Student Workbook
3800
Course No. 3800
Technical Training
Technical Training
Student Workbook
Course No. 3800
Solar Turbines Incorporated

P.O. Box 85376
San Diego, CA 92186–5376
Solar, Saturn, Centaur, Mars, Mercury, Taurus, Titan, SoLoNOx, and Turbotronic are
trademarks of Solar Turbines Incorporated. Cat and Caterpillar are trademarks of Caterpillar Inc.
Specifications subject to change without notice. Printed in the U.S.A.
PUBLICATION NUMBER: TR3800

PROPRIETARY NOTICE
The contents of this technical training instructions manual are proprietary
data of Solar Turbines Incorporated, a subsidiary of Caterpillar Inc. This
material is protected under U.S. copyright law. All reproduction is prohibited
without the express written approval of Solar Turbines Incorporated.
© 2004 Solar Turbines Incorporated. All rights reserved.

Solar Technical Training CONTENTS
CONTENTS
Chapter Page
LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
1 TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC

4 CONTROL SYSTEM
OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1.1
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1.2
METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1.2
CONTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1.2
PREREQUISITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 1.2
2 TT4 CHAPTER 1, LESSON 1 CONTROL SYSTEM CONCEPTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.1
OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.1
CONTROL SYSTEM PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.2
THE FIVE MAIN CONTROL BLOCKS . . . . . . . . . . . . . . . . . . . . . . . .. . 2.2
INFORMATION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.3
INPUT MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.3
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.3
OUTPUT MODULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.4
DECISION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.4
INFORMATION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.5
SIGNAL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.6
DISCRETE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.6
ANALOG DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.7
RTDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.7
PRESSURE TRANSMITTERS . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.9
LEVEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.10
PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.11
MAGNETIC PICKUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.12
INPUT MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.13
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.15
OUTPUT MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.17
DECISION DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.18
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.19
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.20
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.21
PERIPHERAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.23
BACKUP RELAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.24
COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.26
HUMAN MACHINE INTERFACE . . . . . . . . . . . . . . . . . . . . . . . .. . 2.28
PROGRAMMING TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . .. . 2.29
3800 © 2004 Solar Turbines Incorporated. All rights reserved. v

CONTENTS Solar Technical Training
Chapter Page
3 TT4 CHAPTER 1 LESSON 2 CONTROL SYSTEM CONFIGURATION

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.1
CONTROL SYSTEM COMPONENTS: . . . . . . . . . . . . . . . . . . . . . . . .. . 3.3
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.3
I/O MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.3
VIBRATION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.3
GENERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.3
BACKUP PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.4
OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.4
FIRE DETECTION & SUPPRESSION SYSTEM . . . . . . . . . . . . . . .. . 3.4
CONTROL SYSTEM CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . .. . 3.5
ON-SKID CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.5
OFF-SKID CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .. . 3.7
INTERCONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.8
FIELD INSTRUMENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3.8
COMMUNICATIONS OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . .. . 3.9
4 TT4 CHAPTER 1, LESSON 3 LOGIX5000 CONTROLLER

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 4.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 4.1
1756-SERIES CONTROLLOGIX CHASSIS . . . . . . . . . . . . . . . . . .. . 4.2
POWER SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 4.3
CONTROLLOGIX CONTROLLER . . . . . . . . . . . . . . . . . . . . . . .. . 4.5
5 TT4 CHAPTER 1, LESSON 4 I/O MODULES

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 5.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 5.1
DISCRETE INPUT MODULES . . . . . . . . . . . . . . . . . . . . . . . . .. . 5.2
DISCRETE OUTPUT MODULES . . . . . . . . . . . . . . . . . . . . . . . .. . 5.5
ANALOG INPUT MODULE 1794-IE8. . . . . . . . . . . . . . . . . . . . . .. . 5.7
RTD INPUT MODULE 1794-IR8 . . . . . . . . . . . . . . . . . . . . . . . .. . 5.9
THERMOCOUPLE / RTD MODULE 1794-IRT8 . . . . . . . . . . . . . . . .. . 5.11
FREQUENCY INPUT MODULE 1794-IJ2 . . . . . . . . . . . . . . . . . . .. . 5.13
ANALOG OUTPUT MODULE 1794-OE4 . . . . . . . . . . . . . . . . . . .. . 5.15
6 TT4 CHAPTER 1, LESSON 5 COMMUNICATION NETWORKS & DEVICES

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6.1
RS-232 SERIAL COMMUNICATION . . . . . . . . . . . . . . . . . . . . . .. . 6.3
CONTROLNET COMMUNICATION . . . . . . . . . . . . . . . . . . . . . .. . 6.4
ETHERNET/IP COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . .. . 6.8
DATA HIGHWAY+/REMOTE I/O COMMUNICATION . . . . . . . . . . . . .. . 6.12
CONFIGURATION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . .. . 6.12
vi © 2004 Solar Turbines Incorporated. All rights reserved. 3800

Chapter Page
7 TT4 CHAPTER 1, LESSON 6 OPERATOR INTERFACE DEVICES

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.1
TURBINE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.3
TT4000 DISPLAY AND MONITORING SYSTEM . . . . . . . . . . . . . . .. . 7.5
TT4000 COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.6
TT4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.6
STANDARD DISPLAY SCREENS: . . . . . . . . . . . . . . . . . . . . . . .. . 7.9
OPTIONAL DISPLAY SCREENS: . . . . . . . . . . . . . . . . . . . . . . .. . 7.9
TT4000-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.11
COMPRESSOR SCREENS: . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.12
GENERATOR SCREENS: . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.12
TT4000 REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 7.13
8 TT4 CHAPTER 1, LESSON 7 SPECIAL FUNCTION DEVICES

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.1
COMBINATION GENERATOR CONTROL MODULE . . . . . . . . . . . . . . . .. . 8.3
INPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.4
OUTPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.5
COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.5
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.6
FIRE DETECTION & SUPPRESSION SYSTEM . . . . . . . . . . . . . . . . . . .. . 8.7
PRINCIPALS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.8
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.9
CONTROLS AND INDICATORS ON THE LOCAL CONTROL UNIT
INCLUDE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.10
BENTLY-NEVADA 1701 VIBRATION MONITORING SYSTEM . . . . . . . . . . .. . 8.11
TERMINAL BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.12
MONITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.13
TWO TYPES OF MONITORS ARE CURRENTLY AVAILABLE: . . . . . . .. . 8.13
I/O MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.14
KEYPHASOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.14
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.14
COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 8.15
9 TT4 CHAPTER 2 INTRODUCTION TO TT4 PROGRAMMING

OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 9.1
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 9.2
METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 9.2
CONTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 9.2
3800 © 2004 Solar Turbines Incorporated. All rights reserved. vii

Chapter Page
10 TT4 CHAPTER 2, LESSON 1 BASIC INSTRUCTION SET

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
BIT INSTRUCTIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
11 TT4 MODULE 2, LESSON 2 INTRODUCTION TO SOLAR LOGIC

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 TT4 CHAPTER 2, LESSON 3 LOADING A PROGRAM TO

THE PROGRAMMING TERMINAL
OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 12.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 12.1
LOADING THE PROJECT: . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 12.5
UPDATING THE REVISION: . . . . . . . . . . . . . . . . . . . . . . . . . .. . 12.8
13 TT4 CHAPTER 2, LESSON 4 OFF-LINE PROGRAM MONITORING

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 13.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 13.1
OPENING A CONTROLLER PROGRAM: . . . . . . . . . . . . . . . . . . .. . 13.2
RSLOGIX 5000 DISPLAY: . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 13.6
HELP: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 13.11
14 TT4 CHAPTER 2, LESSON 5 RSLOGIX5000 FAMILIARIZATION

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Configuring Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
15 TT4 CHAPTER 2, LESSON 6 SOLAR PROJECT ORGANIZATION

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.1
INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.1
Project Elements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.2
Program Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.4
Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.5
Data Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.8
Pre-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.8
Module-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.9
User-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.10
Tag Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.13
Alias Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.13
Tag Naming Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.16
Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 15.18
viii © 2004 Solar Turbines Incorporated. All rights reserved. 3800

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16 TT4 CHAPTER 2, LESSON 7 CONTROL LOGIC FAMILIARIZATION

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.1
COURSE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.2
PROGRAM PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.2
MAIN ROUTINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.3
SEQUENCE OF EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.3
ROUTINE PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.4
EDITING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.5
STUDENT ACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.8
RUNG FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.9
HARDWARE-SOFTWARE INTERFACE . . . . . . . . . . . . . . . . . . . .. . 16.11
LUBE PROGRAM EXERCISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.14
FUEL PROGRAM EXERCISES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.15
STUDENT ACTIVITY ANSWERS . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 16.17
LUBE PROGRAM EXERCISE ANSWERS . . . . . . . . . . . . . . . . . .. . 16.19
FUEL PROGRAM EXERCISE ANSWERS . . . . . . . . . . . . . . . . . . . . . .. . 16.21
17 TT4 CHAPTER 2 LESSON 8 ANALOG DEVICE PROGRAMMING

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 17.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 17.1
SCALING OF ANALOGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 17.2
SCALING ANALOGS IN RSLogix . . . . . . . . . . . . . . . . . . . . . . .. . 17.5
ANALOG DATA ORGANIZATION . . . . . . . . . . . . . . . . . . . . . . . .. . 17.9
18 TT4 CHAPTER 2 LESSON 9 FUNCTION BLOCK OVERVIEW

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
19 TT4 CHAPTER 2, LESSON 10 RSLOGIX5000 ONLINE FUNCTIONS

OBJECTIVES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.1
CONFIGURING COMMUNICATION DEVICES . . . . . . . . . . . . . . . .. . 19.2
RS232 SERIAL PORT DRIVER. . . . . . . . . . . . . . . . . . . . . . . . .. . 19.3
CONTROLNET DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.5
GOING ONLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.8
DOWNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.11
RUN MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.14
UPLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.16
FORCING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.19
LOCKING THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . .. . 19.23
INTRODUCTION TO ONLINE EDITING . . . . . . . . . . . . . . . . . . . .. . 19.25
3800 © 2004 Solar Turbines Incorporated. All rights reserved. ix

LIST OF ILLUSTRATIONS
Figure Page
2.1 Control System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Information Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3 RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4 Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Pressure Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.7 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.8 Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.9 Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.10 Flex I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
2.11 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.12 ControlLogix 5000-series Controller . . . . . . . . . . . . . . . . . . . . . . . 2.16
2.13 Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
2.15 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
2.16 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.17 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
2.18 Backup Relay System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.19 Backup Relay System Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
2.20 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2.21 Communication Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.22 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.23 Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
3.1 Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2 On-Skid Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3 Off-Skid Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
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4.1 1756-series Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 ControlLogix Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3 ControlLogix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4 Standard Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.5 External High-Capacity Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.6 RS-232 Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
5.1 1794-IB16 Discrete Input Module. . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.2 1794-OB16 Discrete Output Module . . . . . . . . . . . . . . . . . . . . . . . 5.6
5.3 1794-IE8 Analog Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
5.4 1794-IR8 RTD Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 1794-IRT8 Fast Millivolt Input Module . . . . . . . . . . . . . . . . . . . . . . 5.11
5.6 1794-IJ2 Speed Input Module. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.7 1794-OE4 Analog Output Module . . . . . . . . . . . . . . . . . . . . . . . . 5.15
6.1 ControlLogix Chassis with Communication Modules . . . . . . . . . . . . . . 6.2
6.2 RS-232 Serial Port and Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 1756-CNBR ControlNet Interface Module . . . . . . . . . . . . . . . . . . . . 6.4
6.4 ControlNet Node Address Switches . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5 1756-CNBT EtherNet/IP Interface Module . . . . . . . . . . . . . . . . . . . . 6.9
6.6 1756-ENBT Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6.7 1756-DHRIO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
6.8 DHRIO Module Configuration Switches . . . . . . . . . . . . . . . . . . . . . 6.13
7.1 Turbine Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 TT4000 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.3 TT4000 Panel-mounted VDU . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.4 TT4000 Desktop Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.5 TT4000 Operation Summary Screen . . . . . . . . . . . . . . . . . . . . . . . 7.10
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7.6 TT4000S On-skid VDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.7 TT4000S Engine Summary Screen . . . . . . . . . . . . . . . . . . . . . . . 7.12
8.1 Combination Generator Control Module . . . . . . . . . . . . . . . . . . . . . 8.3
8.2 Fire Detection & Suppression Local Control Unit . . . . . . . . . . . . . . . . 8.7
8.3 Local Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.4 1701 Vibration Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . 8.11
10.1 XIC Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.2 XIO Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.3 OTE Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.4 Combining Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.5 Symbolic Logic AND Example . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.6 Branched Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.7 Symbolic Logic OR Example . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
10.8 Complex Ladder Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.9 Complex Symbolic Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.10 OTL Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
10.11 OTL Symbolic Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
10.12 OTU Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
10.13 Combining OTL and OTU Instructions . . . . . . . . . . . . . . . . . . . . . . 10.7
10.14 Latch/Unlatch Symbolic Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
10.15 TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
10.16 TON Timer Element References . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
10.17 TOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
10.18 TOF Timer Element References . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
10.19 RTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
10.20 RTO Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
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10.21 RTO Timer Element Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
10.22 CTU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
10.23 CTU Counter Element References . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.24 CTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.25 CTD Counter Element References . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.26 ControlLogix Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
10.27 EQU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.28 EQU in Function Block Routine . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.29 GEQ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
10.30 LEQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
10.31 CMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
10.32 ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
10.33 SUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
10.34 MUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
10.35 DIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10.36 CPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10.37 Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
10.38 Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
10.39 Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
10.40 Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
10.41 Step 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
10.42 Step 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
10.43 Step 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
10.44 Step 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
10.45 Step 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
10.46 Step 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
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10.47 Step 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
10.48 Step 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49
10.49 Step 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
10.50 Step 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
10.51 Step 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
11.1 Oil Tank Heater Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11.2 Program Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11.3 Function Block Routine Listing . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
11.4 Function Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
11.5 MUL Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
12.1 Project CD Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
12.2 Contents of Project CD Main Folder . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.3 ACD and L5K Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.4 Jobs Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
12.5 TT4000 Project Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5
12.6 Distribute TT4000 Job Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6
12.7 Field TT4000 Distribution Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
12.8 Roll & Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12.9 Selecting Project For Revision . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
12.10 Selecting Files To Revise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
12.11 Selecting New Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12.12 New Revisions In Jobs Directory . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
13.1 Opening A Project In RSLogix . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
13.2 Selecting ACD or L5K File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13.3 Importing .L5K File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
13.4 Saving Project File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
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13.5 RSLogix Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
13.6 Available Toolbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
13.7 Standard Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
13.8 Online Toolbars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
13.9 Path Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8
13.10 New Component Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
13.11 Language Element Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
13.12 Ladder Edit Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
13.13 Bookmark Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
13.14 Instruction Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
14.1 Window Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
14.2 Modifying Fonts & Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
14.3 Ladder Display Customization . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
14.4 Tag Display Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
14.5 Logic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6
14.6 Edit/Monitor Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7
14.7 Results Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8
14.8 Search Task Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
14.9 Find Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.9
14.10 Find All Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10
14.11 Find Next Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
14.12 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
14.13 Go To Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
14.14 Go To Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
14.15 Cross Reference Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
14.16 Edit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
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14.17 Add Ladder Element Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
14.18 Routine Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
14.19 Controller Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
14.20 Access to Controller Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
15.1 Controller Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
15.2 Program Execution Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
15.3 Routines Within The Lube Program . . . . . . . . . . . . . . . . . . . . . . . 15.5
15.4 Designating The Main Routine . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
15.5 Lube Main Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
15.6 Module-Defined Data Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9
15.7 User-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
15.8 Program Response Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
15.9 Alias and Base Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
15.10 Aliasing of Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
15.11 Analog Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
15.12 HMI Analog Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.19
15.13 Available Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
16.1 Lube Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16.2 Lube Main Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16.3 _010_Tank_Level_Sw_Lo_000 . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4
16.4 S388_1 Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
16.5 Lube Tag Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16.6 Tag Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16.7 Tag Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
16.8 Rung Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
16.9 Base Tag Derivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.11
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Figure Page
16.10 Node 08. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.12
17.1 Analog Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
17.2 Analog Equation Using Counts . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
17.3 Simplified Analog Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
17.4 Transmitter Scaling and Fail Detection Logic . . . . . . . . . . . . . . . . . . 17.5
17.5 Header Pressure Val Reference . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
17.6 Header Pressure UDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.9
17.7 Aliasing of Analogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
17.8 HMI Analog Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.10
18.1 Typical Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
18.2 Function Block Instruction Menu . . . . . . . . . . . . . . . . . . . . . . . . . 18.2
18.3 ICON and OCON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18.4 Tag Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18.5 Instruction Parameters Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . 18.4
18.6 Tag Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
19.1 RSLinx Driver Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
19.2 Selecting RS232 Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4
19.3 Autoconfigure RS232 Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5
19.4 Selecting ControlNet Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
19.5 ControlNet Driver Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
19.6 List of Configured Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
19.7 Communications Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8
19.8 Going Online RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8
19.9 Going Online ControlNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9
19.10 Select Recent Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
19.11 Connected To Go Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.12
xviii © 2004 Solar Turbines Incorporated. All rights reserved. 3800

Figure Page
19.12 Download Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.12
19.13 Downloading To The Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 19.13
19.14 Controller In Program Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.14
19.15 Controller In Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.15
19.16 Upload Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.16
19.17 Upload Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.17
19.18 Forcing Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.19
19.19 Creating A Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.20
19.20 Enabling Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.21
19.21 Forces Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.21
19.22 Locking the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.24
19.23 Starting A Rung Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.25
19.24 Accept Pending Program Edit. . . . . . . . . . . . . . . . . . . . . . . . . . . 19.26
19.25 Test Program Edits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.26
19.26 Assemble Program Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.27
19.27 Completed Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.27
3800 © 2004 Solar Turbines Incorporated. All rights reserved. xix

LIST OF TABLES
Table Page
2.1 Information Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.2 Decision Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

5.1 Input Channel Connections For IB16 Discrete Input Module . . . . . . 5.4
5.2 Output Channel Connections For OB16 Discrete Output Module . . . . 5.6
5.3 Input Signal and Channel Commons . . . . . . . . . . . . . . . . . . . 5.8
5.4 RTD Connections for TB3 or TB3S Terminal Bases . . . . . . . . . . . 5.9
5.5 RTD Connections for TB3T Terminal Base . . . . . . . . . . . . . . . . 5.10

5.6 Thermocouple and RTD Connections . . . . . . . . . . . . . . . . . . . 5.12
5.7 Table 7 Connections for 1794-IJ2 Speed Input Module . . . . . . . . . 5.13
5.8 Connections for TB3 or TB3S Terminal Bases . . . . . . . . . . . . . . 5.16

5.9 Connections for TBN or TBNF Terminal Bases . . . . . . . . . . . . . . 5.16
6.1 Diagnostic Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

6.2 ControlNet Channel Status Indicator Diagnostics . . . . . . . . . . . . 6.7
6.3 NET Status Indicator Codes . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6.4 Link Status Indicator Codes . . . . . . . . . . . . . . . . . . . . . . . . 6.11

6.5 OK Status Indicator Codes . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6.6 Diagnostic Codes - DH+ . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
6.7 Diagnostic Codes - RIO . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15

6.8 OK Indicator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
6.9 Channel Status Indicator Codes . . . . . . . . . . . . . . . . . . . . . . 6.16

10.1 Allowable Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
10.2 Compare Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
10.3 CMP Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

10.4 Compute/Math Instructions. . . . . . . . . . . . . . . . . . . . . . . . . 10.18
15.1 Pre-Defined Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
3800 © 2004 Solar Turbines Incorporated. All rights reserved. xxi

Table Page
15.2 Tag Scope Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
15.3 Tag Prefixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17

15.4 Tag Suffixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
16.1 Tag Database Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
16.2 Routine Function Summary . . . . . . . . . . . . . . . . . . . . . . . . 16.10

16.3 Routine Function Summary Student Activity . . . . . . . . . . . . . . . 16.10
16.4 I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.13

16.5 I/O Mapping Student Activity . . . . . . . . . . . . . . . . . . . . . . . . 16.13
16.6 Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.17
16.7 Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.18

16.8 Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.18
17.1 Analog Scaling Student Activity . . . . . . . . . . . . . . . . . . . . . . 17.5
17.2 Header_Pressure.Val. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.7

17.3 LIM Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8
xxii © 2004 Solar Turbines Incorporated. All rights reserved. 3800

Solar Technical Training TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC 4 CONTROL SYSTEM
TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC

4 CONTROL SYSTEM
OBJECTIVES
Upon completion of this chapter the student will be
able to:
1. State the function of the control system.
2. Identify and describe the blocks in a control

system block diagram.
3. List and state the function of peripherals
commonly installed in Solar control systems.
4. Demonstrate understanding of Solars standard
system configuration for on-skid and off-skid
Turbotronic controls.
5. Demonstrate understanding of the functional

characteristics of the Logix5000 controller and
the input and output modules used in Solar
applications.
6. Demonstrate understanding of the

communication devices and protocols utilized in
Solar system applications.
7. Demonstrate understanding of the functional

characteristics of the operator interface devices
used in the Turbotronic 4 control system.
3800 © 2004 Solar Turbines Incorporated. All rights reserved. 1.1

TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC 4 CONTROL SYSTEM Solar Technical Training
8. Demonstrate understanding of the function and

principles of operation of the special function
devices (VibrationMonitoring System. Fire
Detection/Suppression System and Combination
Generator Control Module) included on a typical
Solar package.
MATERIALS
Student workbook
METHODOLOGY
This chapter is designed as an instructor-directed
discussion session.
CONTENT
Chapter 1 consists of the following lessons:
1. Control System Concepts

2. Control System Configuration
3. Logix5000 Controller
4. I/O Modules
5. Communication Networks & Devices
6. Operator Interface Devices

7. Special Function Devices
PREREQUISITES
To successfully participate in this module, the
student must have completed a Solar Operation &
Maintenance training course, or must have equivalent
field experience.
1.2 © 2004 Solar Turbines Incorporated. All rights reserved. 3800

Solar Technical Training TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC 4 CONTROL SYSTEM

TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC 4 CONTROL SYSTEM Solar Technical Training

Solar Technical Training TT4 CHAPTER 1, LESSON 1 CONTROL SYSTEM CONCEPTS
TT4 CHAPTER 1, LESSON 1 CONTROL

SYSTEM CONCEPTS
INTRODUCTION
This lesson introduces the student to the basic
concepts of a microprocessor based control system, and
specifically how it relates to the control of a Solar
turbomachinery package.
It assumes the student has had at least some exposure
to a turbine engine and the way the turbine and its
subsystems operate.
The purpose of the control system is to control
hardware. If the hardware is not operating correctly it
is up to the technician to find and correct the problem
in a timely manner. If the technician understands
how the hardware is supposed to operate he or she is
much more likely to find the source of the problem. In
addition to this fundamental knowledge requirement,
temporary manipulation of the software is often used
as a tool in troubleshooting hardware problems.
OBJECTIVES
Upon completion of this lesson the student will be
able to:
1. State the function of the Turbotronic 4 Control

System
2. Identify and describe the blocks in a Turbotronic

4 Control System block diagram.

TT4 CHAPTER 1, LESSON 1 CONTROL SYSTEM CONCEPTS Solar Technical Training
CONTROL SYSTEM PURPOSE

The Turbotronic 4 Control System sequences, monitors
and protects the turbine and driven equipment
during all phases of operation. During a start, normal
operation or shutdown the control system directs the
sequencing and monitors the turbine, subsystems and
driven equipment. The control system also provides
visual displays for the operator to evaluate package
operations and performance.
Figure 2.1 Control System Block Diagram
THE FIVE MAIN CONTROL BLOCKS

To sequence, monitor and protect the turbine and
driven equipment the control system uses five main
parts.
These parts are:

1. information devices,
2. input modules,
3. controller,
4. output modules,
5. decision devices

INFORMATION DEVICES
Information devices are mounted on the equipment
to be controlled. They convert physical parameters
(e.g. temperature, pressure, speed) into electrical
signals (e.g. volts, amps, ohms, frequency) and send
the information signals through wiring to the input
modules.
INFORMATION DEVICES CONVERT
PARAMETERS INTO SIGNALS
INPUT MODULES
The input modules can be mounted on the equipment

skid or in a control console. They convert the
electrical signals from the information devices into
data (numbers). The input modules then send the
information data to the controller. Data will be in
one of two main formats:
1. Discrete Data in the form of 1 or 0

2. Analog Data in the form of an integer (for
example a range of 0 to 30840)
INPUT MODULES CONVERT SIGNALS INTO DATA
CONTROLLER
The controller, like the input modules, can be mounted
on the equipment skid or in a control console located
up to 300 meters away from the turbine. The controller
contains a Program and makes decisions (decision
data) based on information data received from the
input modules.
THE CONTROLLER USES THE PROGRAM TO
MAKES DECISIONS BASED ON DATA

OUTPUT MODULES
Once the decisions are made the controller sends the
decision data to the output modules. This will be in
the same format as the information data Discrete
Data as a 1 or a 0, and Analog Data as an integer
value, typically ranged from 0 to 30840. As with the
controller and input modules, the output modules can
be mounted on the equipment skid or in a separate
control system console. The output modules convert
decision data from the controller into decision signals
(e.g. volts, amps) and send these signals to the
decision devices.
OUTPUT MODULES CONVERT DATA INTO

SIGNALS
DECISION DEVICES
Decision devices are mounted on the equipment to be
controlled. They convert decision signals from the
output modules into physical movement.
DECISION DEVICES CONVERT SIGNALS INTO

MOTION
When used together these five parts of the control

system form a closed loop that permits the use of
feedback to control the turbine and driven equipment.
For example suppose the turbine is rotating faster

(102% NGP) than the setpoint of 100%.
1. The information devices change the speed of the
turbine into an information signal (frequency)
and send this information signal (frequency)
to the input modules
2. The input modules take the information signal
(frequency) and turn it into information data
(number) and send the data to the controller.
3. The controller stores the data of the NGP speed
in memory, and when it comes to the NGP speed
control section of the control program notices
that the NGP speed is greater than it should be.

4. The controller makes a decision to lower the

NGP speed by decreasing the decision data for
the fuel actuator. If the decision data for the fuel
actuator was 15420 the new decreased data
might be 14000. The controller now sends the
new decision data to the output modules.
5. The output modules convert the decision data

(14000) into a decision signal (milliamps) that
goes directly to the fuel actuator (decision
device).
6. The fuel actuator receives the decision signal and

closes slightly.
7. The reduction in fuel supply causes the turbine
to decrease in speed. Once the turbine is rotating
at the correct speed, the control system will stop
making corrections to the signal to the fuel valve,
and the speed setpoint will be maintained.
INFORMATION DEVICES
Figure 2.2 Information Devices

Information devices are typically mounted on the

equipment to be controlled and are connected by
wiring to the input modules.These devices measure
specific physical parameters (e.g. temperature,
pressure and speed) and change these measurements
into electrical signals (volts, amps, ohms, hertz). Some
typical examples of information devices that Solar
uses are shown in Table 2.1.
Table 2.1 Information Devices
Device Name Measures Signal Type
RTD Temperature Ohms Analog
Thermocouple Temperature Millivolt Analog
Transmitter Pressure Milliamp Analog
Transmitter Fluid Level Milliamp Anlog
Switch Fluid Level Voltage Discrete
Switch Pressure Voltage Discrete
Magnetic Pickup Speed Frequency Analog
SIGNAL TYPES
Both information devices and decision devices can
be put into two groups:
1. Discrete
2. Analog
DISCRETE DEVICES
Discrete devices are always either ON or OFF, there

is no partially on or partially off.
Typical discrete devices are switches, relays and
solenoids.

ANALOG DEVICES
Analog devices are infinitely variable over a specified
range.
Analog devices can measure fluid pressure,

temperature, the level of fluid in a vessel or turbine
rotational speed. Similarly analog devices can position
a fuel valve to closely regulate fuel flow.
Typical analog devices are thermocouples, RTDs,

pressure transmitters, level transmitters, magnetic
speed pickups, and actuators.
RTDs
Figure 2.3 RTD

RTDs, Resistance Temperature Devices, are analog
devices that convert temperature measurements into a
variable resistance or ohm signal. RTDs are normally
used to measure temperatures below 300F, and are
normally made of platinum.
Typical applications of RTDs on Solar packages are T1
(turbine inlet temperature), lube oil header and tank
temperatures, bearing oil drain temperatures, thrust
bearing temperatures, thermocouple cold junction
temperature and process gas temperatures.

Figure 2.4 Thermocouple
Thermocouples, sometimes shortened to TCs, are

analog devices that convert higher temperature
measurements into millivolt signals.
A thermocouple is formed at a junction of any two
dissimilar metals, and will generate a small EMF
or voltage proportional to the temperature at the
junction.
In practice certain metallic junctions are better than
others at generating a signal that has sufficient
strength and is linear over a wide range.
Solar packages utilize two types of thermocouple:
1. Type K a junction of Nickel Chromium (Chromel)

and Nickel Aluminum (Alumel)
2. Type N a junction of Nickel Chromium Silicon

(Nicrosil) and Nickel Silicon (Nisil)
Both types are very similar in range of operation, with
the Type N being slightly more reliable near the top
of the range, and therefore used on turbines where
higher temperatures are experienced.
Typical applications of thermocouples on Solar
packages are T5 (third stage turbine rotor inlet) and
sometimes T7 (exhaust duct) temperatures.

PRESSURE TRANSMITTERS
Figure 2.5 Pressure Transmitter

Pressure Transmitters are analog devices that convert
pressure measurements into milliamp signals,
normally in the range of 4 to 20 mA.
Solar uses pressure transmitters to measure a wide
range of pressures, from relatively low pressures (less
than 10 inches water) to fairly high pressures (up
to 2000 psi).
Typical uses of pressure transmitters in Solar
packages include lube oil header pressure, fuel
pressure, process gas pressure, vessel (tank) pressures
and compressor seal system pressures.

LEVEL SWITCHES
Figure 2.6 Level Switch

Level Switches are discrete devices that convert a
level measurement into a voltage signal. As with
all discrete devices on Solar packages the operating
voltages are either 24Vdc or 0Vdc.
Level switches are used to warn of either low or high
levels of fluids. A typical use of a level switch on a
Solar package would be to check whether the oil level
in the lube oil tank is too low or too high.
24Vdc is connected to one side of the switch. If the
switch is closed the 24Vdc will be connected back to
an input module, and if the switch is open no voltage
will be present at the input module.
In practice Solar often use switches as failsafe devices,
i.e. in the normal or healthy condition the contacts
will be closed. This method gives added protection
against wiring faults.

PRESSURE SWITCHES
Figure 2.7 Pressure Switch

Pressure Switches are discrete devices that convert a
pressure measurement into a voltage signal - again
either 24Vdc or 0Vdc.
Pressure switches are used to warn of either low or
high pressures, or to check for the correct operation of
a device. A typical use of a pressure switch in Solar
packages is checking the pressure of the oil from the
backup lube oil pump, or generating an alarm if the
fuel gas pressure falls below a certain value.
As with the level switches, pressure switches are often
used as failsafe devices.

MAGNETIC PICKUPS
Figure 2.8 Magnetic Pickup
Magnetic Pickups are analog devices used to measure

the speed of a rotor.
Magnetic Pickups consist of a magnetic coil that

is positioned close to either rotating gear teeth or
the tips of compressor blades in the gas turbine. As
the shaft rotates the passing gear teeth or blades
generate a small AC voltage, with the frequency being
dependent on the number of gear teeth or blades, and
the rotational speed of the shaft. Since we know the
number of gear teeth or blades, we can easily convert
the frequency of the signal into a rotational speed.
Magnetic Pickups are used on Solar packages to

measure the speed of the Gas Producer rotor (NGP),
and Power Turbine rotor (NPT) where applicable.

INPUT MODULES
Figure 2.9 Input Modules
Input modules can be mounted in junction boxes on

the equipment skid or in a separate control console.
Input modules convert electrical information signals
from the information devices into data (numbers) and
send the data to the controller.
There are several types of input modules - generally

there is a different type of input module for each type
of input signal. The following is a list of input modules
used on Solar packages:
1. Discrete Input
2. Analog Input
3. Speed Input
4. Thermocouple/RTD Input

Figure 2.10 Flex I/O Modules
Input modules are mounted together on a Flex I/O

Node as shown in Figure 2.10. Note that up to eight
modules can be grouped together on any Node,
and that the modules can be of any type, i.e. any
combination of Input, Output, Discrete and Analog.

CONTROLLER
Figure 2.11 Controller
The controller may be mounted in a control box on the

skid or in a separate control console.
The controller is the manager or decision maker
of the control system. All of the other parts of the
control system are really just converters; converting
information about the turbine into a format the
controller can understand for inputs and converting
controller formatted decisions into motion for the
outputs.
The controller stores information data until the

control program that the controller runs continuously
needs the data to make a decision.
The control program is fundamentally a group of IF,
THEN statements, where the IF part of the statement
is data and the THEN part of the statement is a
decision based on the data.

For example the Controller program may be looking at

a low oil level switch. The program will state IF the
level switch contacts open (meaning that the level has
dropped below a certain point) THEN annunciate an
Alarm to let the operator know that there is a problem.
Figure 2.12 ControlLogix 5000-series Controller

OUTPUT MODULES
Figure 2.13 Output Modules
Output modules can be mounted in junction boxes on

the equipment skid or in a separate control console.
Output modules convert decision data from the

controller into electric signals that are sent to the
decision devices.
Solar uses two types of output modules.

The first is a discrete output module that is capable
of turning on or off a 24Vdc signal. This will be used
to control a discrete decision device such as a relay
or a solenoid.
The second is an analog output module that can vary a
current signal between 4 and 20 milliamps. This will
be used to control an analog decision device such
as a fuel valve actuator.
As mentioned previously output modules will be
grouped together in any combination on Flex I/O
Nodes, often with input modules on the same Node.

DECISION DEVICES
Decision devices are installed on the equipment to be

controlled and are connected to the output modules
by wiring.
These devices convert the decision signals from the
output modules into mechanical movement.
As with information devices, decision devices can

be grouped into two main signal types discrete and
analog.
Some typical examples of decision devices that Solar

uses are shown in Table 2.2
Table 2.2 Decision Devices
Device Name Signal Type
Relay 24Vdc Discrete
Solenoid 24Vdc Discrete
Actuator 4 to 20 milliamps Analog

RELAY
Figure 2.15 Relay
Relays are discrete devices that use the 24Vdc signal

voltage from the discrete output modules to open and
close electrical contacts. The 24Vdc will energize a coil
that will in turn cause a number of separate contacts
to transfer. Some of the contacts will be Normally
Open (N.O.), meaning that the contact will be open
when the coil is not energized, and some will be
Normally Closed (N.C.), meaning that the contact will
be closed when the coil is not energized.
As with some of the discrete information devices, the
decision to either use Normally Open or Normally
Closed contacts will often take into consideration a
failsafe function. For example in Solars Backup Relay
System (to be covered later in the lesson) a series of
relays are latched open when the package is operating
normally. Subsequent malfunction will cause a loss of
power to the relay coils, resulting in all of the contacts
transferring. This will in turn initiate a series of
operations to safely shutdown the turbine package.

One other common use of relays on Solar packages

is as interposing relays to control off-skid devices
such as lube oil cooler fan electrical motors. We use
an output from the control system to energize the
relay coil, however the contacts are wired to a system
independent of the control system. When this is a
separate 24Vdc system, the purpose is to isolate the
power supplies of each system; when this is a higher
voltage the purpose is to provide control of the higher
voltage device from the Solar control system.
SOLENOID
Figure 2.16 Solenoid
Solenoids are discrete devices that use the 24Vdc

signal voltage from the discrete output modules to
energize a magnetic coil. This will move a steel or
iron bar called a plunger, which will open or close a
port inside the solenoid valve. This has two practical
applications:
1. Opening the port allows a fluid to flow through
the solenoid valve directly to the end function.
A typical application of this is the Gas Torch
Shutoff Valve.
2. Opening the port allows fluid acting as servo or

control pressure to pass through the solenoid
valve, and in turn actuate some other device. A
typical example of this is the solenoid valve used
to control the Primary Fuel Shutoff Valve.

ACTUATOR
Actuators are analog devices that use signal current

from the analog output modules to position another
device.
The output modules will provide a signal in the range

of 4-20mA, and in some applications this will be used
to directly actuate the valve or other end device. Other
applications will use this signal purely as a control
signal, and an additional power supply will be used
to actuate the end device. On some applications this
power will be electrical (normally 120Vdc) and on
other applications hydraulic pressure may be used.
Typical examples used on Solar packages are the fuel

valve, bleed valve and guide vane actuators.
Since the hydraulic application is becoming less

common, we will consider the function of an electric
actuator in a little more detail.
The range of an analog output signal is normally

4-20mA. A signal of 4mA represents the fully closed
positions and a signal of 20mA represents the fully
open position. Therefore if a valve actuator receives a
12mA decision signal from the analog output module
then the valve should open to the 50% position. Any
signal between 4 and 20mA will position the valve in
the corresponding position, with only the accuracy of
the valve the limiting factor on the fineness of the
resolution.
Electric actuators normally supply a position feedback
signal to the control system, again 4-20mA. The
actuator command and feedback signal are monitored
by the Controller program, with any deviation greater
than a certain amount initiating an alarm of shutdown
condition.

Figure 2.17 Actuator

PERIPHERAL EQUIPMENT
The five control blocks of information devices, input
modules, controller, output modules and decision
devices constitute the basic control system.
However, there are some functions that are necessary
to ensure safe operation and adequate monitoring
of the turbine package.
These functions include:
1. A backup system in case the control system fails

2. Methods of communicating with various other
systems such as a supervisory control and data
acquisition system (SCADA) or other customer
systems
3. A human machine interface (HMI) to enable the
equipment operator to monitor the operation of
the equipment
4. A programming terminal to monitor, edit and

reload the control program

BACKUP RELAY SYSTEM
Figure 2.18 Backup Relay System

The Backup Relay System shuts down the turbine
and driven equipment safely and performs vital
post-operation control in the event of a controller
failure or when immediate action is required as
specified by certain conditions to protect the package
and personnel.
The backup system comprises a series of relays and

time delay relays to initiate and schedule post-lube
and to control the fire suppression system (on enclosed
units) when the backup system is activated.
The entire system is configured in the failsafe manner,

i.e. under normal operating conditions the relays are
all latched by 24Vdc. Any condition which requires the
backup relay system to activate will cause a loss of
24Vdc power to the relay coils, and the subsequent
transfer of all of the relay contacts will initiate the
necessary shutdown and safety systems.

The Solar standard for activating the backup relay

system is as follows:
1. Controller failure
2. Manually initiated Fast Stop (sometimes called

Emergency Stop). Can be initiated from the
control console / skid or by using a remote fast
stop
3. Backup overspeed of the turbine. A separate

magnetic pickup sends a speed signal to a backup
overspeed monitor. This initiates an overspeed
sgutdown at a setpoint slightly higher than the
setpoint in the Controller program.
4. A fire detected by the fire system

When the backup relay system has been activated it
must be reset by using a manual reset keyswitch
or pushbutton on the control console. This will
momentarily apply 24Vdc to the coils of the relays,
and if the condition that caused the backup activation
has been cleared, the coils will remain latched when
the pushbutton or keyswitch are released.Figure 2.19
illustrates typical backup system hardware:
Figure 2.19 Backup Relay System Hardware

COMMUNICATIONS
Figure 2.20 Communications
Communications is a large part of modern process

control, and is a main feature of Turbotronic 4 control
systems.
Several methods are available to facilitate

communications with programming terminals,
SCADA / DCS systems, and display systems. These
methods include: RS232-C Serial Link, ControlNet,
EtherNet, Data Highway Plus and Modbus.
All Solar projects will allow communications using

RS232-C Serial Link and ControlNet, since the
hardware required for these methods will always
be available. RS232-C Serial Link communication
involves connecting directly into the port on the front
of the Controller. The Controller communicates with
I/O modules using the ControlNet system, therefore a
minimum of two ControlNet communications modules
will be present on each project.
EtherNet, DH+ and Modbus will require additional
hardware which will be project-specific.
Figure 2.22 illustrates the modules used for EtherNet

and ControlNet communications.

Figure 2.21 Communication Cards

HUMAN MACHINE INTERFACE
Figure 2.22 HMI
Although commonly used to designate the display

system, the Human Machinery Interface (HMI) also
comprises everything that the operator interacts with.
It includes various control switches (e.g. START,

STOP, RESET), various indicator lights (e.g. ALARM,
READY, LOCAL) and various types of video display
terminals (e.g. TT4000, TT4000S).
The interface has been specifically designed to make

operating the turbine and collecting information about
the turbine as easy and uncomplicated as possible.
HMI devices can be located either on-skid, in the

optional control console or remotely from the package,
according to the specific package configuration. This
subject will be covered later in more detail.

PROGRAMMING TERMINAL
Figure 2.23 Programming Terminal

The programming terminal is used to load the control
program into the controller and to help technicians
locate and troubleshoot problems in the hardware.
The programming terminal can be connected to the
control system by most of the methods listed in the
Communications section, specifically:
1. ControlNet
2. RS232-C Serial Link

3. EtherNet
4. Data Highway Plus
As with the Communications options, some of these

methods will be site dependent, however ControlNet
and RS232 Serial Link will always be available.

NOTES:

STUDENT ACTIVITY
1. List the five main parts of the control system.
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
2. What are the two main types of signal?
_____________________________________________
_____________________________________________
3. State the function of the Backup Relay System.
_____________________________________________
4. List four conditions that will initiate the Backup
Relay System.
_____________________________________________
_____________________________________________
5. List four methods of communicating with the

Turbotronic 4 control system.
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. List the five main parts of the control system.
INFORMATION DEVICES
INPUT MODULES
CONTROLLER
OUTPUT MODULES
DECISION DEVICES
2. What are the two main types of signal?
DISCRETE
ANALOG
3. State the function of the Backup Relay System.
SHUTSDOWN THE PACKAGE AND

INITIATES NECESSARY ACTIONS IN AN
EMERGENCY.
4. List four conditions that will initiate the Backup

Relay System.
FAST STOP
CONTROLLER
BACKUP OVERSPEED
FIRE DETECTED
5. List four methods of communicating with the

Turbotronic 4 control system
RS232-C SERIAL LINK
CONTROLNET
ETHERNET
DATA HIGHWAY PLUS
MODBUS

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Solar Technical Training TT4 Chapter 1 Lesson 2 Control System Configuration
TT4 Chapter 1 Lesson 2 Control System Configuration
OBJECTIVES:
Upon completion of this lesson, the student will be
able to:
1. Given a system block diagram, identify and
state the function of each of the major elements
comprising the Turbotronic 4 control system.
2. Provide a brief description of the functional
characteristics of each of the major elements
of the control system.
3. Discuss the principle differences between

the on-skid and the off-skid control system
configurations.
4. Describe the methods used in the Turbotronic 4

control system to transfer information between
the major elements of the system.
INTRODUCTION
The Turbotronic 4 Control System is a
microprocessor-based system that provides precise
integrated control, protection and monitoring of
Solar’s turbomachinery packages. The system
provides information needed by the operator and
the data required by the customer’s plant control
system. The system requires a source of 24 Volt
DC power, normally supplied by a control system

TT4 Chapter 1 Lesson 2 Control System Configuration Solar Technical Training
battery with associated battery charger. Power may

also be supplied from other sources according to site
conditions and user preferences.

CONTROL SYSTEM COMPONENTS:

Refer to Figure 3.1
Figure 3.1 Control System Components
CONTROLLER
The Allen-Bradley ControlLogix 5000 Controller is the

primary control device in the system.
I/O MODULES
The Allen-Bradley Flex I/O modules provide the

interface between package instrumentation and the
processor.
VIBRATION MONITORING
The Bently-Nevada 1701 Field Monitor monitors
vibration for the turbine and driven equipment.
GENERATOR CONTROL
For generator packages, the Allen-Bradley/Basler
Electric Combination Generator Control module
provides multiple power generation control and
protection features, including synchronization and
voltage regulation.

BACKUP PROTECTION
A separate backup shutdown system shuts the

package down in a safe manner and initiates
necessary post-shutdown actions if primary control is
compromised.
OPERATOR INTERFACE
All operator interface devices are designated the
Human Machinery Interface or HMI. The system
includes options for convenient operator interface,
including:
1. TT4000 Display and Monitoring System - Solar’s
fully-functioning display system.
2. Turbine Control Panel - A set of switches and

indicator lamps providing operator interface
independent of the display system.
3. TT4000S System - A subset of the TT4000

product that provides an on-skid digital display
panel and operator interface with multiple
status and alarm screens.
FIRE DETECTION & SUPPRESSION SYSTEM
A separate certified fire monitoring and suppression

system is installed on packages equipped with
enclosures.

CONTROL SYSTEM CONFIGURATIONS

The system can be configured in a number of
ways, depending on hazardous area classification
requirements and customer preferences.
ON-SKID CONTROL SYSTEM
For areas with a National Electric Code (NEC) Class

I, Division 2 rating, packages can be supplied with
an on-skid control system. All the essential control
hardware devices are mounted on the package skid
in one or more NEMA 4 panels (see Figure 3.2).
Typically, the controls for the gas turbine are mounted
on the driver skid and the controls for the driven
equipment are mounted on the driven skid. All the
key system components, including the processor, I/O
modules, vibration monitoring system and generator
control devices are rated for operation in an NEC
Class I, Div 2 area and do not require installation in
explosion-proof panels.
Figure 3.2 On-Skid Configuration

An operator interface consisting of a TT4000S display

system with a touch screen and several control
switches is provided for basic operation and control.
Expanded operator interface is available off-skid,
typically in a non-hazardous area, such as a control
room. This off-skid interface can be either a single-bay
control console with the full TT4000 display and
monitoring system and a turbine control panel, or
it can be a desk-top computer configured with the
TT4000 system.
The major advantage of the on-skid control

configuration is the large reduction in interconnect
cabling required. The connection to the control room
is primarily through the ControlNet serial link.
A limited number of hard-wired signals are still
required, such as emergency stop and any process
signals that are critical to the operation. All other data
and control signals are routed through the serial link.

OFF-SKID CONTROL SYSTEM
The off-skid control configuration is available for

packages that are to be installed in all permissible
hazardous areas, including NEC Class I, Div.1 and
Div.2, and CENELEC/ATEX Zone 2. Key components
of the NEC control system are installed in a 2-bay
console suitable for installation in a non-hazardous
area (see Figure 3.3).
Figure 3.3 Off-Skid Configuration
NOTE
Note that the TT4000-S display device is still
located at the package skid, and there is
also the option of a remote TT4000 display
terminal.

INTERCONNECT CABLES
Interconnect cables connecting the package and field
instrumentation to the off-skid control console are
typically not in Solar’s scope of supply. The cable
provider should consider the following cable length
guidelines:
1. Up to 60 m. (200 ft.) - standard wire types and
gauges may be used.
2. 60-150 m. (200-500 ft.) - wire gauges need to

be reviewed to ensure voltage drops are not
excessive.
3. 150-300 m. (500-1000 ft.) - special

low-capacitance cables should be used for higher
-frequency signals (such as vibration and speed).
4. Greater than 300 m. (1000 ft.) - interconnect

cables cannot be used. Solar can provide special
engineering solutions if the control room location
requires more than 300 m. (1000 ft.) of cabling.
FIELD INSTRUMENTATION
For compressor sets and mechanical drive units with
third-party driven equipment, a separate NEMA 4
panel is provided for installation of the I/O modules
for field and balance-of-plant instrumentation. The
exact configuration depends on the project specifics.
This panel may be mounted near the field devices to
minimize wiring, since the ControlNet connects the
panel to the Controller.

COMMUNICATIONS OPTIONS
Referring back to Figure 3.1 it can be noted that the

principal method of communications in Turbotronic 4
control systems is ControlNet 1.5.
The ControlNet system connects all of the core control

system elements, other than those elements that
require to be isolated from the main control system,
such as the Backup Relay System and Fire System.
Devices connected to the Controller by ControlNet

include:
1. I/O Modules
2. Turbine Control Panel (via I/O Modules)
3. TT4000 Display
4. TT4000 Display
5. Vibration Monitoring System
6. Combination generator Control Module

(generator applications)
In actual fact the most recent generation of fire system
is also connected by ControlNet, and this will be
covered in a later section of Turbotronic 4 training.
One of the principal advantages of the Turbotronic

4 control systems is the ability to interface with
a wide variety of other systems using a variety of
communications protocols.

The 1756 ControlLogix Chassis can accommodate

several different types of communications modules,
including:
1. ControlNet
2. EtherNet
3. Data Highway Plus (DH+)

4. Modbus
The standard configuration for a Solar Turbotronic

4 project is that two ControlNet modules will
be installed in the 1756 chassis to allow the
communications to take place between the package
I/O modules and the Controller.
Other communications module types will be selected

on a project basis to suit customer interface
requirements. Fore example Figure 1.1 shows a Serial
Link connection between the 1756 Chassis and the
customer this will be a common feature on many
projects, and will use a Modbus module installed in
the 1756 Chassis. Other customers may require or
prefer communications to their DCS or SCADA system
using EtherNet or ControlNet.

STUDENT ACTIVITY
1. What is the main consideration in the selection

of on-skid or off-skid control systems?
_____________________________________________
_____________________________________________
2. What are the two main display systems available

in a Turbotronic 4 project?
_____________________________________________
_____________________________________________
3. What method is used to communicate between
the main elements of a Turbotronic 4 control
system?
_____________________________________________
_____________________________________________
4. List three communications protocols supported

by a Turbotronic 4 control system.
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. What is the main consideration in the selection

of on-skid or off-skid control systems?
HAZARDOUS AREA CLASSIFICATION
2. What are the two main display systems available

in a Turbotronic 4 project?
TT4000
TT4000-S
3. What method is used to communicate between
the main elements of a Turbotronic 4 control
system?
CONTROLNET 1.5
4. List three other communications protocols
supported by a Turbotronic 4 control system.
ETHERNET
DATA HIGHWAY PLUS
MODBUS



Solar Technical Training TT4 Chapter 1, Lesson 3 Logix5000 Controller
TT4 Chapter 1, Lesson 3 Logix5000 Controller
OBJECTIVES:
able to:
1. describe the functional characteristics of the
1756-series ControlLogix chassis.

power supply used with the 1756-series chassis.

ControlLogix 5000-series Controller.
INTRODUCTION
The 1756-series ControlLogix system is a modular
control platform, consisting of an I/O chassis, a power
supply, a ControlLogix Controller, and the I/O modules
required to support the control and monitoring needs
of the turbine package.
With the exception of an RS-232 port built into
the Controller, all interfacing with communication
networks is modular. Separate communication
interface modules are available for communication
between the chassis backplane and EtherNet/IP,
ControlNet, DeviceNet, Data Highway Plus, and
Universal Remote I/O links.

TT4 Chapter 1, Lesson 3 Logix5000 Controller Solar Technical Training
1756-SERIES CONTROLLOGIX CHASSIS

Refer to Figure 4.1
Figure 4.1 1756-series Chassis
The ControlLogix chassis is available in 4-, 7-, 10-,

13- and 17-slot sizes. Any compatible module can be
placed in any slot, although Solars convention is that
the Controller is always placed in the first slot.
The chassis backplane provides a high-speed

communication path between modules. With multiple
communication modules on the backplane, a message
can be sent across a link into a port on one module
and can be routed from there across the backplane,
out another module’s port, and across another link to
its ultimate destination.
All chassis are 137 mm (5.4) high and 145 mm (5.8)
deep, and range from 263 mm (10.4) to 738 mm (29.1)
wide (4 17 slot).
The chassis is designed for operation at temperatures

between 60F. and 140F., and can be stored at
temperatures between -40F. and 185F.

POWER SUPPLIES
See Figure 4.2.

A ControlLogix power supply is used with the chassis
to provide DC voltage to the chassis backplane.
Power supplies are available for 120/240 VAC, 47-63
Hz, or 24 V dc input power (Solar’s standard will
normally be the 24 V dc version). Both versions are
rated at 75W maximum output power.
The power supply is attached to the left end of the
chassis, connecting directly to the chassis backplane.
Different devices on the chassis require different

voltages, therefore the power supply provides power
to the chassis at:
1. 1.2 V dc (1.5A max)

2. 3.3V dc (4A max)
3. 5V dc (10A max)
4. 24V dc (2.8A max)

A green LED on the front panel of the power supply
indicates the status of the power supply. Input power
(either 120/240V ac or 24V dc) is connected to a
terminal block behind the front panel door. A power
switch is also located behind the front door.

Figure 4.2 ControlLogix Power Supply

CONTROLLOGIX CONTROLLER
See Figure 4.3.
The Controller is a Logix5555 or Logix5563 model.
The Logix5555 requires a memory sub-module to

function. Memory is available in 750K, 1.5M, 3.5M,
and 7.5M byte sizes.
The Logix5563 has 8M bytes of fixed memory; optional
non-volatile memory may be also installed in a built-in
CompactFlash socket. The Logix5563 executes ladder
logic approximately twice as fast as the Logix5555,
and executes function block, REAL data type math,
and motion instructions 4-5 times as fast as the
Logix5555. For this reason, the Logix5563 will be
Solar’s standard.

Both Controller versions require 5V dc and 24V dc

power from the chassis backplane. Peak backplane
current requirements are 1.25A on the 5V dc supply,
and 14mA on the 24V dc supply.
Figure 4.3 ControlLogix Controller

To retain the contents of the Controllers memory
when the chassis is powered down or when the
module is removed from the chassis, a lithium battery
is installed in a compartment on the module (see
Figure 4.4).

A red LED on the front panel of the Controller will

illuminate when the Controller detects that the
remaining battery life is approximately 50%. The
battery should be replaced with the Controller module
installed in the chassis and the chassis powered up
to avoid loss of memory contents.
Figure 4.4 Standard Battery
An externally-mounted, higher-capacity battery is

available and is highly recommended for Logix5563
Controllers. The extended battery is installed in a
3-inch cubical case, and can be mounted on a DIN rail
or other convenient location near the chassis (see
Figure 4.5). The battery housing includes a cable that
connects to the battery connector on the Controller.
A door on the case provides access to replace the
battery when required.

Figure 4.5 External High-Capacity Battery
The Controller can accommodate up to 128,000 digital

I/Os (any mix), up to 4,000 analog inputs, and up
to 2,000 analog outputs.

A serial port (RS232) on the Controller may be used to

connect a programming terminal or other serial device
(see Figure 4.6); however this is a very slow interface
and should be used only if other communication
methods are unavailable. For optimum effectiveness,
the EtherNet/IP or ControlNet interface should be
used.
Solar’s standard interface for package I/O’s is

ControlNet, and Solar’s FSRs carry programming
terminals equipped with ControlNet interface cards.
If an EtherNet/IP module is installed in the chassis,
access is available through a standard network
adapter.
Figure 4.6 RS-232 Serial Port

The other main features of the Controller are the

status LEDs located on the front of the Controller,
and the Mode Switch, also located on the front of
the Controller.
Status LEDs indicate some of the following conditions:
1. Controller OK
2. Controller in the RUN position

3. FORCES are present
4. ControlNet I/O responding

5. BATTERY condition
The Mode Switch is a keyswitch that can be used to

place the Controller in the following modes:
1. PROGRAM - used when downloading the

software
2. RUN - used in normal operation

3. REMOTE - transfer to Program or Run is
controlled by the programming terminal
NOTE
Placing the Controller in the PROGRAM
mode will result in a loss of communication
with all I/Os. Ensure that the turbine package
is stopped and the post-lube sequence has
been completed before placing the Controller
in the PROGRAM mode.

STUDENT ACTIVITY
1. What is the communications protocol available

as a direct connection to the Controller?
_____________________________________________
_____________________________________________
2. Which of the following voltages are supplied to

the chassis by the power supply?
a) 1.2 V dc
b) 3.3V dc
c) 5V dc
d) 24V dc
e) 120V dc
3. How is the Controller memory retained when

the chassis is powered-down?
_____________________________________________
_____________________________________________
4. What are the three positions of the Mode switch

on the Controller?
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. What is the communications protocol available

as a direct connection to the Controller?
RS232-C SERIAL LINK
2. Which of the following voltages are supplied to

the chassis by the power supply?
1.2 V dc
3.3V dc
5V dc
24V dc
3. How is the Controller memory retained when
the chassis is powered-down?
EXTERNAL OR INTERNAL LITHIUM

BATTERY
4. What are the three positions of the Mode switch

on the Controller?
PROGRAM
RUN
REMOTE



Solar Technical Training TT4 Chapter 1, Lesson 4 I/O Modules
TT4 Chapter 1, Lesson 4 I/O Modules
OBJECTIVES:
able to:
1. state the purpose of the input and output
modules installed in the Turbotronic 4 control
system.
2. demonstrate understanding of the functional
characteristics of each of the input and output
modules installed in the system.
3. describe the process by which the input and

output modules communicate with the system
controller.
INTRODUCTION
The ControlLogix controller in the Turbotronic 4
control system has no physical connections to the
electrical monitoring and control devices installed on
the turbomachinery package or plant equipment.
All electrical signals to and from these devices must
be routed through input and output modules. As
discussed in earlier lessons, these signals are of either
Discrete or Analog types, and are processed by I/O
modules designed expressly for the type of the signals
being transferred.

TT4 Chapter 1, Lesson 4 I/O Modules Solar Technical Training
DISCRETE INPUT MODULES
Discrete input modules convert field signals from

switches or other on/off devices into data (numbers) for
the Controller. These modules take the 24 Vdc (closed)
or 0 Vdc (open) from the input circuitry, convert it to
bits (1s and 0s) and send it to the Controller.
A logical 1 in a bit position in the input image word

means that the corresponding input circuit is active,
or that the input contact connected to that point is
closed. A logical 0 in the same bit position indicates an
inactive input circuit, or one that is in the path from
an open contact.
This status will be transferred to any Tags in the

Controller software that are addressed to this input
channel. This process will be covered in more detail
later in the training.

The 1794-IB16 is a 16 channel discrete input module.

Each of the channels are designed to operate with a
voltage range of 10 to 31.2 Vdc for active or closed
circuits and zero to less than 10Vdc for inactive or
open circuits. Each input circuit (channel) is connected
to the module by the terminal block. Table 1 shows
the input channel to terminal number correlations.
Notice on the Flex I/O input module that the input
numbering system is decimal (0 through 15) not octal.
Figure 5.1 1794-IB16 Discrete Input Module
The front panel has a labeling tag, LED indicators and

a keyswitch indicator. The labeling tag has enough
room to write the input device/circuit names next to
the appropriate channel. One LED is provided for each
input, and these indicate the status of the channel. If
the input has 10 to 31.2 Vdc the corresponding LED
will be illuminated; if the input signal is less than 10
Vdc the appropriate indicator will not be illuminated.
Finally the front panel indicates the position the
keying-switch on the Terminal Base needs to be in to
accept the module.

The 1794-IB16 requires the use of either a TB3 or

TB3S terminal base. The TB3/TB3S has a total 51
terminals. The terminal base key must be turned to
position 2 to accept the IB16 module.
Table 5.1 Input Channel Connections For IB16 Discrete Input Module
CHANNEL INPUT VOLTAGE CHANNEL INPUT VOLTAGE
SIGNAL TERMINAL SIGNAL TERMINAL
0 A-0 C-35 8 A-8 C-43
1 A-1 C-36 9 A-9 C-44
2 A-2 C-37 10 A-10 C-45
3 A-3 C-38 11 A-11 C-46
4 A-4 C-39 12 A-12 C-47
5 A-5 C-40 13 A-13 C-48
6 A-6 C-41 14 A-14 C-49
7 A-7 C-42 15 A-15 C-50

DISCRETE OUTPUT MODULES

The discrete output modules process discrete (decision)
data from the Controller and send the processed data
out to end devices. These modules take the decisions
that have updated the status of Tags in the Controller
software, and turn each of the output circuits that are
addressed by these Tags on or off correspondingly.
Again this process will be examined more closely
later in the training.
A logical 1 in the Tag Address causes the corresponding

output channel to be gated on; a 0 in the same Tag
Address turns off the output. When the output is
gated on it connects 24 Vdc to the appropriate output
terminal and when the output is turned off 0 Vdc is
connected to the output terminal.
Figure 3.2 depicts a Flex I/O discrete output module.

This particular module is capable of handling up
to 16 channels of output data. The channels are
designed to operate with an output voltage range
of 10 to 31.2 V dc. Each output circuit is connected
to the module by the terminal block. Table 2 shows
the correlation between the output channel and the
terminal numbers. As with the input module the
numbering system is in decimal (0 through 15) not
octal (0 through 7 and 10 through 17).

The front panel provides space for writing the

controlled device name next to the channel indicators.
The channel indicators are LEDs, each LED indicates
the condition of its channel. If the Controller turns
the channel on the LED will be illuminated; if the
Controller commands the channel off the appropriate
indicator will not be illuminated.
Figure 5.2 1794-OB16 Discrete Output Module

The 1794-OB16 requires either a TB3 or TB3S
terminal base. The channel and power supply to
terminal number correlations are shown below in
Table 5.2. For the terminal base to accept the OB16
module the keyswitch must be set to position 2.
Power for the Flex I/O output module is supplied on
terminals 16 (0V) and 34 (24Vdc).
Table 5.2 Output Channel Connections For OB16 Discrete Output Module
CHANNEL INPUT SIGNAL VOLTAGE CHANNEL INPUT VOLTAGE
TERMINAL SIGNAL TERMINAL
0 A-0 C-35 8 A-8 C-43
1 A-1 C-36 9 A-9 C-44
2 A-2 C-37 10 A-10 C-45
3 A-3 C-38 11 A-11 C-46
4 A-4 C-39 12 A-12 C-47
5 A-5 C-40 13 A-13 C-48
6 A-6 C-41 14 A-14 C-49
7 A-7 C-42 14 A-15 C-50

ANALOG INPUT MODULE 1794-IE8

The analog input module takes data from external
sensors, conditions it, and finally digitizes the data for
transfer to the Controller.
The module can accept 8 single-ended inputs; a
different module is used for differential inputs.
Each channel is individually configured for current or

voltage by choosing where the input wire is connected
on the terminal base and this configuration should
also match the I/O Configuration in the Controller
software.
Allowable voltage and current ranges are:
1. -10 to +10 Vdc

2. 0 to 10 Vdc
3. 4 to 20 mA
4. 0 to 20 mA
Table 5.3 shows the correlation between input channel,

terminal number and voltage/current configuration.
Figure 5.3 1794-IE8 Analog Input Module

Table 5.3 Input Signal and Channel Commons

INPUT SIGNAL TYPE CHANNEL COMMONS
CHANNEL CURRENT VOLTAGE CURRENT VOLTAGE
0 A-0 A-1 B17 B18
1 A02 A-3 B19 B20
2 A_4 A-5 B21 B22
3 A-6 A-7 B23 B24
4 A-8 A-9 B25 B26
5 A-10 A-11 B27 B28
6 A-12 A-13 B29 B30
7 A-14 A-15 B31 B32
This module requires the use of a TB3 or TB3S

(51 terminal) terminal base. For installation, the
keyswitch on the terminal base must be turned to 3.
This module has only a power indicator not individual

channel indicators. If the module has between 19.2
and 31.2 Vdc the power indicator will be green.

RTD INPUT MODULE 1794-IR8
The 1794-IR8 RTD module takes data from external

sensors, conditions it, and finally digitizes the data for
transfer to the Controller. This module can accept up
to 8 RTD inputs.
Tables 5.4 and 5.5 show the correlation between

input channel, terminal number and voltage/current
configuration. This module requires the use of a TB3,
TB3S or TB3T (51 terminal) terminal base, with the
keyswitch in position 3.
Figure 5.4 1794-IR8 RTD Module

Table 5.4 RTD Connections for TB3 or TB3S Terminal Bases
RTD SIGNAL
CHANNEL HIGH LOW RETURN SHIELD
0 A-0 A-1 B-17 B-18
1 A-2 A-3 B-19 B-20
2 A-4 A-5 B-21 B-22
3 A-6 A-7 B-23 B-24
4 A-8 A-9 B-25 B-26
5 A-10 A-11 B-27 B-28
6 A-12 A-13 B-29 B-30
7 A-14 A-15 B-31 B-32

Table 5.5 RTD Connections for TB3T Terminal Base

RTD SIGNAL
CHANNEL HIGH LOW RETURN SHIELD
0 A-0 A-1 B-17 C-39
1 A-2 A-3 B-19 C-40
2 A-4 A-5 B-21 C-41
3 A-6 A-7 B-23 C-42
4 A-8 A-9 B-25 C-43
5 A-10 A-11 B-27 C-44
6 A-12 A-13 B-29 C-45
7 A-14 A-15 B-31 C-46
The RTD module requires only software configuration.

The module can be configured with software for
different types of RTDs (Solar standard is 100 ohm
Platinum) and degrees C or degrees F, and this is
completed in the RSLogix 5000 software.
The module has a red or green status indicator. If the
module is operating correctly the indicator is green.

THERMOCOUPLE / RTD MODULE 1794-IRT8
Figure 5.5 1794-IRT8 Fast Millivolt Input Module

This module is capable of measuring both RTDs and
thermocouples, however it will normally be used to
measure the T5 thermocouple voltages.
The IRT8 module supports 2 groups of 4 inputs
for a total of 8. Each group can be either RTDs or
thermocouples, but input types may not be mixed
within a group.
The module is software configured for different RTD
Types (including the Solar standard 100 Platinum)
and thermocouples (Solar standard types K and N),
using RSLogix 5000 software.
This module requires the use of a TB3G or TB3GS
terminal base, with the keyswitch in positrion 3.
The thermocouple or RTD inputs will be connected

as shown in Table 5.6.

NOTE
For thermocouple use this module should
have a thermistor connected on terminals 37,
38, 39 and 4, for input channels 0 through 3
and 46, 47, 48 and 12, for input channels 4
through 7. Also each channel will have a 10K
resistor across it for fail-safe.
Table 5.6 Thermocouple and RTD Connections
Module T/C + T/C - RTD lead 1 RTD lead 2 RTD lead 3
Channel
0 2 3 0 3 2
1 6 7 4 7 6
2 10 11 8 11 10
3 14 15 12 15 14
4 19 20 17 20 19
5 23 24 21 24 23
6 27 28 25 28 27
7 31 32 29 32 31
The RTD/Thermocouple module has a module power

indicator and failure indicators for each channel. Note
that the channel failure indicator will light when a
channel is unused or spare.

FREQUENCY INPUT MODULE 1794-IJ2
Figure 5.6 1794-IJ2 Speed Input Module
The 1794-IJ2 is the Flex I/O module for speed signals.

The module is capable of 2 channels of input signals.
It can measure up to 32767 Hertz.
This module requires the use of a TB3G or TB3GS

terminal base, with the keyswitch in position 1.
The inputs will be connected as shown in Table 5.7.
Table 5.7 Table 7 Connections for 1794-IJ2 Speed Input Module
Module Channel Signal+ Return - Shield
1 5 3 16
2 10 12 33

NOTE
Several issues with speed input signals have
resulted in Solar issuing Technical Letters
and Service Bulletins concerning wiring
and shielding modifications consult these
documents for the latest update.
The module has the standard power/status

indicator. It illuminates green when the
module has power and the hardware is good.
The module also has yellow indicators behind
the Freq and Gate labels. A summary of
channel status is as follows:
1. Yellow indicator illuminated - the channel is on

and connected properly
2. Yellow indicator off - the channel is either turned

off or not connected properly
3. Red fault indicators off - normal operation
4. Red fault indicators flashing fault condition

ANALOG OUTPUT MODULE 1794-OE4
Figure 5.7 1794-OE4 Analog Output Module

The 1794-OE4 is a 4-channel output module. This
module converts decision data in the form of an
integer number (sent to it by the Controller) into
analog signals.
The 1794-OE4 is capable of outputting several
different types of analog signals:
1. 0 to 20 mA
2. 4 to 20 mA
3. 10 to +10 Vdc
4. 0 to 10 Vdc
The module must be configured for range and type
of signal to be sourced. Both software and hardware
configuration is required. The software configuration
(step two in the Analog Output Read Write subsection)
is set up in the Controller software (RSLogix 5000),
and sets the range of signal to be used. The type of
signal to be used (Volts or Amps) is configured by the
terminal circuit connections.
Tables 5.8and5.9 show the channel and terminal

connections for both Current and Voltage signals, for
the different terminal bases.

This module requires the use of either TB3, TB3S,

TBN or TBNF terminal bases, with the keyswitch
in position 4.
Table 5.8 Connections for TB3 or TB3S Terminal Bases
OUTPUT CURRENT VOLTAGE
CHANNEL
SIGNAL COMMON SIGNAL COMMON
0 A-0 A-1 A-2 A-3
1 A-4 A-5 A-6 A-7
2 A-8 A-9 A-10 A-11
3 A-12 A-13 A-14 A-15
Table 5.9 Connections for TBN or TBNF Terminal Bases

OUTPUT CURRENT VOLTAGE
CHANNEL
SIGNAL COMMON SIGNAL COMMON
0 B-0 C-1 B-2 C-3
1 B-4 C-5 B-6 C-7
2 B-8 C-9 B-10 C-11
3 B-12 C-13 B-14 C-15
The module has a power indicator. If the module has

between 19.2 and 31.2 Vdc the power indicator will
be green.

STUDENT ACTIVITY
1. List five types of input or output module

commonly used on Solar packages.
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
2. State the number of channels available on each
of the five module types listed above.
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. List five types of input or output module

commonly used on Solar packages.
Discrete Input
Discrete Output
Analog Input
Analog Output
RTD Input
Thermocouple Input
Frequency Input
2. State the number of channels available on each
of the five module types listed above.
Discrete Input - 16
Discrete Output - 16
Analog Input - 8
Analog Output - 4
RTD Input - 8
Thermocouple Input - 8
Frequency Input - 2



Solar Technical Training TT4 Chapter 1, Lesson 5 Communication Networks & Devices
TT4 Chapter 1, Lesson 5 Communication

Networks & Devices
OBJECTIVES:
able to:
1. list the available methods of connecting to the

Logix5000 platform.
2. state the functional characteristics of the devices

used to connect to the Logix5000
3. describe the procedures necessary to establish

communication with the Logix5000 platform
using
a. RS232 serial link
b. ControlNet
c. Data Highway+
d. EtherNet/IP
INTRODUCTION
The Logix5000 Controller module is equipped with a
front panel-mounted RS232 serial port, which may
be used to connect a programming terminal or other
serial device. All other communication methods
require that an interface module of the appropriate
type be installed in the chassis. Each connection
method is described in the following sections.

TT4 Chapter 1, Lesson 5 Communication Networks & Devices Solar Technical Training
Figure 6.1 ControlLogix Chassis with Communication Modules

RS-232 SERIAL COMMUNICATION

See Figure 6.2
The 9-pin serial port connector on the front of the

Controller module is configured for RS-232 protocol. A
prefabricated cable is available (Allen-Bradley P/N
1756-CP3), or a cable can be fabricated locally as
illustrated in Figure 6.2. Ensure that the cable length
does not exceed 15.2m (50 ft).
The RS-232 DF1 devices communication driver must
be configured using RSLinx; once this has been
accomplished, the connection method may be selected
from a pull-down menu on the startup screen in
RSLogix 5000 to establish communication with the
Controller.
Figure 6.2 RS-232 Serial Port and Cable

CONTROLNET COMMUNICATION
The ControlNet 1.5 protocol is used to link the
Controller to the I/O network. The standard interface
module is the 1756-CNBR (redundant) module, as
shown in Figure 6.3.
BNC coaxial connectors on the 1756-CNBR provide
for connection to the ControlNet adapters in the I/O
system. RSNetWorx for ControlNet software must be
loaded to use the 1756-CNBR interface (RSNetWorx is
included in the RSLogix 5000 Professional package).
Figure 6.3 1756-CNBR ControlNet Interface Module

A programming terminal may also be connected
to the system using the ControlNet CNBR. The
standard Solar programming terminal is equipped
with a 1784-PCC adapter and cable which connects
to the RJ-45 Network Access Port on the front of the
1756-CNBR module.

The CNBR modules must be allocated Node addresses

in the ControlNet system. Two rotary 10-position
switches on the top of the module are used to set the
Node address (see Figure 6.4). Addresses between
01 and 99 are selected by these switches (00 is an
invalid address).
Figure 6.4 ControlNet Node Address Switches

Status and diagnostic information are provided by the

Module Status Indicator LED and the Module Status
Display on the front of the module (see Figure 6.3).
If status and operation are normal, the LED will be
green and the display will read: Refer to Table 6.1 to
interpret indications of malfunction conditions.
Table 6.1 Diagnostic Indications
Diagnostics
LED Display Cause Action
Off None Module not communicating due to a 1.Check power supply

power supply fault or internal fault. 2.Check cables/connectors
3.Make sure module is firmly seated in
chassis
4.If the indicator remains off, replace module
Red Msg Module’s network address is set to 1.Turn chassis power supply off
scrolls 00 2.Remove module from chassis
3.Set network address switches to valid
address (01-99)
4.Install module in chassis
5.Turn chassis power supply on.
Red BPA# Module detected a different slot Replace chassis or module
ERR address from that latched in a
power-up.Excessive noise on
backplane causes this error.
Red BPRX Too many CRC errors being Replace module
ERR generated by multicast backplane
receiver, so backplane receivers
have been shut off
Red BPIC Hardware fault within the module Replace module
ERR
Red CNIC Hardware fault within the module Replace module
ERR
Solar control systems use two-channel ControlNet

systems to allow for redundancy (Channel A and
Channel B). Both channels communicate with all of
the I/O modules, therefore each channel passes the
same information to the Controller. The ControlNet
system will select the channel that carries the stronger
signal, although the difference between the channels
should be small.

Two ControlNet Channel Status LED indicators are

used to show the status of the ControlNet channels
(see Figure 6.3.). Refer to Table 6.2 to interpret
indications other than the normal green appearance.
Table 6.2 ControlNet Channel Status Indicator Diagnostics
A and B Cause Action
Off No Power None, or power up
Steady Red Faulted Unit Cycle power or rest unit. If fault persists,
contact Solar
Alternating Red/Green Self Test None
Alternating Red/Off Incorrect node cnfiguration Check network address and other ControlNet
configuration parameters
A or B
Off Channel Disabled Program network for redundant media, if
required
Steady Green Normal Operation None
Flashing Green/Off
Temporary errors None: unit will self-correct
Flashing Green/Off Node is not configured to Make sure the configuration manager node is
go on-line present and working and selected address is
not greater than UMAX.
Flashing Red/Off Media fault Check media for broken cables, loose
connectors, missing terminators, etc.
Flashing Red/Off No other nodes present on Add other nodes to network
network
Flashing Red/Green Incorrect network Cycle power or reset unit. If fault persists,
configuration contact Solar

ETHERNET/IP COMMUNICATION
See Figure 6.5
The ControlLogix platform may be accessed through

a 1756-ENET or 1756-ENBT interface module.
Solar’s standard interface module is the 1756-ENBT,
which is the more current version featuring faster
communication rate and larger on-board memory
capacity.
The module must be properly configured to establish

communication.Configuration is accomplished using
RSLinx or the Rockwell BootP disk that is shipped
with the module. Configuration sets the module’s IP
(Internet Protocol) address, gateway address, and
subnet mask.
NOTE
In practice most modules installed in a Solar
package will be pre-configured, with the
only action required being for the user to
establish the IP address and then configure a
communications driver to match this address.

Figure 6.5 1756-CNBT EtherNet/IP Interface Module
The front of the 1756-ENBT module is provided

with an alphanumeric display and LED status
indicators (see Figure 6.6). When power is applied,
the alphanumeric display should cycle through the
following states: “TEST - PASS - OK - REV x.x”, where
”x.x” is the module’s firmware revision.
The display then alternates between “OK” and the

module’s default BOOTP address. The three bi-color
(red/green) LED status indicators provide diagnostic
information about the module and its connections to
the network. Tables 6.36.4 6.5describe each indicator
condition.

Figure 6.6 1756-ENBT Front Panel

Table 6.3 NET Status Indicator Codes
State Status Description
Off Not Powered, no IP adddress Moduleis not powered, or does not have an IP address.
1. Verify there is chassis power and the module is
completely inserted into the chassis and backplane.
2. Make sure the module has been configured.
Flashing Green No Connections Module has obtained an IP address, but has no
established connections
Green CIP Connections Module has an IP address and at least one established
connection.
Flashing Red Connection Timeout One or more of the connections in which the module is
the target has timed out.
Red Duplicate IP address Module has detected that the IP address is already in
use. Assign a unique IP address to the module.

Table 6.4 Link Status Indicator Codes

Off No data transmission Module is not ready to communicate
Green Ready Module is ready to communicate
Flashing Green Data transmission in Module is communicating over the network
progress
Table 6.5 OK Status Indicator Codes

Off No Power Module does not have 24V dc power. Verify there is
chassis and the module is completely inserted into the
chassis and backplane.
Flashing Standby Module is not configured
Green
Green Operational Module is operating correctly.
Flashing Red Minor Fault A recoverable fault has been detected. This could be
caused by an error in the configuration.
Red Major Fault An unrecoverable fault has been detected. Recycle
power to the module. If this does not clear the fault,
replace the module.
Flashing Self-test Module performing power-up self-test.
Red/Green

DATA HIGHWAY+/REMOTE I/O COMMUNICATION

See Figure 6.7
The 1756-DHRIO module can be used for

Data Highway+ (DH+) messaging, Control &
Information Protocol (CIP) messaging, or Remote I/O
communication with the ControlLogix system.
The front panel includes an alphanumeric status

indicator, channel and module status LEDs, two
3-pin channel connections, and an 8-pin mini-DIN
programming terminal connector. The programming
terminal connection is the same physical link as the
Channel A connection. Channel A must be configured
for DH+ communication to use the programming
terminal connection. The module must be configured
using RSLinx; once this is accomplished, the module
can be addressed in the controller program.
Figure 6.7 1756-DHRIO Module
CONFIGURATION SWITCHES
See Figure 6.8. Before installing the module, the

configuration switches behind the side panel must be
set to select DH+ or RIO communication. For a channel

configured as DH+, the node address switches must

be set to the appropriate address. The node address
switches do not apply to a channel set up for RIO
Figure 6.8 DHRIO Module Configuration Switches

The alphanumeric display and the status LEDs on the
module’s front panel provide diagnostic information
about the module. When the module is powered up,
two events take place:

1. The alphanumeric display illuminates and cycles

through the following message sequence:
a. Channel A and the network used for
Channel A - DH+ or RIO
b. Channel A node address, if used for DH+
c. Channel A status
d. Channel B and the network used for
Channel B - DH+ or RIO
e. Channel B node address, if used

f. Channel B status
This sequence runs continuously during normal

module operation.
2. Module OK status LED shows solid Red, then
flashes Green.
Diagnostic codes are flashed on the alphanumeric

display at approximately 1 second intervals. Tables6.5
and6.6 summarize the codes.
Table 6.6 Diagnostic Codes - DH+
Data Highways+
Code Description Recommended Action

OFF LINE Data Highway+ link is in STOP state Correct the configuration
DUPL Data Highway+ duplicate node address Choose another node address and reset
MNDE switches
ONLY Only node on Data Highway+ link Check the cables
NODE
CNFG Incorrect DH+ routing cable configuration Correct the configuration
FALT Incorrect DH+ object configuration Verify the module is inserted in correct slot
OK Normal operation for that channel None
LINK OFF Channel B is disabled because Channel None
A is used for 230K operation

Table 6.7 Diagnostic Codes - RIO

Remote I/O
Code Description Recommended Action

MUTE No adapters found on RIO Add an adapter to the RIO network
LINK
RACK Rack overlap on RIO Reconfigure RIO racks
OVER
DUPL Duplicate scanner on RIO Check RIO adapter settings
SCAN
MAX DEV Maximum devices exceeded on RIO Remove devices to meet limitations on RIO
network
CHAT Babble detected on RIO Check RIO device and network connections
LINK
OFF LINE Not trying to communicate None- normal state if controller is not
controlling remote I/O
OK Normal operation None
The three Status LEDs also provide diagnostic

information. Tables 6.7 and 6.8 summarize the
information provided by the indicators:
Table 6.8 OK Indicator Codes
Module OK Indicator
If the indicator is: Module Status Recommended Action

Off Not Operating Apply chassis power
Verify module is completely inserted into chassis
and backplane
Green flashing Operating but not routing None, if no messages are actively being routed
messages and no controller through the module and no controller transferring
transferring I/O I/O.
To route messages or transfer I/O, use module
default configuration or configure module
Red, then Off Performing self-test None, normal operation
Green Operating and routing None, normal operation
messages
Red In major fault Reboot module. If Red recurs, replace module
Red flashing In major fault or configuration Check alphanumeric display and take action
fault described in tables 4.6/4.7

Table 6.9 Channel Status Indicator Codes

Channel Status Indicators
If the Channel A or In this channel mode: then the channel take this action:
B indicator is: status is:
Off All Not on line Place channel on line
Green RIO Scanner Active RIO link. All adapter None, normal operation
DH+ modules are present and None, normal operation
not faulted.
Operating
Green flashing RIO scanner One or more nodes faulted Check power at other racks
DH+ or failed Check cables
No other node on the
network
Red All Hardware fault Reboot module. If Red
recurs, replace module
Red flashing RIO Scanner Faulted adapters detected Check cables; check
DH+ Duplicate node detected power at other racks
Check node address

STUDENT ACTIVITY
1. List four methods used to communicate with the

Logix 5000 controller.
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
2. What methods will always be available on a

standard Solar project, since they do not require
optional hardware in the 1756 chassis?
_____________________________________________
_____________________________________________
3. What software is used to configure
communications drivers?
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. List four methods used to communicate with the

Logix 5000 Controller.
RS232-C SERIAL LINK
CONTROLNET
DATA HIGHWAY PLUS
ETHERNET/IP
2. What methods will always be available on a

standard Solar project, since they do not require
optional hardware in the 1756 chassis?
RS232-C SERIAL LINK
CONTROLNET
3. What software is used to configure
communications drivers?
RSLINX



Solar Technical Training TT4 Chapter 1, Lesson 6 Operator Interface Devices
TT4 Chapter 1, Lesson 6 Operator Interface Devices
OBJECTIVES:
able to:
1. name the devices used in the Turbotronic
4 control system for operator control and
monitoring of package operations.
characteristics of each of the operator interface
devices used in the Turbotronic 4 control system.
3. given a system block diagram, describe the

methods used in the Turbotronic 4 control system
to connect each of the operator interface devices
to the system controller.
INTRODUCTION
The configuration of the operator interface is
determined by site requirements and customer
preferences (as discussed in a previous lesson).
For on-skid controls, a digital gauge panel with

integral status and alarm screens (TT4000-S) and a
minimal basic array of control switches are mounted
on the skid; a more comprehensive Human-Machine
Interface (TT4000) unit, with or without an extended
Turbine Control Panel, may be installed in a control
room or other location remote from the skid.

TT4 Chapter 1, Lesson 6 Operator Interface Devices Solar Technical Training
The off-skid control configuration includes a

fully-functional control console, with integral HMI
(TT4000), Turbine Control Panel, and all primary
control elements. An additional remote TT4000 can
also be installed as a customer-selected option.
The following paragraphs describe each of the operator
interface devices.

TURBINE CONTROL PANEL

See Figure 7.1.
The Turbine Control Panel consists of an array of

switches and indicator lamps, which connect to
the controller through Discrete I/O modules. The
panel includes the minimum controls and indicators
necessary for basic operation of the package.
Figure 7.1 Turbine Control Panel
The standard switches on the panel include:
1. Off/Local/Remote keyswitch
2. Start
3. Normal Stop (shutdown with normal no-load

cooldown)
4. Emergency Stop (shutdown without cooldown)

5. Horn Silence (audible alarm)
6. Acknowledge (alarms and shutdowns)

7. Lamp Test
8. Backup Reset (keyswitch)
9. Reset (alarms and shutdowns)

10. Speed Control (increase and decrease)

11. Manual Anti-Surge Valve (open/close) - with

optional surge control system for compressor
packages
12. Load Setpoint Auto/Manual (with process control
option on compressor/mechanical drive packages)
The standard indicator lamps on the panel include:
1. Local/Remote
2. Ready
3. Starting
4. Ready To Load
5. On Load
6. Backup Active
7. Cooldown
8. Stopping
9. Alarm Summary
10. Shutdown Summary

TT4000 DISPLAY AND MONITORING SYSTEM
See Figure 7.2.
Figure 7.2 TT4000 Display

The TT4000 Display and Monitoring System
is a product developed by Solar specifically for
turbomachinery control applications. The TT4000
display hardware comprises an Allen-Bradley 6180
industrial computer.
TT4000 displays and stores data and provides a wide

range of interface capabilities. TT4000 interfaces
with, but is separate from the package control system.
This allows TT4000 to perform multiple tasks without
interfering with the critical control and protection
functions handled by the Controller.
TT4000 provides a window into the package control

system. It shows engine conditions, stores information,
alarms, shutdowns and events, and can permit
varying levels of control. While beneficial to the
operator, the TT4000 is not responsible for control
of the package, since that function rests with the
package control system.
With the following features, the TT4000 is consistent

with current industry software standards:

1. The system runs under the Windows 2000

operating system.
2. The system is compliant with Transmission
Control Protocol and Internet Protocol (TCP/IP)
to permit easy transmission of data between
TT4000 and other programs
3. The system is compliant with Object Linking and

Embedding for Process Control (OPC) standards.
This facilitates integration with other compliant
software systems.
4. Historical data are readily viewable within the

program; also, files in Comma-separated Value
(.csv) format can be created for easy export to
other programs such as Microsoft Excel.
5. TT4000 incorporates Visual Basic for Application

(VBA) scripting that can be used to assist in
analysis and reduction of data.
6. The program supports Active-X controls.
Referring to Figure 5.2 it can be noted that both the

TT4000 and the TT4000-S displays communicate with
the Controller via the ControlNet system.
TT4000 COMPONENTS
The TT4000 family of systems includes various

configurations to support different operational
requirements:
TT4000
TT4000 is the fully-featured display and monitoring

consisting of either a panel-mounted video display
(VDU) or a desktop PC configured with the Windows
2000 operating system, the TT4000 application
software, and the specific project software files. The
system can store extensive amounts of data in addition
to its display, communications and control capabilities.
It is designed for operation in a non-hazardous area,
such as a control room. Figure 7.3 illustrates the
panel-mounted VDU.

Figure 7.3 TT4000 Panel-mounted VDU
The panel-mounted VDU consists of an industrial

computer and HMI display software. The VDU with
Solar’s TT4000 HMI software performs several key
functions to facilitate operation of the turbomachinery
equipment through a user-friendly interface. The
HMI system monitors the turbine and driven
equipment parameters, calculates performance
factors, annunciates alarms, reports on the running
status of the equipment, stores data, and provides a
comprehensive set of analysis tools.
The desktop version of TT4000 can be packaged in a
self-contained roll-around console (see Figure 7.4) with
a standard keyboard and pointing device (mouse).

Figure 7.4 TT4000 Desktop Unit
TT4000 can be integrated as part of a larger network

for data sharing and remote display communications.
The VDU operates independently of the control system
and provides additional operator and maintenance
information. Typical screens include:

STANDARD DISPLAY SCREENS:
1. Operation Summary (illustrated in Figure 7.5)

2. Temperature Summary
3. Vibration Summary
4. Alarm Summary
5. First Out Alarms
6. Discrete Events Log
7. Historical Data Display

8. Strip Chart Function
9. Program Constants
10. Package Valve Mimic Diagram (for compressor
sets)
11. Generator Summary (for generator sets)
OPTIONAL DISPLAY SCREENS:

1. Gas Turbine Performance Map
2. Driven Compressor Performance Map

3. Surge Control with Map
4. Process Control
5. Subsystem Screens

While any of the screens is being displayed, there is a

full-time indication of fault conditions. The top line
of the display is dedicated to the identification of up
to four alarm conditions. If there are more than four,
the operator is directed to go to the Alarm Summary
screen for a complete sequential listing.
Figure 7.5 TT4000 Operation Summary Screen

TT4000-S
See Figure 7.6
TT4000-S is a scaled-down version of the full TT4000

program.
Figure 7.6 TT4000S On-skid VDU
TT4000S is installed in an on-skid computer. Due

to the harsher environment, this computer has no
moving media other than a 3 1/2 Floppy Disk Drive,
and thus has limited storage capabilities compared
to the off-skid product.
The computer replaces the on-skid gauge panel and

provides greatly expanded operating information at
the package skid. The data display is modified to fit
the reduced screen size, but a selection of screens is
accessible from the menu screen. All other screens
include a “soft button” to return to the menu screen.

Typical screens include:
1. Engine Summary (see Figure 7.7)
2. Turbine Temperatures
3. T5 Temperatures
4. Fuel System
5. Lube Oil System

6. Turbine Vibration
COMPRESSOR SCREENS:
1. Compressor Temperatures
2. Compressor Vibration
3. Process Control
4. Anti-Surge Control
5. Unit Valves
GENERATOR SCREENS:
1. Generator Summary
2. Generator Information
Figure 7.7 TT4000S Engine Summary Screen

TT4000 REMOTE
When remote monitoring and control are required
from an additional location, a secondary TT4000
unit can be provided, typically in a desktop PC.
This remote TT4000 can interface with the primary
TT4000 system either through an Ethernet network
or by a dial-up connection. The TT4000 remote unit
is programmed for the same display screens as the
primary TT4000 unit.

STUDENT ACTIVITY
1. Which of these statements is true?
a. The Human Machinery Interface comprises

the on-skid and off-skid display terminals.
b. The Human Machinery Interface comprises
all operator interface devices, including the
on-skid and off-skid display terminals and
the turbine control panel.
c. The Human Machinery Interface comprises
customer furnished controls such as DCS or
SCADA.
2. What are the two types of display system used
on Solar Turbotronic 4 packages?
3. What method of communication is used between

the Controller and the display system?

NOTES:

ANSWER KEY
1. Which of these statements is true?
2. What are the two types of display system used

on Solar Turbotronic 4 packages?
TT4000
TT4000-S
3. What method of communication is used between
the Controller and the display system?
CONTROLNET



Solar Technical Training TT4 Chapter 1, Lesson 7 Special Function Devices
TT4 Chapter 1, Lesson 7 Special Function Devices
OBJECTIVES:
able to:
1. state the purposes of the special function devices
(Combination Generator Control Module,
Fire Detection and Suppression System, and
Vibration Monitoring System) installed on a
typical Solar turbomachinery package.
characteristics of each of the special function
devices.
3. demonstrate understanding of the methods
by which each of the special function devices
communicates with the controller in the
INTRODUCTION
Special Function Devices will be installed in
Turbotronic 4 control systems depending on the
application and package configuration. These include
the following:
1. Combination Generator Control Module (used on

generator sets)
2. Fire Detection & Suppression System (used

on enclosed packages)

TT4 Chapter 1, Lesson 7 Special Function Devices Solar Technical Training
3. Bently-Nevada 1701 Vibration Monitoring

System (all packages other than PG, where a
different vibration system is used)
The major features of these devices will be described
in this lesson.

COMBINATION GENERATOR CONTROL MODULE

See Figure 8.1
The Combination Generator Control Module (CGCM)

is a microprocessor-based generator control and
protection device with programmable settings.
Functionally, the CGCM replaces following load

sharing and automatic synchronizing devices used in
previous control system versions:
1. Automatic Voltage Regulator (AVR)

2. KVAR/Power Factor Controller
3. Load Sharing Module (LSM)
Figure 8.1 Combination Generator Control Module

In addition to the control functions mentioned

above, the CGCTM provides the following generator
protective features:
1. Loss of excitation current
2. Overexcitation voltage
3. Generator overvoltage
4. Generator undervoltage
5. Loss of sensing
6. Loss of Permanent Magnet Generator (PMG)
7. Reverse VAR
8. Overfrequency
9. Underfrequency
10. Reverse power
11. Phase rotation error

12. Generator overcurrent
13. Field current limit
INPUT CONNECTIONS
The CGCM has input connections for the following:

1. bus and generator voltage sensing
2. generator current sensing
3. current input for cross-current sensing

4. +/-10 VDC input for remote setpoint control
5. 24 VDC power from the package control system

power supply
6. AC power for generator exciter field excitation

from the permanent magnet generator (PMG)

OUTPUT CONNECTIONS
The CGCM provides the following outputs:

1. DC voltage to the generator exciter field for
voltage and reactive current (kVar/PF) control
2. load sharing output for paralleling operations
3. relay drive output for common fault annunciation
COMMUNICATIONS
The CGCM communicates with the control system

controller through the ControlNet interface for
configuration and data exchange functions. The
following data is transmitted:
1. module status data

2. calculated and scaled digital values
a. Voltages
b. Currents
c. reactive, apparent and true power
d. frequencies
e. phase relationships

CONFIGURATION
The CGCM is configured entirely by software no DIP

switches or other physical configuration devices are
available. The CGCM is designated a Node on the
ControlNet system and is configured using RSLogix
5000 software. Configuration will include settings for
generator design parameters, alarm and shutdown
setpoints, and the selection of protective features to be
used, as this will be project-specific.
A redundant CGCM may be installed as an optional
feature, using the interconnects provided on the
module.

FIRE DETECTION & SUPPRESSION SYSTEM

See Figure 8.2
Figure 8.2 Fire Detection & Suppression Local Control Unit
NOTE
Different versions of Fire Systems are in use
on Solar Turbotronic 4 packages. The version
illustrated in this section is the Detronics
Eagle Quantum. This system has now been
superceded by the Detronics Eagle Quantum
Premier. The Premier system essentially uses
the same operating principles, but utilizes
updated hardware and communicates with
the Controller over the ControlNet system for
status and configuration purposes.

PRINCIPALS OF OPERATION
A fire detection system is available for installation

in the enclosure. The primary fire detection system
utilizes ultraviolet (UV) detectors. The system includes
an automatic optical integrity feature that provides a
continuous check of the optical surfaces and detector
sensitivity. The secondary detection system utilizes
rate compensated thermal detectors that will detect a
rapid rise in temperature. The two detection systems
act completely independently in detecting a fire, and
may also be configured to utilize a voting system.
A fire system supervisory release panel is furnished
primarily to supervise the fire system circuitry. An
open circuit, ground fault condition, or loss of integrity
in the electrical wiring results in a trouble signal.
If a fire is sensed, the detectors transmit an electrical
signal via the fire system controller and the fire
system supervisory panel to activate the fire
suppression system.
In receiving this signal, the explosion-proof control
heads activate the discharge valves on the primary
and extended extinguishing cylinders, releasing the
extinguishing agent into the enclosure. The fire
extinguishant pressure is also used to initiate the
closure of all vent openings. The fire suppression
system achieves a static air condition and then
floods the enclosure with the proper concentration of
suppressant to extinguish the fire.

SYSTEM COMPONENTS
The primary system components are illustrated in

Figure 8.3:
Figure 8.3 Local Control Unit
1. Logic Controller Module - a microprocessor-based

programmable controller that contains the logic
used for monitoring and fire suppression control.
2. Communication Gateway Module - includes two
serial links for configuration and communication
with other compatible devices.
3. LON (Local Operating Network) Isolator Module
- provides isolation for the serial ports between
the gateway and host devices, and isolates shorts
in the LON and monitors for ground faults.

CONTROLS AND INDICATORS ON THE LOCAL

CONTROL UNIT INCLUDE:
1. AUTO Indicator - Green lamp which illuminate

when the AUTO/INHIBIT switch is in the AUTO
position
2. INHIBIT Indicator - Amber lamp which

illuminates when the AUTO/INHIBIT switch is
in the INHIBIT position.
3. DISCHARGED Indicator - Red lamp which

illuminates when extinguishing agent is
discharged into the enclosure.
4. AUTO/INHIBIT Switch - Two-position keyswitch

that selects the system operating mode.
Enables normal automatic mode in the AUTO
position; disables automatic operation in the
INHIBIT position (NOTE: Manual operation is
still enabled with the switch in the INHIBIT
position).
5. MANUAL RELEASE Switch - Guarded

push-button switch that releases extinguishing
agent into the enclosure and initiates a unit
Backup Shutdown when pressed.

BENTLY-NEVADA 1701 VIBRATION MONITORING SYSTEM

See Figure 8.4
Traditionally Solar vibration monitoring equipment
has either been mounted remotely from the main
control system, for example on the control console
door, or mounted directly in the Controller chassis,
for example when using the 2201 vibration system
mounted in the 1771 chassis.
The 1701 Vibration Monitor System is not of this

type, but is a distributed system that physically
and functionally integrates with the control system
Controller using the ControlNet Flex I/O network
through the 1794-ACNR adapter module.
Figure 8.4 1701 Vibration Monitoring System

TERMINAL BASE
The primary system components are mounted on a
terminal base, which provides:
1. the mounting platform for the system
2. installation slots for up to four monitors,

allowing up to 8 channels of vibration monitoring
3. installation slots for four internal transducer i/os
or internal transducers (one required for each
monitor)
4. installation slot for the power supply
5. installation slot for an optional Keyphasor

module
6. I/O terminations
7. Flexbus connection
8. Synchronous serial static port
9. 9 co-axial connectors for buffered dynamic

signals from the 8 vibration channels and the
Keyphasor
10. dynamic connector for connecting the 8 vibration
channels to an online diagnostic system or to a
patch panel for easy diagnostic access
The terminal base has 10 slots for mounting system
modules. Slots are identified with numbers embossed
on the base.
Two primary components are required to collect and

process the vibration data:
1. Monitors
2. I/O Modules or Internal Transducer Modules
These must be installed in pairs. Pairs are installed in

slots that have the same slot number, for example 2
and T2. Monitors install in slots 2, 3, 4, and 5, and
I/O modules or internal transducer modules install in
slots T2, T3, T4, and T5.

MONITORS
Monitors perform the following functions:
1. digitize the vibration signals
2. scale the signals into a range

3. provide error checking
4. provide OK checking
5. alarm processing
TWO TYPES OF MONITORS ARE CURRENTLY

AVAILABLE:
1. Proximitor Input
2. Seismic Input
The Proximitor Input Monitor is configured as either

a Radial Vibration or a Thrust Position Monitor and
the Seismic Input Monitor is configured as either a
Velocity or Acceleration Monitor.

I/O MODULES
The purpose of the I/O modules is to receive the

vibration data and send it to the Monitor Module. The
modules are two channel, as are the monitor modules,
therefore each pairing of monitor module / transducer
module will accommodate two vibration channels.
Two types of I/O module are available:
1. Transducer I/O Module

a. Interfaces between monitor and remote
transducer
2. Internal Transducers
a. Connect directly to the sensor

Selection will largely depend on the physical layout
of the package, i.e. cable lengths.
KEYPHASOR
Keyphasors are often used by Solar to obtain a
reference of the shaft rotation. The keyphasor is a
proximitor that is located next to a notch in the shaft.
As the shaft rotates the vibration system obtains a
pulse corresponding to each rotation of the shaft. This
can be used for vibration diagnostics purposes.
The Keyphasor Module installs in slot 1K and its I/O or
Internal Proximitor installs in slot T1K. Field wiring
termination, buffered outputs, and the Keyphasor
output terminals are identified by slot number and
channel, where channels are identified as A or B.
POWER SUPPLY
The power supply installs in the large slot in the

terminal base. The supply receives 24 Vdc power from
the package control system and provides logic (24Vdc)
and transducer (-18Vdc) voltages to the 1701 system.

COMMUNICATIONS
The Controller is the host for the vibration system,

and controls system configuration and alarm /
shutdown initiation. Vibration data will also be sent to
the display system.
All system configuration is completed using RSLogix

5000 software.
Communication between the controller and the

monitor includes the controller sending the monitor its
configuration, setpoints and other data such as time
delays and filters. The monitor sends the controller
the vibration and status data.
This communication takes place first between the

controller and the ACNR via the ControlNet; then
the ACNR communicates with the monitor via the
Flexbus connection.

STUDENT ACTIVITY
1. Name the three devices used in earlier Solar

control systems that have their functions
completed by the CGCM.
_____________________________________________
_____________________________________________
2. How does the CGCM communicate with the

Controller?
_____________________________________________
_____________________________________________
3. How is the CGCM configured?
a. DIP switches and jumpers
b. DIP switches and software

c. Software
4. What two main types of devices are used to

detect a fire?
_____________________________________________
_____________________________________________
5. How many vibration channels (excluding the

Key Phasor) can be accommodated on one 1701
terminal base?
_____________________________________________
_____________________________________________

6. State the communications path from a vibration

signal to the Controller in the 1701 vibration
system. (6 STEPS).
a. - Vibration Probe
b. -
c. -
d. -
e. -
f. - Controller
7. What software is used to change channel

configuration in the 1701 vibration system?
_____________________________________________
_____________________________________________

ANSWER KEY
1. Name the three devices used in earlier Solar

control systems that have their functions
completed by the CGCM.
AUTOMATIC VOLTAGE REGULATOR
KVAR/POWER FACTOR CONTROLLER
LOAD SHARING MODULE
2. How does the CGCM communicate with the

Controller?
CONTROLNET
3. How is the CGCM configured?
SOFTWARE (RSLOGIX 5000)
4. What two main types of devices are used to

detect a fire?
UV DETECTORS
THERMAL DETECTORS
5. How many vibration channels (excluding the
Key Phasor) can be accommodated on one 1701
terminal base?
EIGHT
6. State the communications path from a vibration
signal to the Controller in the 1701 vibration
system.
VIBRATION PROBE
TRANSDUCER I/O MODULE
MONITOR MODULE
ACNR
CNBR
CONTROLLER

7. What software is used to change channel

configuration in the 1701 vibration system?
RSLOGIX 5000



Solar Technical Training TT4 CHAPTER 2 INTRODUCTION TO TT4 PROGRAMMING
TT4 CHAPTER 2 INTRODUCTION TO TT4

PROGRAMMING
OBJECTIVES
Upon successful completion of this chapter, the
student will:
1. demonstrate understanding of the function of the

basic instruction set used in Solar projects.
2. demonstrate the ability to replicate logical

functions using the basic instruction set.
3. demonstrate understanding of the common

menus and functions of the RSLogix5000
programming software as used in Solar
applications.
4. demonstrate the ability to load project software

from a project CD to the programming terminal.
5. be able to view a Solar project in off-line mode.
6. understand the organizational structure and

conventions used in a Solar project.
7. understand the conventions used in

programming discrete and analog devices.
8. be able to describe the function of program logic
instructions as used in Solar applications.
9. be able to relate physical devices installed on

the Solar package to logical elements in the
controller program.

TT4 CHAPTER 2 INTRODUCTION TO TT4 PROGRAMMING Solar Technical Training
10. interpret commonly-used program logic and

describe logic functions in normal and abnormal
conditions.
11. demonstrate understanding of Function Blocks
as used in Solar applications.
12. demonstrate the ability to monitor a Solar

project in the on-line mode.
13. Demonstrate the ability to perform simple on-line

functions such as forcing and simple edits.
MATERIALS
1. Student Workbook
2. Student Programming Terminals with:
a. Windows 2000
b. RSLogix5000
c. RSLinx
3. Project CD
4. Project Electrical Schematics

5. Software Docs (to be used where Programming
Terminals are not available)
6. TT4 Simulator or Available Control System (to

be used during Lesson 10 if possible)
METHODOLOGY
This chapter uses a combination of instructor-directed

discussions and hands-on exercises to enable the
student to gain familiarity with the RSLogix5000
programming environment and Solar-specific
controller logic and control processes.
CONTENT
Chapter 2 consists of the following lessons:

1. Instruction Set
2. Introduction To Solar Logic

3. Loading a Program to the Programming

Terminal
4. Off-line Program Monitoring
5. RSLogix5000 Familiarization
6. Solar Project Organization
7. Control Logic Familiarization
8. Analog Device Programming

9. Function Block Overview
10. On-line Program Monitoring

NOTES:



Solar Technical Training TT4 Chapter 2, Lesson 1 Basic Instruction Set
TT4 Chapter 2, Lesson 1 Basic Instruction Set
OBJECTIVES:
able to:
1. demonstrate understanding of the basic
instructions used in the controller in a
2. explain the execution sequence utilized by the
controller in a ladder logic program
3. given a logic block diagram or written

instructions, create ladder logic to replicate the
functions performed in the logic block diagram or
described in the written instructions.
INTRODUCTION:
This lesson introduces the student to the basic
instructions used in the microprocessor-based
controller, and the methods by which the instructions
are assembled into a logical sequential program. The
instruction categories discussed include:
1. Bit Instructions
2. Timer and Counter Instructions
3. Compare Instructions
4. Move and Logical Instructions

TT4 Chapter 2, Lesson 1 Basic Instruction Set Solar Technical Training
A functional description of each instruction is

provided, and application examples of each are
illustrated.
BIT INSTRUCTIONS:
Bit instructions are used to monitor and control the

status of bits.
Examine if Closed (XIC):---] [---The XIC instruction
examines a bit (operand) to see if it is set(logic ”1”).If
the bit is set, the instruction is TRUE, and the
controller proceeds to the next instruction on the
rung.The bit to be tested is a data bit of the Boolean
(BOOL) type, and is identified with a TAG. In the
example in Figure 10.1, the XIC instruction has the
tag: First_Pass.
Figure 10.1 XIC Instruction
Examine if Open (XIO): ---]/[--- The XIO instruction

examines a bit (operand) to see if it is cleared (logic
”0”). If the bit is cleared, the instruction is TRUE, and
the controller proceeds to the next instruction on
the rung. The bit to be tested is a BOOL type , and
is identified with a tag.
Figure 10.2 XIO Instruction
Output Energize (OTE): ---( )--- The OTE instruction

sets or clears a data bit (operand). When the OTE
instruction is enabled, the controller sets the data bit;
when the OTE instruction is disabled, the controller
clears the data bit. Example:

Figure 10.3 OTE Instruction
These instructions are assembled in rungs to monitor

and control the status of bits, as illustrated in the
following examples.
Figure 10.4 Combining Logic

The logic in the example can also be expressed in
symbolic logic form, as in the example:
Figure 10.5 Symbolic Logic AND Example

The logic statement in the AND function is that for
output Q to be TRUE (“1”), both inputs A and B must
be TRUE simultaneously. The truth table in the
illustration lists the status of Q for each condition
status of A and B. In either form, the logic statement
is valid: for AL_799_H to be TRUE, S396_1 must be
CLEAREDand First_Pass must be SET.

NOTE
Although our industry-standard
representation of the truth table in
Figure 10.5(and the remaining symbolic
logic examples) shows 1 or 0 as the
inputs, when we transpose this to
ladder logic we MUST think of TRUE or
FALSE status (or SET and CLEARED).
As explained above input instructions
can be in either condition with a 1 or a 0
depending on the input depending on
the instruction type (XIC or XIO).
If the logical objective is to enable either input to
energize the output, branched logic could be utilized,
as in the following example:
Figure 10.6 Branched Logic

With this arrangement, either First_Pass must be
set, or S396_1 must beclearedto enable the OTE
instruction and energize AL_799_H.
The symbolic form of this logic would use the OR

function, as:
Figure 10.7 Symbolic Logic OR Example

Often, logic will be combined to express more complex

statements; for example:
Figure 10.8 Complex Ladder Logic
The logic statement in this example is: for AL_799_H

to be TRUE, PGM_HMI. Start must be SET, and
either First_Pass must be SET or S396_1 must be
CLEARED.
In symbolic logic form, the expression would be as

shown in Figure 10.9. Complete Figure 9 with the
correct tag addresses taken from Figure10.8.
Figure 10.9 Complex Symbolic Logic
Derivations of the Output Energize instruction are

used when the control bits conditioning the rung are
only momentarily set (TRUE), but it is desired to
maintain the bit in the output in a specific state; i.e.,
to latch the bit in one condition or the other. These
instructions are called: “;Output Latch (OTL)” and
”Output Unlatch (OTU)”.
Output Latch (OTL): ---( L )--- Like the OTE, the OTL
willsetthe data bit identified in the operand when it
is enabled; however, the OTL will not clear the data
bit when it is disabled. In the example illustrated
in Figure 10.10, when the rung becomes TRUE (all
conditioning instructions on the rung are TRUE), the
OTL sets AL_799_H. When the rung becomes FALSE,
AL_799_H remains in the TRUE state.

Figure 10.10 OTL Ladder Logic
Symbolically, the OTL is represented as illustrated in

Figure 10.11.
Complete Figure10.11 with the correct tag addresses
from Figure 10.10
Figure 10.11 OTL Symbolic Logic
Output Unlatch (OTU): ---( U )--- It may be

desired/necessary to clear a data bit upon transitioning
rung conditions, in this case, the OTU is used.
Figure10.12 illustrates the ladder logic for an OTU:
Figure 10.12 OTU Ladder Logic
Since the device related to the tag: PGM_HMI.Start is

a normally closed switch, pressing the switch would
make the XIO instruction TRUE, enabling the OTU
and clearing AL_799_H. When the switch is released,
AL_799_H will remain in the FALSE (cleared) state
until set by another instruction.
The OTL and OTU instructions can be combined, as in
the following example:

Figure 10.13 Combining OTL and OTU Instructions
When the OTL is enabled, AL_799_H is set and the

XIC in the second rung sets DS_175. When the OTU
is enabled, AL_799_H is cleared and the XICclears
DS_175.
Symbolically, the logic becomes the same as Figure

10.14.
Complete Figure10.14 with the correct tag addresses
from Figure 10.13.
Figure 10.14 Latch/Unlatch Symbolic Logic
Timer and Counter Instructions: Timer and

Counter instructions control operations based on time
or a number of events.
Timer On Delay (TON):

Figure 10.15 TON
This timer begins to accumulate time in millisecond

increments when the rung in which the timer is
programmed goes TRUE. The Accumfield in the
instruction reflects the accumulated value. Two entries
are made to complete creation of the instruction:
the name main operand assigned to the instruction
is entered in the Timer field, and the desired timer
interval (in milliseconds) is entered in the Preset
field. The timer illustrated in Figure10.15 is named:
Diagnostic_Delay_Timer , and is programmed for a
30 second timer interval.
Elements of the instruction may be used by other
instructions in the project as references. The Enable
(EN), Timing (TT) and Done (DN) status are often
used in bit instructions, and the integer values in
the Preset Accum fields are referenced in arithmetic,
logical and move instructions (see Figure 16 for
examples). In the TON, and in all timer and counter
instructions, references to status bits are identified
by a two-character mnemonic (, .EN, .TT, .DN), and
references to Preset and ACCum values are identied
by a three-character mnemonic (.PRE, .ACC).
With the rung false, the instruction clears the status
bits and the accumulated value. When the rung goes
TRUE, the Enable and Timing bits are set, and the
accumulated value begins to collect time. When the
accumulated value is equal to the Preset value, the
Timing bit is cleared, and the Done bit is set. The
timer remains in this state until the rung again goes
FALSE, at which time the Enable and Done bits are
cleared, and the accumulated value is returned to 0. If
the rung goes FALSE while the timer is timing, the
status bits and the accumulated value are cleared. The
Enable bit is a valid indicator of the rung’s status (it is
always TRUE when the rung is TRUE).

Figure 10.16 TON Timer Element References
Timer Off Delay (TOF):
Figure 10.17 TOF

This timer is reset when the rung is TRUE, and
begins to accumulate time in the Accum field when
the rung goes FALSE. Like the TON, creation
of the instruction requires two entries: a Main
Operand (name), and a Presetvalue in milliseconds.
The TOF illustrated in Figure10.17 is named:
”Pump_Lag_Delay_Pre_Post_TOF” and it is set for a
60 second interval.
With the rung TRUE, the Accum value and status bit
.TT are cleared, and status bits.EN and .DN are set.
When the rung goes FALSE, the .EN bit is cleared,
the .TT bit is set, and the Accum value begins to
accumulate time. When the .ACC value is equal to the

.PRE value, the .DN and .TT bits are cleared. The
timer is said to be “timed out”. The timer is reset
when the rung goes TRUE (whether the timer has
timed out or not).
Valid elements of the instruction can be referenced by
other instructions, as in the following examples for
Pump_Lag_Delay-Pre_Post_TOF:
Figure 10.18 TOF Timer Element References

Retentive Timer On (RTO):
Figure 10.19 RTO
The RTO is functionally identical to the TON, with

one exception: when the rung goes FALSE, the RTO
does not clear its Accum value (because of this,
the .DN bit also remains set if the .ACC value is
greater than .PRE.) This instruction requires a
Reset (RES) instruction referencing the RTO to clear
.ACC and DN. Figure10.20 illustrates the RES for
T5_TC_Max_Temp_RTO:
Figure 10.20 RTO Reset

As with the TON and TOF timers, valid instruction

elements of the RTO can be referenced by other
instructions:
Figure 10.21 RTO Timer Element Reference
Count Up (CTU)
Figure 10.22 CTU

To create this instruction, a tag is entered in the
Counter field, and an integer value is entered in the
Preset field. The CTU increments its .ACC value when
the rung it is in goes TRUE and the Count Up Enable
(.CU) bit is cleared. When the .ACC value equals
.PRE, the Done (.DN) bit is set. Successive rung
transitions will continue to increment the count in
.ACC, and the >DN bit will remain set. To clear the
.DN bit and the accumulated value, a Reset (RES)
instruction referencing the counter’s tag must be
issued, or 0 Must be written to the accumulated value.
The .PRE and the .ACC fields are scaled for double
integer (DINT) values; allowing values between
-2,147,483,647(10) and +2,147,483,648(10). If the count
exceeds the maximum value, the Overflow (.OV)
bit will be set, and the count will wrap around to
the maximum negative value and continue to count
upward from there.
Valid elements of the instruction can be referenced by
other logic, as illustrated in the following example in
Figure 10.23:

Figure 10.23 CTU Counter Element References
Count Down (CTD):
Figure 10.24 CTD
This instruction is functionally similar to the CTU,

except that it decrements its accumulated value when
the .CD bit is cleared and the rung goes TRUE. As
with the CTU instruction, the .DN bit is set when the
accumulated value is equal to or great than .PRE. The
count will continue to decrement below zero until the
maximum negative value (-2,147,483,648(10) in .ACC is
reached; then the Underflow (.UN) bit will be set, and
the count will roll over to +2,147,483,247 and continue.
Most applications will use this counter in conjunction
with a CTU that references the same tag, typically as
a totalizer in a production control system. Otherwise,
a Reset instruction referencing the counter’s tag must
be issued, or 0 must be written to .ACC.
Other instructions may be referenced to the CTD’s
elements as shown in Figure 10.25:
Figure 10.25 CTD Counter Element References
Compare Instructions:Compare instructions allow

comparison of values by using an expression or a
specific compare instruction. Compare instructions
are used to condition a rung; if the values in the
instruction are such that the instruction expression is

TRUE, the instruction is TRUE. Values of different

types can be compared, such as floating pointand
integer (an instruction executes faster and requires
less memory if all the operands of the instruction are
of the same type). Allowable data types are:
Table 10.1 Allowable Data Types
Data Description: Range:
Type:
BOOL 1-bit boolean 0_‘=off
1-‘=on
SINT 1-byte integer -128 to +127
INT 2-byte integer -32,768 to 32,767
DINT 4-byte integer -2,147,483,648 to +2,147,483,647
REAL 4-byte floating-point -3,402823E38 TO -1,1754944E-38(negative values)
number and
0
and
1.1754944E-38 to 3.402823E38(positive values)

Figure 10.26 ControlLogix Data Types
Available Compare instructions are:

Table 10.2 Compare Instructions
To Perform This Comparison: Use this instruction:
Test whether two values are equal Equal To (EQU)
Test whether one value is greater than or equal to a second value Greater Than or Equal to (GEQ)
Test whether one value is greater than a second value Greater Than (GRT)
Test whether one value is less than or equal to a second value Less Than or Equal to (LEQ)
Test whether one value is less than a second value Less Than (LES)
Test whether one value is between two other values Limit (LIM)
Pass two values through a mask and test whether they are equal Mask Equal to (MEQ)
Test whether one value is not equal to a second value Not Equal to (NEQ)
Compare values based on an expression Compare
The most commonly-used compare instructions will be

described in this lesson.

Equal to: (EQU):
Figure 10.27 EQU
The EQU instruction tests whether Source A is

equal to Source B. When A=B, the instruction is
TRUE, enabling the rung through the position of the
instruction.
Compare instructions can be used in Function Block

routines. Figure 10.28 illustrates an EQU instruction
in a Function Block routine:
Figure 10.28 EQU in Function Block Routine

When used in a function block routine, the EQU
functions in the same manner as when used in a
ladder logic routine. The Dest output is used to enable
other function block logic. An Enablein input to the
EQU can be used to enable or inhibit the instruction if
desired. The default for Enablein is set.
Greater than or Equal to (GEQ):

Figure 10.29 GEQ
In the example shown in Figure 10.29, the instruction

will be TRUE when Ngp.val is equal to or greater
than 15.
The GEQ can also be programmed in a Function
Block routine.
Less Than or Equal to (LEQ):
Figure 10.30 LEQ
The LEQ instruction is TRUE when A is equal to or

less than B.
The LEQ can be used in a Function Block routine.

Compare (CMP):
Figure 10.31 CMP

The CMP instructions performs a comparison on the

arithmetic operations specified in an expression which
is entered in the instruction. To create the instruction,
the desired expression is entered, using operators,
tags and immediate values as required
The example in Figure 10.31 compares the
value tagged: GV_Position.Val with the value:
(GV_Command.Val+10). If the Position (feedback)
value is greater than the Command value plus 10, the
instruction is TRUE. This logic is used to generate
a malfunction shutdown annunciation indicating
that there is unacceptable error in the guide vane
positioning system.
This instruction is not available for Function Block

logic.
Table 10.3 lists the most commonly-used operators

that can be entered in CMP expressions:
Table 10.3 CMP Operators
Operator Description Optimal Data Type
+ Add DINT, REAL
- Subtract/Negate DINT, REAL
* Multiply DINT, REAL
/ Divide DINT, REAL
= Equal DINT, REAL
< Less Than DINT, REAL
<= Less Than or Equal DINT, REAL
> Greater Than DINT, REAL
>= Greater Than or Equal DINT, REAL
<> Not Equal DINT< REAL
Compute/Math Instructions: These instructions

evaluate arithmetic operations using an expression or
a specific arithmetic instruction. Table 10.4 lists the
available compute/math instructions:

Table 10.4 Compute/Math Instructions

To Perform this Operation: Use This Instruction:
Add two values ADD
Subtract two values SUB
Multiply two values MUL
Divide two values DIV
Determine the remainder after one value is divided by another MOD

Calculate the square root of a value SQR
Take the opposite sign of a value NEG
Take the absolute value of a value ABS
Evaluate an expression CPT
Data types can be mixed, but rounding errors

and/or loss of accuracy may occur. A compute/math
instruction executes faster and requires less memory
if all the operands of the instruction use the same
optimal data type, typically DINT or REAL.
The most commonly-used compute/math instructions
will be described in this lesson.
Add (ADD)
Figure 10.32 ADD
Three entries are required to create this instruction,

and most of the other compute/math instructions.
Source A and Source B entries may be a valid tagged
data type or an immediate (constant) value. The
destination (DEST) entry must be a valid tag (the
controller must be told where to store the results
of the operation). The instruction adds Source A to
Source B and stores the result in DEST.

Subtract (SUB)
Figure 10.33 SUB
The SUB instruction subtracts Source B from Source

A and stores the result in DEST.
Multiply (MUL):
Figure 10.34 MUL

The MUL instruction multiplies Source A by Source
B and stores the result in DEST.
Divide (DIV):

Figure 10.35 DIV
The DIV instruction dividesSource A by Source B and

stores the result in DEST.
Compute (CPT)
Figure 10.36 CPT
The CPT instruction performs the arithmetic

operations entered in the expression. When it is
enabled, the instruction evaluates the expression and
stores the result in the Dest. The operands in the
expression can be immediate or tag values, but the
destination must be a valid tag. The CPT illustrated in
Figure 10.36 scales the measured DC supply voltage
in Volts and stores the result in DC_Supply.Val.

STUDENT ACTIVITY - LOGIC EXERCISES
Introduction
Using the logic instructions learned in this lesson,

create ladder logic to perform the functionality of the
following written descriptions.
Use the names given in the descriptions as the Tag

Addresses for inputs, outputs, and other instructions.
Use the resulting logic from each exercise in
the following exercise.
If you already have experience of RSLogix and have a

programming terminal available, these exercises can
be completed using the software.
Otherwise sketch the logic in the spaces provided.
Refer to the previous lesson for a reminder of the

symbols to be used.

Exercise 1 Bit Instructions
Step 1
When Input_1 is ON, turn ON Output_1.

Step 2
When Input_1 or Input_2 is ON, turn ON Output_1.

Step 3
When Input_1 or Input_2 is ON, and Input_3 is OFF,

turn ON Output_1.

Step 4
Have Output_1 remain ON even if any of the three

inputs change state.

Step 5
Turn Output_1 back off when Input_4 is ON.

Exercise 2 Timers and Counters
Step 6
When Output_1 is ON, turn ON Output_2 after 10

seconds using Timer_1.

Step 7
Turn ON Output_3 whenever Timer_1 is timing.

Step 8
Turn OFF Output_2 3 seconds after Timer_1 has

timed out. Use Timer_2.

Step 9
Reset Timer_2 when Input_5 is ON.

Step 10
Count the number of times Timer_2 times out, up to

a maximum of 5. Use Counter_1.

Step 11
Turn Output 4 ON when Timer_2 has timed out

5 times.

Step 12
When Output_4 is ON, initiate a TOF with a Preset of

15 seconds. Use Timer_3.

Step 13
Reset Counter_1 15 seconds after Output_4 is ON.

Exercise 3 Compare, Move and Logical

Instructions
Step 14
When Timer_3 Accumulated value is higher than or

equal to 10 seconds, turn ON Output_5.

Step 15
When Output_5 is ON, modify the existing logic for

Output_4 to be ON when Timer_2 has timed out 10
times.
When the exercises have been completed, refer to the

answer sheets that follow.

NOTES:

NOTES:

ANSWER KEY
Exercise 1 Bit Instructions
Step 1
When Input_1 is ON, turn ON Output_1.
Figure 10.37 Step 1
Step 2
When Input_1 or Input_2 is ON, turn ON Output_1.

This is an example of an OR gate either Input_1
OR Input_2 will turn on the output.
Figure 10.38 Step 2

Step 3
When Input_1 or Input_2 is ON, and Input_3 is OFF,

turn ON Output_1.
The OR gate has now been combined with an

AND gate.
Figure 10.39 Step 3

Step 4
Have Output_1 remain ON even if any of the three

inputs change state.
By using a latch (OTL) rather than an OTE we

can have the output remain on after initial
energizing, even if the rung conditions change.
This is commonly used by Solar in Alarm and
Shutdown annunciation, but also has practical
uses in logic sequencing.
Figure 10.40 Step 4

Step 5
Turn Output_1 back off when Input_4 is ON.
Latches (OTLs) are reset by using an Unlatch

(OTU) with the same address.
Figure 10.41 Step 5

Exercise 2 Timers and Counters
Step 6
When Output_1 is ON, turn ON Output_2 after 10

seconds using Timer_1.
Timers are commonly used in Solar logic
applications, with the most common being the
TON. The TON will start to increment time when
the rung transitions from False to True.
Note the Preset value of 10000 all RSLogix
timers increment in milli-seconds, so this is a
10 second timer.
When the ACC = PRE the DN (Done) bit will
become true the timer has timed out.
The DN bit is then used to sequence further

actions in this case turning on another output.
Note that although the DN bit is the most

commonly used timer element, other elements
are also available the EN (Enable) and TT
(Timer Timing).

Figure 10.42 Step 6

Step 7
Turn ON Output_3 whenever Timer_1 is timing.
As mentioned in Step 6, various timer elements

are available for use in the ladder logic. In this
case we have used the TT (Timer Timing) bit
to turn on an output. This has some practical
applications in having lamps flash or ramping
an analog output signal up or down.
Figure 10.43 Step 7

Step 8
Turn OFF Output_2 3 seconds after Timer_1 has

timed out. Use Timer_2.
This illustrates how to have an output cycling on

and off, for example a flashing lamp. Output_1
will come on after 10 seconds and remain on for
3 seconds. Logic could be written to restart the
cycle using another timer element to condition
the original rung.
Figure 10.44 Step 8

Step 9
Reset Timer_2 when Input_5 is ON.
Although the question stated “reset”, the reset

instruction is normally used for the RTD timer
or a counter. The requested logic can easily be
accomplished by placing an XIO instructor in
the same rang as the timer to be “reset”. When
Input_5 is ON, the XIO will be FALSE, and the
timer will reset.
Figure 10.45 Step 9

Step 10
Count the number of times Timer_2 times out, up to

a maximum of 5. Use Counter_1.
The CTU (Count Up) is the most commonly

used Counter. It will increment when the rung
transitions from False to True.
Note that the Counter will continue to

increment beyond the Preset, therefore logic
should be written to reset the Counter when it
has completed its desired function.
When ACC = PRE the DN (Done) bit becomes

true, and like the Timers this element can be
used to sequence other events.
The other type of Counter is the CTD (Count
Down). This acts in a similar manner to the CTU,
but is rarely used by Solar.
Figure 10.46 Step 10

Step 11
Turn Output 4 ON when Timer_2 has timed out

5 times.
The DN bit from the Counter has been used to

turn on another output. Practical applications
of this include Solars surge detection system,
where a counter registers the number of surge
events (flow pulses) and will shutdown the unit
if a certain number are detected in a certain
time.

Step 12
When Output_4 is ON, initiate a TOF with a Preset of

15 seconds. Use Timer_3.
The TOF (Timer Off) requires some careful

thought before use. The TOF has the DN and EN
bits set when the rung is True. It will start to
increment when the rung transitions from True
to False. Hence a XIO instruction has been used
in this case to condition the rung.
When the rung is True the DN and EN bits are

set. As the rung transitions to False the TT bit
becomes set. When the ACC = PRE all three bits
are reset.

Step 13
Reset Counter_1 15 seconds after Output_4 is ON.
This is an example of the use of TOF elements.

Again careful though is required. If using
the DN or EN bits remember that these are
initially set as the TOF waits for the rung to
transition to False. Hence in order to satisfy
our logic requirements we have had to use an
XIO instruction again.
This time we have reset a Counter.

Exercise 3 Compare, Move and Logical

Instructions
Step 14
When Timer_3 Accumulated value is higher than or

equal to 10 seconds, turn ON Output_5.
This logic could have been completed by

varying methods, including a CMP (Compare)
instruction and the GEQ (Greater Than Or
Equal) as used in this example.
Note that the fields in the GEQ instruction can
either reference other Tags or elements (for
example comparing error signals and selecting
which error to use in the fuel signal calculation),
or can be a pre-set value, as in this example.
A practical example of the latter method
would be determining the number of active
T5 Thermocouples, and initiating an alarm or
shutdown if the number drops.


Step 15
When Output_5 is ON, modify the existing logic for

Output_3 to be ON when Timer_2 has timed out 10
times.
This illustrates moving of values between

instructions. In this example we change the
preset value of Counter_1, depending on other
conditions. This technique can also be used with
Timers and various Compare instructions.
An example of this is the selection of the

Ignition Timer preset dependant on the type of
fuel selected (the ignition time on liquid fuel is
longer).



Solar Technical Training TT4 Module 2, Lesson 2 Introduction to Solar Logic
TT4 Module 2, Lesson 2 Introduction to Solar Logic
OBJECTIVES:
able to:
1. demonstrate understanding of the differences
between ladder logic and function block logic.
2. describe the methods used in the controller to

relate digital signals to/from the input and
output modules to logical processes in the
controller’s program.
3. state the order of execution of the logic contained

in the controller’s program.
INTRODUCTION:
The controller receives digitized information from
input and communication modules and sends digital
information to output and communication modules.
The logical processes that take place in the controller
are defined by the controller’s program.
The controller program uses both Ladder Logic and

Function Block routines to evaluate input data, act
on the data, and send updated data to control and
monitoring devices.

TT4 Module 2, Lesson 2 Introduction to Solar Logic Solar Technical Training
Ladder Logic: Ladder logic is an effective and

practical method of organizing and evaluating
information from a variety of sources, and for
establishing protocols for managing specific control
functions. Ladder logic is particularly well-suited
for management of discrete (on/off) functions, where
certain conditions must be satisfied to initiate (or to
permit) subsequent actions.
Discrete functions to the logic can come from Discrete

Input modules or from internal decision-making
processes. Discrete outputs to control external devices
are generated in the logic and routed to the devices
through Discrete Output modules.
Consider the requirements for controlling a lube oil

tank heater on a turbine package: The objective is to
automatically maintain the temperature of the oil in
the tank within a specific range. An electric heater
is installed in the tank for this purpose. An RTD is
installed to measure the oil temperature. The signal
from the RTD is routed to the logic through an RTD
Input module, and is scaled by program logic. This
signal will be compared to preset control settings
(setpoints) to establish the desired temperature range.
Under certain conditions, it would be inappropriate
to operate the heater These conditions include:
inadequate level of oil in the tank, a package fire
detected, engine running or in test crank, detected
failure of the oil tank RTD, and a Backup shutdown
initiated. All of these controls and safeguards can be
easily implemented using ladder logic. Refer to Figure
11.1, which is the oil tank heater control logic from an
actual turbine package:

Figure 11.1 Oil Tank Heater Control Logic
In the top rung of the ladder logic, the scaled

value representing oil tank temperature
(Tank_Temp.Val) is being compared with a set point
value (KT_Heater_Imm_On.Val). If the measured
temperature is less than or equal to the setpoint
(65.0?F. in this example), the compare instruction is
TRUE. The output instruction (OTE) at the right end
of the rung is enabled whenever the rung is TRUE, so
the internal control bit: Heater_IMM_Reg is set to the
TRUE state. Other instructions in the program can
refer to this bit, and the bit’s status will determine
the responses of these instructions. For instance,
there is an input instruction (XIC) in the lower branch
on the top rung that refers to Heater_Imm_Reg.
This instruction will now be TRUE because the oil
temperature is below its 70?Fsetpoint. This keeps the
heater control bit enabled as the oil temperature rises
above the 65?F. setpoint in the compare instruction in
the branch, and the instruction will transfer to fALSE,
disabling the rung and clearing the control bit. The
effect of this rung is to turn the control bit on when oil
temperature drops below 65?F., and turn the bit off
when oil temperature rises above 70?F.

The second rung in the illustration contains the logic

required to implement the protective permissives.
All instructions in the rung must be TRUE to
enable the output instructions (OTEs). One of the
OTEs activates a channel on a Discrete Output
module, which is connected to a 24 VDC contactor
control relay for the heater circuit. The tag on this
OTEUF2090:O.Data[1].1 defines the path to the
output channel: UF2090 is the reference designator for
the ControlNet Adapter through which the controller
communicates with the Discrete Output module;
O.Dataidentifies the Output data element of the block
being sent to the module;[1]designates slot 1 as the
module position; and .1 is the data channel assigned
to the heater control function. For convenience in
identifying data elements, the output also has another
tag assigned to it. The tag: H_390 relates the output
to the heater’s reference designator on the package
Electrical Schematic. The text: Lube Oil Tank Heater
above the instruction is a description which is added
for information and clarity.
The OTE in the lower branch controls a status bit
which is assigned to the HMI data interface.
All of the input instructions in the second

rung are referenced to internal control
bits.Heater_Imm_Req is controlled by the logic
in the top rung, and has been discussed. The
XIO instructions: PGM_Sequence.Start_Run and
PGM_Sequence.Test_Crank are TRUE when the start
and test crank functions are inactive.
The XIO instruction: PGM_Enclosure.Fire_Detected
will be TRUE if no fire has been detected.
The XIO instruction: Tank_Level_LL will be TRUE
if the oil level in the tank is sufficient to transfer
the low oil level float switch to clear the shutdown
annunciation.
If the oil tank RTD signal exceeds programmed range

limits, indicating a failure of the RTD, the RTD
monitoring logic will set the bit: RT390_Fail, and
the XIO with the same tag will be FALSE, disabling
the rung.

Finally, the XIO: PGM_Framework.BackupLatchAct

will be TRUE unless a backup shutdown is initiated.
Any of the input instructions in the rung that is
FALSE will disable the rung and lock out the heater.
All of the ladder logic in the controller’s program

operates in the same manner, executing the logic in
each Routine from top to bottom and left to right, as we
would read a book. Each Program has a routine which
is scanned automatically called the Main Routine.
.This Main Routine acts as the scheduler for the other
Routinesin each Program. Programs exist for each of
the package sub-systems or other specific functionality,
and are grouped together intoTasks(Solar’s practice is
to use only one Task, named: Turbomachinery_Task).
Figure 11.2 illustrates the program structure for a
typical Solar unit. The Programs in the task are
performed in the order in which they are listed.
The order can be changed, if necessary, by moving
Programs up or down in the listing.
Figure 11.2 Program Listing

Figure 11.3 illustrates the routines within the

Generator Program. Note the Main Routine at the
top of the list.
Function Block Logic: This logic form is ideal for
process control and other applications that require
relatively complex calculations. Function block
instructions are arranged in groupings called Function
Block Diagrams. Figure 11.3 shows the Function Block
Routines in a typical generator program. Figure 11.4
is an example of a Function Block Diagram.
Figure 11.3 Function Block Routine Listing

Figure 11.4 Function Block Diagram
The diagram is selected for display from the controller

organizer window (_100_kW_Percent_000 is the
selection in this example). The diagram has grid
coordinates to assist in locating elements.
The diagram can consist of a number of sheets (there

is no limit to the number), although Solar at present
tend to use one sheet only per routine.
The function block editor uses the same database as
the ladder editor, so tag names, analog scaling and I/O
identities are compatible. Many of the instructions
that are used in the ladder editor are also available
to the function block editor, and there are additional
instructions that are unique to function block
programming.
The instructions in the diagram can be “wired”

together in specific flow paths by the designer if
desired, or they can stand alone in the diagram.

The programming software automatically determines

the order of execution of instructions in the function
block diagram. In general, the controller will:
1. latch in all input values
2. execute other function blocks as determined by

how they are wired
3. write output values

Each instruction symbol has a small “ellipsis” box in
the upper right corner - clicking on this box will open a
dialog box for entry of detailed instruction parameters.
Figure 11.5 illustrates the dialog box for the MUL
instruction in the function block diagram.
Figure 11.5 MUL Parameters

From this dialog box, elements of the instruction
can be selected either to be displayed or hidden
(elements that are wired cannot be hidden), and other
configuration and operating data may be viewed.

STUDENT ACTIVITY
1. Briefly describe the differences between Ladder

Logic and Function Block Logic.
_____________________________________________
_____________________________________________
2. State the order of execution of Ladder Logic

during a single scan by the Controller.
_____________________________________________
3. State the three levels of project organization
hierarchy used in a Solar project, starting with
the highest level of organization.
_____________________________________________
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. Briefly describe the differences between Ladder

Logic and Function Block Logic.
Ladder logic is mainly used to sequence

events, and Function Block Logic is mainly
used to perform complex calculations.
2. State the order of execution of Ladder Logic

during a single scan by the Controller.
Left to right, and top to bottom.
3. State the three levels of project organization

hierarchy used in a Solar project, starting with
the highest level of organization.
TASK (TURBOMACHINERY_TASK)
PROGRAM
ROUTINE



Solar Technical Training TT4 Chapter 2, Lesson 3 Loading a Program to the Programming Terminal
TT4 Chapter 2, Lesson 3 Loading a Program

to the Programming Terminal
OBJECTIVES:
able to:
1. demonstrate understanding of the standard file

directory structure in the programming terminal
for ControlLogix projects.
2. demonstrate the ability to load a project to the

programming terminal using RSLogix and the
project tools installed on the programming
terminal.
3. demonstrate the ability to update the project

revision to create a working file using the project
tools.
INTRODUCTION:
A project is released to the field on a CD, which
contains the controller program, the HMI program,
and utilities for installing additional unit features,
such as fire detection/suppression system software.
The primary project files are in a directory named with
the unit Sales Order number, as shown in the example:

TT4 Chapter 2, Lesson 3 Loading a Program to the Programming Terminal Solar Technical Training
Figure 12.1 Project CD Directory
Within the primary directory are subdirectories that

contain the various elements comprising the project
software: Drawings, HMI, HMI-S (on-skid VDU), QTM
(fire system), and RSLogix, which is the controller
program directory. The .acd and the .l5k files are the
controller program files.

Figure 12.2 Contents of Project CD Main Folder
Figure 12.3 ACD and L5K Files
RSLogix 5000 can use either of the files (.acd or

.l5k); both are provided on the project CD. Note
that both files are named with the release level:A0,
signifying a tested and approved release from Controls
Engineering. The .acd file is the actual working file
that RSLogix will use. The. L5K file is a text version of
the .ACD. This is useful when transmitting project
software electronically, as the .L5K file is smaller
in file size, as shown in Figure 12.3. Opening and
saving an .L5k file using RSLogix will be covered
in a later section.

When the project is loaded into the programming

terminal using the project tools utilities, the directory
structure from the CD is replicated in the directory
C:\ jobs\72571 in the programming terminal (see
Figure 12.4):
Figure 12.4 Jobs Directory

LOADING THE PROJECT:

Many of the tools used in Turbotronic 4 are located in
TT4000 Shortcuts / Project Tools. These were loaded
automatically with TT4000 Version 3.3.53 Service
Pack 1 or higher.
To load the project from the project CD, use the
Distribute TT4000 Job utility which is accessed
through the Project Tools, as follows:
1. With the project CD in the appropriate drive,
open the TT4000 shortcuts folder, then click on
Project Tools the screen shown in Figure 12.5
appears:
Figure 12.5 TT4000 Project Tools

2. Click Distribute TT4000 Job; when the dialog

box appears, click TT4 Field Distribution as
Figure 12.6 Distribute TT4000 Job Tool

3. Make the following entries in the entry boxes

(see Figure 12.7):
Source: CD
Drive D (or whatever the CD drive letter is on the laptop)
Job - select the PD number from the list (normally only one PD will be on each
CD)
Destination: FS Laptop
Drive C
Note that the tool will automatically create the directory C:\Jobs, if it does not already exist.
4. Click Distribute.
Figure 12.7 Field TT4000 Distribution Tool

5. A small dialog box will open confirming that the

process has completed.
6. Exit and use Windows Explorer to confirm that
the job was loaded in the proper directory path.
UPDATING THE REVISION:

It is good practice to update the revision as soon as
practicable, to create a working copy of the program.
Edits should be made to the working copy to protect
the integrity of the original (normally A0) program.
A tool is provided in the TT4000 Project Tools package
for this purpose; it is called: Roll and Release. This
tool should always be used whenever the project is to
be revised, since it prevents any possible errors that
may result from manually renaming individual files.

To use the tool, select it from the TT4000 Project Tools

menu, then clickUpdate Revision andRun Wizard
(see Figure 12.8)
Figure 12.8 Roll & Release

Select the project from the list of projects in C:\ Jobs

that appears then clickNext (see Figure 12.9)
Figure 12.9 Selecting Project For Revision

Click All Files (see Figure 12.10)
Figure 12.10 Selecting Files To Revise

Click Next, then enter the new revisions for both

Display and RSLogix files (see Figure 12.11).
NOTE
Note that the tool will find the current
revision and offer the next consecutive
revision number. Available options for both
fields are A to Z and 0 to 9. The revision of
the first field is normally completed by San
Diego engineering (i.e. Rev A to Rev B, etc.)
The released revision (normally A0) is revised
to AF at the end of the project commissioning.
For reasons that will become apparent as
the Turbotronic 4 training proceeds, it is
recommended that revision to AF is made at
this point in time, and that this revision is
downloaded into the Controller. This will
prevent file-naming conflicts at a later stage.
Figure 12.11 Selecting New Revision
Click Finish: the wizard opens RSLogix, saves the

program files with the new revision levels and returns
to the tools menu. Note that this process may take
several minutes to complete wait for the confirmation
dialog box to appear before closing any tools.

Check to see that the jobs directory now includes

the new revisions (see Figure 12.12). Note that ALL
folders have been revised to AF.
Figure 12.12 New Revisions In Jobs Directory
NOTE
Other methods, such as Windows Explorer,
can be used to transfer the files from the
project CD to the programming terminal -
but some of the tools may not run correctly.
It is important that the file structure and
the location of the files follow the formats
established by the tools utilities. RSLogix will
explore these established directory paths to
locate and save the necessary files.

STUDENT ACTIVITY
1. What tool is used to load a Solar project from the

Project CD to a programming terminal?
_____________________________________________
2. In which directory will project files be placed?
_____________________________________________
3. What tool is used to revise a Solar project?
_____________________________________________
4. Why is it important that the correct tools are

used?
_____________________________________________
5. Where are these tools located?
_____________________________________________
6. What are the two file formats for an RSLogix

project?
_____________________________________________
7. State the main functionality of the two file

formats.
_____________________________________________

NOTES:

ANSWER KEY
1. What tool is used to load a Solar project from the

Project CD to a programming terminal?
Distribute TT4000 Job
2. In which directory will project files be placed?
C:\JOBS
3. What tool is used to revise a Solar project?
Roll & Release
4. Why is it important that the correct tools are

used?
To main the correct file structure and

enable all the TT4 tools to work correctly.
5. Where are these tools located?
TT4000 Shortcuts \ Project Tools

6. What are the two file formats for an RSLogix
project?
ACD
L5K
7. State the main functionality of the two file

formats.
ACD is the working file in RSLogix
L5K is a text file - smaller file size is useful

for electronic transmission.



Solar Technical Training TT4 Chapter 2, Lesson 4 Off-line Program Monitoring
TT4 Chapter 2, Lesson 4 Off-line Program Monitoring
OBJECTIVES:
able to:
1. open RSLogix 5000 on the programming terminal
2. locate and open a project controller program

using RSLogix 5000
3. demonstrate familiarity with the screen

elements and menu structure presented on the
RSLogix 5000 display
4. demonstrate the ability to navigate through the

controller program as displayed on the RSLogix
5000 display screens
INTRODUCTION:
When RSLogix 5000 is installed, a program icon
(shortcut) is placed in normal Windows Start Menu.
On Solar-supplied programming terminals a shortcut
may also exist Controls Applications folder on the
desktop. Either shortcut points to an executable
(.exe) file which is located in the path: C:\Program
Files\Rockwell Software\RSLogix 5000\rs logic 5000.
When this file is invoked by clicking the shortcut
icon, RSLogix 5000 is initialized. Once RSLogix 5000
is opened, several menu options are available. This
lesson will focus on off-line program monitoring.

TT4 Chapter 2, Lesson 4 Off-line Program Monitoring Solar Technical Training
OPENING A CONTROLLER PROGRAM:
Many of the icons and controls are the same as other

standard Windows programs. With RSLogix 5000
opened, to open a project controller program, first click
the folder icon or the:File text selection in the upper
left corner of the screen:
Figure 13.1 Opening A Project In RSLogix

When the file dialog box opens, cursor to the desired
program (72571 will be used in this example), then
click on either the .ACD or the .L5K file to place it
in the File Name selection box (.ACD is used in the
example).

NOTE
Note that RSLogix may have a default
directory other than C:\Jobs. If this is the
case then use the program options to set
C:\Jobs as the default directory.
Figure 13.2 Selecting ACD or L5K File

If the .L5K file had been selected above, a second

dialog box would have opened, and the .L5K would
have been imported and saved as an .ACD file for
programming this is shown in Figure 13.3.
Figure 13.3 Importing .L5K File

In either case, the file that is actually used for
programming (the working file) is the .ACD file. The
.L5K file is useful for making copies of a program,
since it occupies much less space than the .ACD file.

Once the project ACD file has been opened, it can

be saved either as an ACD or L5K file at any time,
using the standard Windows SAVE orSAVE AS
commands. At this point the file type can be selected
- see Figure 13.4.
NOTE
Remember that standard procedure means
that no change to the PD number or revision
should be made using theSAVE AS function.
Revisions should only be made using the Roll
& Release tool as previously discussed.
Figure 13.4 Saving Project File

RSLOGIX 5000 DISPLAY:

With a program opened, a variety of tools is available
to the user. The following is a discussion of the most
commonly-used features.
Refer to Figure 13.5 for the following descriptions.
Toolbars: The various tool bars will be described in

the next section.
Controller Organizer: This is the display that shows

the organization of the controller program in tree
format. It can be toggled on and off by clicking the tree
icon above the Path Toolbar.
Quick Pane Properties View: Provides a description

and properties of the item selected in the organizer.
May be minimized by dragging it downwards out of
view.
Ladder/Function Block Window: This is the primary
viewing area for monitoring and editing ladder logic
and function block files.
Results Window: This window displays the results of
search and verification activities.

Figure 13.5 RSLogix Main Screen
Figure 13.6 shows all of the available tool bars. Note

that some of the toolbars are probably not required for
everyday use, and some duplicate options available
elsewhere. Therefore, the user should establish the
preferred configuration of their own display. The
toolbars can be selecting for viewing or hidden by
using standard Windows commands. They can also
be dragged and resized to a certain extent in order to
maximize the viewing areas.
Figure 13.6 Available Toolbars

Standard Toolbar: This is presented and used in the

same manner as standard Windows toolbars. Clicking
on a selection will produce a pull-down with additional
available selections.
Figure 13.7 Standard Toolbar
Online Toolbars: Two different Online Toolbars are

available, and both are shown in Figure 13.8. The
toolbar on the left displays the controller status when
online, and the controller mode can be selected. Forces
can be enabled and disabled. The toolbar on the
right (called the Classic Online) duplicates the same
information in a different format, and also has the
communications path displayed. There is little need to
have both toolbars displayed.
Figure 13.8 Online Toolbars
Path Toolbar: This shows the current connection path

for online operations. To change the path, click on
the pulldown arrow and select a new device and/or
address. The small network icon at the end of the
toolbar illuminates to indicate online activity.
Figure 13.9 Path Toolbar

New Components Toolbar: One of these icons can be

clicked to add a new element to the project.
Figure 13.10 New Component Toolbar

Language Element Toolbar: Logic elements to be
added can be selected by clicking on the appropriate
icon. Tabs can be clicked to show additional instruction
listings.
Figure 13.11 Language Element Toolbar
Ladder Edit Toolbar: Click one of these icons to modify

a logic branch or add an input or return parameter.
Figure 13.12 Ladder Edit Toolbar

Bookmark Toolbar: Bookmarks can be assigned or

accessed with these buttons.
Figure 13.13 Bookmark Toolbar

HELP:
A Help menu is available by clickingHelp on the
Standard toolbar. The help function is well-organized
and provides useful assistance with a variety of topics.
Instructions for using the help features are included.
Figure 13.14 illustrates the Instruction Help, which is
a particularly useful feature.
In addition to the standard Help features, RSLogix

includes a variety of manuals in PDF format, also
accessed through the Help command.
Figure 13.14 Instruction Help

NOTES:

NOTES:



Solar Technical Training TT4 Chapter 2, Lesson 5 RSLogix5000 Familiarization
TT4 Chapter 2, Lesson 5 RSLogix5000 Familiarization
OBJECTIVES:
Upon completion of this lesson, the student will:
1. demonstrate familiarity with the principal
RSLogix 5000 toolbar functions, including: File,
Edit, Search, Logic, Tools and Communications.
2. demonstrate the ability to configure the screen

displays in the RSLogix 5000 software.
INTRODUCTION:
The RSLogix 5000 program features that will
normally be used most often in the field are those
relating to accessing, modifying and saving program
files. These features will be discussed and illustrated
in this lesson.

TT4 Chapter 2, Lesson 5 RSLogix5000 Familiarization Solar Technical Training
Configuring Screen Displays

Window (see Figure 14.1)
Figure 14.1 Window Settings
The format for the screen can be modified as desired

by clicking the Window option and then any of the
selections. The screen can be split horizontally or
vertically, tiled in either plane, or cascaded, just as in
any Windows-based application.

Tools To set the preferences for the display, click Tools,

then Options, and expand the categories by clicking
the + sign at the desired category. The desired change
can be made by following the prompts (see Figure
14.2).
Figure 14.2 Modifying Fonts & Colors

Ladder Display Customization
Another option in Tools allows the ladder display to be

customized to user preferences (see Figure 14.3).
Figure 14.3 Ladder Display Customization

Tags Display
The display for tags can be customized (see

Figure14.4).
Figure 14.4 Tag Display Customization

Logic
Selecting Logic will produce the menu box shown in

Figure 14.5.
Figure 14.5 Logic Menu
From this menu, assigned Controller tags can be

either monitored or edited. Once a selection is made,
tabs at the bottom of the display can be clicked to
toggle between Edit and Monitorfunctions.

Figure 14.6 Edit/Monitor Tags

Produced and Consumed Tags
If Produced Tags is selected, a window will appear

listing tags designated as Produced Tags. Produced
tags are those that are available to other controllers.
Only controller-scoped tags can be designated as
Produced tags.
Conversely, a Consumed Tag is a tag whose value

comes from another controller.
At present Solar do not normally use multiple

Controllers, so produced and consumed tag
designations will not normally be present.
Verification
Verification will check the controller, program, routine
or tag database for errors, such as invalid instructions
or tags.
To verify the integrity of the controller or the tag
database, select Verify, then click Tags or Controller as
appropriate. To view the results of the verification,
a Results window can be opened at the bottom of
the ladder/function block window by selecting View,
then clicking Results, or by pressing ALT and1
simultaneously. See Figure 14.7.
Figure 14.7 Results Window

Search
The Search task provides several options (see Figure

14.8):
Figure 14.8 Search Task Options

Find
Clicking Find (or pressing Ctrl+F) will open a dialog

box (see Figure 14.9):
Figure 14.9 Find Dialog Box

If the cursor was not on a logic element in the ladder
display, a search reference must be entered in the
Find What window.

If the cursor was on a logic element, the Find

Whatwindow will contain the tag assigned to the
element.
The additional entry windows can be used to configure
the search utility by clicking the pulldown arrows and
selecting the desired settings.
Additional features (Wrap on/off, Search Direction,

etc.) are configured by clicking in the relevant toggle
buttons.
With a reference in theFind What window, select the

desired function by clicking one of the boxes on the
right side of the dialog box.
Figure 14.10 illustrates the effects of selecting Find

All:
Figure 14.10 Find All Results

The Results window at the bottom of the screen
shows a listing of the occurrences of the tag:
PGM_Sequence.Ready_To_Load. The Results window
can be scrolled to view all occurrences. Double clicking

any of the occurrences of the tag in the Results

window will jump to the selected occurrence of the tag
within the ladder logic.
Find Next
Find Next advances the search to successive

occurrences of the search reference, highlighting each
in the ladder logic, as illustrated in Figure 14.11.
Each time Find Next is clicked, the next occurrence
is found and displayed.
Figure 14.11 Find Next Results

Replace (Ctrl+H)
The Replace dialog box feature provides a window for

entering replacement text (see Figure 14.12).
Once the replacement text is entered, Find Next

or Find All can be selected as desired to make the
modifications.
Figure 14.12 Replace

Go To (Ctrl+G)
This selection opens a dialog window (see Figure

14.13) to select the desired response.
Figure 14.13 Go To Dialog Box
By positioning the cursor in the Go to What window:

1. the Cross Reference database for the referenced
element can be viewed,
2. the selected tag can be monitored or edited,
3. the properties of the selected element can be

edited,
4. or the cursor (caret) can be positioned to a
specific rung.

Cross Reference (Ctrl+E)
This feature accesses the cross-reference database

to display a summary of all occurrences of the
selected reference. A cross-reference is executed by
highlighting the selected tag and pressing Ctrl+E, or
alternatively right clicking the tag and selecting Go To
Cross Reference from the dialog box. See Figure 14.14.
Figure 14.14 Go To Cross Reference

Figure 14.15 illustrates the cross-reference results for

the tag Header_Pressure.Val, which is the scaled
value of the lube oil header pressure transmitter.
Double clicking any of the results will open up the
ladder logic at that selected occurrence.
Figure 14.15 Cross Reference Results

Edit
The Edit task offers a menu of functions (see Figure

14.16) from which selections may be made:
Figure 14.16 Edit Menu

Cut (Ctrl+X):
The response to this selection depends on the position

of the cursor in the ladder logic when the selection is
made. If the cursor is on a logic element, that element
will be cut from its location and placed into a buffer
(temporary data location), and the rung display will
reflect the removal of the item. If the cursor is not on a
logic element, the rung it is on will be cut and placed
in a buffer. Rungs or elements which are cut from the
logic can be pasted into another rung or routine.
Copy (Ctrl+C):
Selected rungs or logic elements can be copied, to
be inserted into another rung or routine. This is a
non-destructive feature (the selected items remain
intact in their original locations).
Paste (Ctrl+V):
Items that have been placed in the buffer are inserted

into the location following the cursor position.

Delete Ladder Element (Del):
The rung or ladder element is deleted.
Double-click the desired item to be added, or highlight

the item and click OK to complete the entry.
Figure 14.17 Add Ladder Element Dialog Box

Edit Ladder Element
Two options are available:

Edit Element (Enter): If the cursor is not on an
instruction, a dialog box is opened with an entry
window containing the ASCII text for the logic
on the rung. Edits can be made to the text as
desired, then applied by clicking the button with
the green checkmark. The edits can be reversed
by checking the button with the red X.
If the cursor is on an instruction, a window with a

pulldown arrow is opened. Scroll down through
the entries in the pulldown to select a different
tag. For instructions with multiple tags, place the
cursor on the tag to be edited and initiate the edit.
Edit Element Comment (Ctrl+D): A Rung

comment or instruction can be added or edited,
depending on the cursor position when the edit
is initiated.
NOTE
Any of these actions can be undone by clicking
Undo in the Edit task.

Select All
Selects all rungs in the routine, or all instructions on

a rung for edits. Clicking in another cursor position
clears the selection.
Properties (Alt+Enter)
Opens an information window containing the name

assigned to the routine, a description of the routine,
the location (program) of the routine, the type and
size of the routine.
Figure 14.18 Routine Properties

Controller Properties
When this feature is selected, a popup appears with

several options available (see Figure 14.19):
Figure 14.19 Controller Properties
Click any of the tabs to view or change configuration

settings for the controller.

The Controller Properties display can also be accessed

by:
1. Clicking the pulldown in the Online Toolbar,
then Controller Properties,
2. Clicking the Controller Properties button on

the Online Toolbar, or
3. Right-clicking the Controller Name in the

Controller Organization window, then selecting
Controller Properties.
Figure 14.20 illustrates the location of these options.
Figure 14.20 Access to Controller Properties



Solar Technical Training TT4 Chapter 2, Lesson 6 Solar Project Organization
TT4 Chapter 2, Lesson 6 Solar Project Organization
OBJECTIVES:
able to:
1. describe the characteristics of the major software
elements used in Turbotronic 4 controllers,
including:
a. Tasks
b. Programs
c. Routines
2. describe the structure of the database in the

controller software.
3. define the data types used in the controller

software.
INTRODUCTION:
In this lesson, the architecture and organization of the
controller software will be described and illustrated.
Solar’s control systems are designed to certain logic
and documentation conventions. The information
in this lesson is based on those standards and
conventions. A Solar Project includes the elements
described in the following text.

TT4 Chapter 2, Lesson 6 Solar Project Organization Solar Technical Training
Project Elements:
A project file consists of the following elements:

Controller Properties (see Figure 15.1): This
element contains information about the controller
used in the project, such as: Controller Type,
Chassis size and type, slot number of the controller,
description, file path, Name (file name), serial port
configuration, fault status, and definitions of Fault
Handler and Power-up Handler files, if used.
Figure 15.1 Controller Properties
Tasks
The Task is the highest level of program organization.
A task can be either periodic or continuous. A
continuous task executes continuously while
periodic tasks occur at regular timed intervals.
Solar’s current practice is to use only one task
(Turbomachinery_Task); and this will be a continuous
task.
Programs
The next level of organization is the Program.
Programs organize logically-, functionally-, or
physically-related devices. Figure 15.1 also shows the
Programs that comprise the Turbomachinery Task in
a typical Solar project.

Note that a separate Program exists for each of

the package sub-systems, as well as a Framework,
Sequence, Serial Interface and HMI program. The
function of these Programs will be covered in later
lessons.
The programs are shown in the order in which
they will execute within the task.The order can be
modified using the Task Properties option illustrated
in Figure 15.2. This is accessed by right clicking
Turbomachinery_Task, then selecting Properties.
By convention, the Framework and Sequence

programs should execute first, and the HMI program
should execute last, to ensure that the most current
data is sent to the HMI.
Programs are named according to the functions they

will perform, followed by four characters to identify
the specific configuration, and three digits used to
identify the revision level.
Figure 15.2 Program Execution Order

Program Types
Programs can be organized into four categories:
1. I/O Control Programs
• These monitor and control the package

systems. Examples are Lube Oil, Fuel,
Shaft Bearings, etc.
2. Package State Program
• This program (called Sequence) receives

status signals from other programs,
updates the state the package is currently
in (for example it could be in the Purge
Crank or Ignition Sequence) and then
sends status signals back to other programs
to help sequence further events.
3. Interface Programs
• These programs (called Serial Interface and

HMI) provide an interface with customer
furnished systems such as DCS or Scada,
and also the Solar TT4000 display,
TT4000-S display, and all other operator
interface points.
4. Framework Programs
• This program performs functions necessary

to the operation of the control system, such
as monitoring I/O module status, watchdog
timers, etc.

Routines
The lowest organization of logic is the Routine.
Routines usually comprise very small sections of logic
to control and small sub-system. Figure 15.3 shows
the Routines that make up a typical Lube Program.
Figure 15.3 Routines Within The Lube Program
Routines appear in the program in alphanumeric

order, and will be executed in this order, except the
routine that is designated as the Main Routine.
The Main Routine always appears first after the

Program Tags folder, and is always executed first.
Solar’s practice is to begin the routine name with
a number, to control the order of execution. Since
RSLogix 5000 does not permit a routine name to begin
with a number, the routine names begin with an
underscore (“_”).

The Program Properties window is used to identify

a routine as the Main Routine. This is accessed by
right clicking the Program and then selecting The
Program Properties window is used to identify a
routine as the Main Routine. This is accessed by right
clicking the Program and then selecting The Program
Properties window is used to identify a routine as the
Main Routine. This is accessed by right clicking the
Program and then selecting Properties.
Figure 15.4 Designating The Main Routine

The Main Routine contains only Jump to Subroutine

(JSR) instructions, which call the other routines in the
program in sequence. A routine that is listed but is not
called in the Main Routine will not be executed. See
Figure 15.5 for an example of a Main Routine.
Figure 15.5 Lube Main Routine

Data Organization
Traditional controllers have data files where groups of
similar types of data are stored together. There are no
predefined data files in a Logix5000 controller. Users
must define the memory in the Logix5000 controller
by creating tags.
A tag is a text-based name for an area of memory in
the Logix5000 controller. Tags are identified by data
type and scope. Data Types include:
1. pre-defined
2. module-defined
3. user-defined
Pre-Defined Data Types
Commonly-used memory sizes, typically used with

ladder logic, that are already defined in the software.
Table 15.1 is a listing of the pre-defined data types
used in a typical Solar application:
Table 15.1 Pre-Defined Data Types
Pre-Defined Data Type Memory Location For:
BOOL Single bit where 1=ON and 0 = OFF
SINT Short integer (8 bits) between -128 and +127
INT An integer between -32.768 and +32,767
DINT Double word (32 bits), used to store a base integer number in the range
of -2,147,483,648 to +2,147,483,647
REAL 32-bit value that contains a mantissa and an exponent (power of ten to
which it will be raised), that can be very large or very small
CONTROL Length and position for file-level instructions
COUNTER Incrementing or decrementing a number
PID Loop instruction that is used to maintain a particular setting for speed,
pressure, temperature, etc. (the three gains: Proportional, Integral, and
Derivative, work together to determine how quickly and in what manner
the error is corrected)
TIMER Timed incrementer that measures in milliseconds
MESSAGE Control Structure for a message instruction

Module-Defined Data Types

A data type assigned to a tag that is automatically
generated when a communications or I/O module
is configured. Figure 15.6 illustrates an example of
the data types assigned to a 16-channel discrete
input module.
Figure 15.6 Module-Defined Data Types

User-Defined Data Types

A User-Defined Data Type (UDT) is simply a template
that is created by the user to group data for a specific
application.
Solar uses several user-defined data type tag
definitions (UDTs). Figure 15.7 illustrates a listing
of UDTs in a typical project, and shows an example
where the user-defined tag: “UDT_ANALOG” is used
to store data from a pressure transmitter input. This
UDT is the most commonly-used in Solar logic, and
has four members, or fields:
1. Val contains the scaled value of the analog, and

is the only member updated by the logic.
2. EuMin and EuMax contain the input minimum
and maximum values for the transmitter, in
Engineering Units.
3. The Eu member is a string that can hold up to

20 characters, and contains the engineering
units that the scaling will represent, such as:
psig, degF, etc.
Figure 15.7 User-Defined Data Types

Another commonly used User-Defined Data Type

is illustrated in Figure 15.8. This is the Program
Response Tag.
Each Program within the Task will have certain data
that needs to be referenced by other programs. In order
that this data can be accessed by other programs, it
would need to be created as a Controller-scoped tag.
NOTE
Reference the next section for a description of
the difference between Controller-scoped and
Program-scoped tags.
This would create a large number of Controller-scoped
tags within the Controller Tag Database, and although
this system would work, it would present difficulties
in organization.
Solar therefore create a User-Defined Data Type
for each of the Programs that are required to pass
information to other programs. Within these UDTs are
separate elements for each piece of data to be passed
to the other programs.
Refer to Figure 15.8. On the left side of the screen
there is a list of all the Program Response UDTs in
a typical Solar project.
On the right side of the screen is an extract from
the Controller Tag Database. Note that although
each Program response UDT is created in the Data
Types section of the program, they actually exist as
Controller-scoped tags in the Controller Tag Database.
By this method each element or tag within the various
UDTs can be accessed by any program within the
Task. The added benefit is to group together the tags
in the Controller Tag Database for ease of recognition
and better organization.

The UDT for the Enclosure Program has been

expanded in Figure 15.8. Note the naming convention
used:
1. Tag begins with PGM, indicating a member of a
Program Response UDT.
2. The next part of the tag indicates the program

that the data is derived from in this case
Enclosure.
3. The next part of the tag is a description of the

tag data for example Fire_Detected.
Figure 15.8 Program Response Tags

Tag Scope
Tags can be created at two different scopes:
1. Controller-scoped tags
• Controller-scoped tags are available to

every task and program within a project.
2. Program-scoped tags
• Program-scoped tags are available only to

the program in which they are associated.
Table 15.2 outlines requirements for specific tag uses.

Table 15.2 Tag Scope Requirements
To Use A Tag: Select This Scope:
That is generated when an I/O module is configured (I/O status, Controller
data, etc.)
In more than one program within the project Controller
To produce or consume data (share it with other controllers) Controller
In a message instruction or with a Panelview 1000C terminal Controller
In only one program (and it is not a message instruction or a Program
produced or consumed tag)
Alias Tags
An alias tag is a tag that refers to another tag (or a
second name for a single area of memory). Both tags
point to the same area of memory: both tags, therefore,
reflect the same value and changes.
Aliasing is commonly used in Solar applications to
map alarms and shutdowns, and to reference physical
I/Os to program logic.
Figure 15.9 is an extract from the Lube Oil Tag

Database, which illustrates several different uses
of Alias Tags.

Aliasing of Alarms and Shutdowns
AL_RT380_H is a program-scoped tag. It has been

created in the Tag database of the Lube Program as a
program-scoped tag, and is therefore only available to
the Routines within the Lube Program. It is also an
Alias Tag for the Base Tag HMI_ALARM[3].27.
This Base tag is also a controller-scoped tag and can

be found in the Controller Tag Database. Therefore
whenever the logic within the Lube Program
updates the Alias Tag AL_RT380_H, the Base Tag
HMI_ALARM [3].27 will also be updated, and the
alarm will be sent to the HMI display.
Aliasing of Analogs
AN_Lube_Filter_DP is a program-scoped tag that is

used to send an analog value to the HMI display in
a similar manner to the Alarm described above. It is
an alias for the Base Tag HMI_Analog_Array [65].
Once again when the logic within the Lube Program
updates the value of AN_Lube_Filter_DP, this value
will also be updated in the HMI display.
Figure 15.9 Alias and Base Tags

Aliasing of Inputs and Outputs
When an Input or output Module is added to the

I/O configuration each channel on the module is
automatically allocated a Base Tag, which is a
Controller-scoped tag, and therefore available to all
programs.
This base tag could theoretically be used within

the program logic, however the format of the Tag
name, although exactly describing the physical
connection point of the I/O, does not lend itself to
easy understanding of the ladder logic. We therefore
create an Alias Tag within the program, which is an
easily-understood description of the function of the tag
(normally the Reference Designator of the end device
will be incorporated in the Tag name.)
Figure 15.10 is another extract from the Lube Tag

Database. This illustrates a common example.
S388_1 is the Lube Oil Tank Low level Alarm Switch.
It is connected to UF2080 Module 1 (therefore ZF2081)
Input Channel 5. This has been automatically given
the Base Tag UF2080:1:I.5. As mentioned above when
we want to address this switch in the ladder logic, we
could use this Base Tag and the logic would function
correctly. However doing so would not allow us to
easily understand the logic. We therefore create an
Alias Tag for UF2080:1:I.5 within the Lube Program
and call it S388_1. It will reflect the same condition as
the Base Tag, but will be more easily understood.
The same procedure is used with outputs (see the
Alias Tag B598_1 in Figure 15.9 for an example) and
also for analog inputs and outputs.
Figure 15.10 Aliasing of Inputs and Outputs

Tag Naming Conventions

Solar applications adhere to certain standards for tag
naming. Tags are named consistently using verb-noun
combinations. Names that are non-specific are
generally avoided. Words within the tag name begin
with capital letters and are separated by underscores,
for example:
Gas_Valve_Check_Complete
The tag database lists tags in alphabetical order, so to
organize tags in logical groupings a topical word is
selected to precede the tag.
For example instead of using:
Pri_Gas_Fuel_Vlv and Sec_Gas_Fuel_Vlv

We would use:
Gas_Fuel_Vlv_Pri and Gas_Fuel_Vlv_Sec.
The related tags would then be placed close

together in the database and facilitate analysis and
troubleshooting.
In some cases capitalized alphabetic characters are
used in front of the tag name to identify the usage of a
tag. For example, a Fast Stop Non-Lockout Shutdown
tag name would be prefaced with the characters: ”FN”,
as in: FN_Fail_To_Start.
Capitalized characters are also used as suffixes to
identify the instruction the tag is associated with,
such as: Gas_Fuel_Chk_TON for a Timer ON Delay
instruction.

Table 15.3 lists the approved prefixes for various

different types of tags.
Table 15.3 Tag Prefixes
ID Type Description
AL BOOL Alarms-Alias of bit in HMI_ALARM
CN BOOL Cooldown Non-Lockout-Alias of bit in HMI_CDNL
CL BOOL Cooldown Lockout-Alias of bit in HMI_CDLO
FN BOOL Fast Stop Non-Locketout-Alias of bit in HMI_FSNL
FL BOOL Fast Stop Lockout-Alias of bit HMI_FSLO
ST BOOL Discrete display status-Alias of HMI_STATUS
KF UDT_ANALOG/ Fixed product constant-Not modified by HMI
UDT-ANALOG-ARRAY
KT UDT_ANALOG/ Project tuning constant-Modifiable by HMI
UDT-ANALOG-ARRAY
LSP UDT_ANALOG Local set point variable-Modifiable by Local HMI
RSP UDT_ANALOG Remote set point variable-Modifiable by Remote HMI
KA REAL ARRAY Constants for function generators-May be modified by HMI
LC BOOL Local control bit-Modifiable by Local HMI
RC BOOL Remote control bit-MOdifiable by Remote HMI
AN REAL HMI analog display-Alias of element in
HMI_ANALOG_ARRAY
If an alarm or S/D can be tied directly to an instrument

it should be named similar to ISA standards.
The name should be composed of three parts. The

2-letter prefix shown in the Table 15.3 indicating
the type of alarm, the reference designator of the
monitoring device, and one of the five possible
extensions shown in Table 15.4.
An example of an entire tag would be AL_S388_1_L,
for the Lube Oil Tank Level Switch Alarm.
Table 15.4 Tag Suffixes
_LL Low level, temperature, pressure etc. Shutdown
_L Low level, temperature, pressure etc. Alarm
_H High level, temperature, pressure etc. Alarm
_HH High level, temperature, pressure etc. Shutdown
_Fail Transmitter failure

Arrays
An array is a numerically-indexed sequence of tags of
the same data type, grouped together in the memory
of the controller. An element is a single tag in an array.
An array always begins with element 0. Arrays are
used to transfer data to the HMI, and to manage
analog data. Figure 15.11 illustrates the array address
format for a specific tag in an array.
Figure 15.11 Analog Array

Figure 15.12 illustrates the HMI Analog Array within

the Controller Tag database, with the array element
for the DC supply voltage shown in Figure 113.
Figure 15.12 HMI Analog Array

In this example, the MOV instruction moves
an element of REAL data into the tag address:
AN_Dc_Supply_Voltage, which is aliased to
HMI_Analog_Array[0]. The HMI tag is for element
[0] in the array: HMI_Analog_Array , which has a
dimension of 119 elements.

Figure 15.13 illustrates the different Arrays available

in a typical project. These are all located in the
Controller Tag Database.
Figure 15.13 Available Arrays

NOTES:

STUDENT ACTIVITY
1. What are the three levels of organization within

a Solar project, starting with the highest level?
_____________________________________________
_____________________________________________
_____________________________________________
2. What name is given to the Task in a Solar

project?
_____________________________________________
_____________________________________________
_____________________________________________
3. Which of the following is not a type of Program
in a Solar project?
a. I/O Control Program
b. Package State Program

c. Controller Status Program
d. Interface Program
e. Framework Program
4. What is the function of the Main Routine in

each Program?
_____________________________________________
_____________________________________________
_____________________________________________
5. What are the three data types in a Solar project?
_____________________________________________
_____________________________________________
_____________________________________________

6. Briefly explain the purpose of the UDT_Analog.
_____________________________________________
_____________________________________________
_____________________________________________
7. Briefly explain the purpose of the Program

Response UDT.
_____________________________________________
_____________________________________________
_____________________________________________
8. When creating a new tag, what two scopes can
be selected?
_____________________________________________
_____________________________________________
_____________________________________________
9. Briefly describe the function of an Alias Tag

that addresses a physical connection point on
an I/O module.
_____________________________________________
_____________________________________________
_____________________________________________
10. Which of the following tag names for an Alarm

would correctly follow Solar conventions?
a. AL_S388_1_L
b. S388_1_Low_Alarm
c. Alarm_S388_1_Low
d. S388_1_L_AL

11. State three examples of Arrays available in the

_____________________________________________
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. What are the three levels of organization within

a Solar project, starting with the highest level?
a. Task
b. Program
c. Routing
2. What name is given to the Task in a Solar

project?
Turbomachinery_Task
3. Which of the following is not a type of Program
in a Solar project?
c. Controller Status Program
4. What is the function of the Main Routine in

each Program?
Uses Jump To Subroutine (JSR)

instructions to schedule the other routines
in the program.
5. What are the three data types in a Solar project?
a. Pre-Defined
b. Module-Defined
c. User-Defined
6. Briefly explain the purpose of the UDT_Analog.
Used as template to provide four members

to scale analog inputs and outputs.
7. Briefly explain the purpose of the Program
Response UDT.
Used to group together data from each

program that needs to be available to other
programs.

8. When creating a new tag, what two scopes can

be selected?
a. Controller-scoped (available to all
programs).
b. Program-scoped (available only in the

program in which it is created).
9. Briefly describe the function of an Alias Tag

that addresses a physical connection point on
an I/O module.
Provides an easily recognizable tag name

for a base tag which has been automatically
assigned a tag name reflecting the I/O
module and channel.
10. Which of the following tag names for an Alarm

would correctly follow Solar conventions?
a. AL_S388_1_L
11. State three examples of Arrays available in the
HMI_Alarm
HMI_Analog_Array
HMI_CDLO
HMI_CDNL
HMI_Discrete_Array
HMI_FSLO
HMI_FSNL
HMI_Snapshot_Array
HMI_Status



Solar Technical Training TT4 Chapter 2, Lesson 7 Control Logic Familiarization
TT4 Chapter 2, Lesson 7 Control Logic Familiarization
OBJECTIVES:
able to interpret the logic in a typical Solar controller
program to:
1. describe the purpose of the program
2. describe the basic functions performed by the

each of the routines included in the program.
3. demonstrate understanding of the responses of

the program’s logic elements to dynamic input
conditions.
4. demonstrate the ability to cross refer physical

devices on the package to RSLogix tags, and
vice-versa.
INTRODUCTION
The material in this lesson is based on the project:
72571_A0, and program: Lube_1055_000. The program
will be described in general terms, followed by a
detailed review of selected example routines included
in the program. The student will then be directed to
complete a series of worksheets summarizing the
processes performed in additional routines as directed
by the instructor.

TT4 Chapter 2, Lesson 7 Control Logic Familiarization Solar Technical Training
COURSE MATERIALS
For students equipped with programming terminals,
the instructor will issue the project software for
PD72571_A0, to allow the student to complete the
exercises in this section, and the following sections.
In the case where programming terminals are not

available, the exercises that follow may be completed
by referencing the printed Software Docs that
accompany the course.
PROGRAM PURPOSE
The Lube program consists of the files and
routines illustrated in Figure 16.1. This includes a
Program Tags folder; Main Routine containing JSR
instructions; and a series of individual Routines for
the various sub-systems.
Figure 16.1 Lube Program
The purpose of the program is to monitor inputs

relevant to the lube oil system, establish the sequence
of operations for control of lube oil system equipment,
generate the outputs required to effect safe and
efficient control of the system, and provide outputs to

the operator interface system. Each of the routines

in the program is dedicated to accomplish specific
components of the monitoring and control process.
MAIN ROUTINE
The Main Routine (identified by the “1”; in the

routine icon) runs automatically when the program is
activated. All other routines are scheduled by Jump to
Subroutine (JSR) instructions in the Main Routine.
The order of execution of the subroutines is determined
by the sequence of the JSRs (see Figure 16.2).
Figure 16.2 Lube Main Routine
SEQUENCE OF EXECUTION
Within each routine, the ladder logic is executed in
normal sequence (top-to-bottom, left-to-right). Inputs
are scanned and outputs are updated according to
input status and instruction logic.

ROUTINE PURPOSE
Refer to Figure 16.3 for the following description:
Figure 16.3 _010_Tank_Level_Sw_Lo_000

The purpose of this routine is to monitor the status
of the oil tank level switches, and to annunciate an
alarm and/or shutdown as appropriate based on
switch status. An additional function is to control a
permissive in the oil tank heater logic.
The first rung (Rung 0) is used to facilitate addition

of the rung comment that appears at the top of the
page. The No Operation (NOP) instruction is used to
complete the rung and performs no function.
Rung 1 contains an XIO instruction and an OTL

instruction. The XIO is referenced to a physical input
(CN AdapterUF2080,Input Data, Slot 1, Discrete Input
Channel 5). and also has a tag that is related to the
reference designator of the device attached to the
input (S388_1). The text: Lube Oil Tank Level Low
Alarm Switch that appears above the instruction is
a description that is added in the Tag Database for
additional information.
Similar documentation is assigned to the OTL

instruction. Note that the output is referenced to the
HMI as an Alarm, and has a tag identifying it as
AL_S388_1_L.There is also a description: Lube Oil
Tank Level Low.

EDITING TAGS
Tags and descriptions can be viewed and/or edited
using the following procedures (the Lube Oil Tank
Level Low Alarm Switch S388-1 will be used in this
example; see Figure 16.4):
To view/edit the tags for an instruction:
1. Place the cursor on the Tag
2. Right-click
3. SelectGo To Cross Reference For “S388_1”
Figure 16.4 S388_1 Cross Reference
This screen shows that the tag S388_1 is a

Program-scoped tag (Lube_1055_000), it is
referenced to Base Tag UF2080:I.Data[1]. it
is assigned to one instruction (XIO), located in
Routine_010_Tank_Level_Sw_Lo_000, Rung 1. The
description related to the instruction is also shown. If
there had been other instructions with this tag, they
would be listed with relevant data.

Detailed information about the tag can also be found

in the Tag Database, as shown in Figure 16.5.
Figure 16.5 Lube Tag Database
For a quick view of tag data, place the mouse pointer

on the instruction. A small information box provides
a summary of tag data:
Figure 16.6 Tag Data

Tag properties can also be viewed by right-clicking the

tag, then selecting Edit “S388_1” Properties:
Figure 16.7 Tag Properties

STUDENT ACTIVITY
To gain familiarity with accessing and using the tag
database, complete the worksheet below for the other
instructions in this routine.
Table 16.1 Tag Database Analysis
Instruction Tag Scope Alias For: Location Description
XIO S388_1 Program UF2080:1:I.5 Rung 1 Lube Oil Tank Level Low Alarm
Switch
OTL Rung 1
XIO Rung 2
OTL Rung 2
OTE Rung 2

RUNG FUNCTIONS
To evaluate the functional characteristics of the logic
in the routine, view Rung 1, as illustrated in Figure
16.8.
Figure 16.8 Rung Function
We know that the physical discrete input from S388-1

is connected to Input 5 of Module 1 in Node 08 of
the ControlNet network.
We also know that the Normally Open contacts of the

switch are used, so that when the oil level in the tank
is above the alarm level, the N.O. contacts are closed.
Under these conditions, the XIO instruction is FALSE,
and the rung is FALSE - no action takes place.
Should the oil level in the tank fall below the switch’s
setpoint, the N.O. contacts will open; the XIO
instruction will then be TRUE, and the OTL will be
enabled.
The Alarm bit AL_S388_1_L will be set (TRUE). This

tag is aliased to HMI_ALARM[4].0, so any references
to this tag will reflect the fact that the bit is set i.e. an
alarm will be annunciated on the display.

Using this process to evaluate the functions performed

by the remaining logic in the Routine, the Routine’s
function could be summarized as seen in the following
table:
Table 16.2 Routine Function Summary
Routine Function
010_Tank_Level_Sw_Lo_000 If S388-1 opens, alarm bit AL_S388_1_L is latched; HMI alarm
is initiated. If S388-2 opens, shutdown bit CL_S388_2_LL is
latched; HMI CDLO shutdown is initiated, and Tank_Level_LL is
enabled to lock out tank heater.
STUDENT ACTIVITY
Use the same process to complete the following
worksheet forRoutine_040_Tank_Temp_000 and
Routine_050_Tank_Press_Sw_AL_000.
Table 16.3 Routine Function Summary Student Activity
Routine Function

HARDWARE-SOFTWARE INTERFACE
As explained previously, the I/O modules perform the
conversion of digital data to electrical signals (and
vice versa). To see the complete path between an end
device and the logic, both the Electrical Schematic and
the controller program are required. The following is
an example illustrating the relationships:
In the routine discussed above (
010_Tank_Level_Sw_Lo_00).the hardware imputs

to the logic are S388-1 and S388-2. To locate these
devices, refer to the Reference Designator Guide on
Electrical Schematic 72571-149450. Both switches are
located on Sheet 29 of the schematic.
Figure 16.9 illustrates the derivation of the Base Tags
for the switch inputs.
Figure 16.9 Base Tag Derivation

The Discrete Input module is installed in Slot 1 of

Node 08, as seen in Figure 16.10:
Figure 16.10 Node 08

The Base Tags to the ControlNet referenced
designator(UF2080); the Discrete Input module is
in Slot 1, and the switch inputs are connected to
Channels .5 and .6. The Alias Tags S388_1 and S388-2
are assigned to these inputs in the tag database.

The complete path for the input from S388-1 can be

described in tabular form:
Table 16.4 I/O Mapping
Tag Aliases Base Tag I/O Terminal & Wire No. End Device Reference Designator
S388_1 UF2080:1:I.5 TS309-14, S388I S388-1
STUDENT ACTIVITY
Using the Electrical Schematic 72571-149450 and the
controller software or software docs for PD 72571,
complete the following tables (all tags are taken from
the Lube Program).
Table 16.5 I/O Mapping Student Activity
S324_1
S322-5

LUBE PROGRAM EXERCISE

Search for the OTE of B321
1. What Program is this in?
_____________________________________________
2. What routine is this in?
_____________________________________________
3. What is the base Tag?
_____________________________________________
4. What Node is this?
_____________________________________________
5. What physical slot position on the chassis is
it on?
_____________________________________________
6. What Module address is used?
_____________________________________________
7. Is it an Input or an Output?
_____________________________________________
8. What channel is being used?
_____________________________________________
9. What Electrical schematic sheet is it on?
_____________________________________________
10. What actually starts B321?
_____________________________________________
11. What must be satisfied for K2913 to be
energized?
_____________________________________________
12. What is K2910-1?
_____________________________________________

FUEL PROGRAM EXERCISES

1. What is the tag name for overspeed?
Tag name =__________________________________
2. What routine is it in?
Routine = ___________________________________
3. What is the setpoint?
Setpoint = ___________________________________
4. When does the Bleed Valve open & close?
Open = ______________________________________
Close = ______________________________________
5. What routine are they in?
Routine = ___________________________________
6. What is the T5 Base for gas and liquid fuels?
Gas = _______________________________________
Liq =________________________________________
7. What is the tag name for the T5 Base on liquid

fuel?
Tag name =__________________________________

NOTES:

STUDENT ACTIVITY ANSWERS

Table 16.6 Answers
Instruction Tag Scope Alias For: Location Description
XIO S388_1 Program UF2080:1:I.5 Rung 1 Lube Oil Tank Level Low Alarm
Switch
OTL AL_S388)_1_LProgram HMI_ALARM Rung 1 Alarm active when tank level is

[4]O at Lo
XIO S388_2 Program UF2080:1:I.6 Rung 2 Lube Oil Tank Level Low
Shutdown Switch
OTL CL_S388_2_LL
Program HMI_CDLO[0]4 Rung 2 Cooldown Lockout Shutdown
active when tank level is at LoLo
OTE Tank_Level_LLProgram Rung 2 Internal bit active when tank level

is at LoLo

Table 16.7 Answers

Routine Function
_040_Tank_Temp_000 If RT390 fails set HMI_FSLO(2).18 if the unit is shut down, or
set HMI_Alarm(3).29 if the unit is running.
Lube tank temperature is being sent to HMI_Analog_Array(68).
When the unit is shut down and if the tank temperature is LEQ
52 then set HMI_FSNL(0).21
_050_Tank_Press_Sw_AL_000. If S324_1 contacts open set the HMI_Alarm(3).31
Table 16.8 Answers

S324_1 UF2080:1:I.3 ZF2081 CHANNEL 5 S324-1
TERMINALS V40 & 5 S3881P
& S3881
S322_5 UF2080:1:I.2 ZF2081 CHANNEL 2 S322-5

TERMINALS V37 & 2 S3225P
& S3225

LUBE PROGRAM EXERCISE ANSWERS

Search for the OTE of B321
1. What Program is this in?
Lube_1055_000
2. What routine is this in?
_400_Pmp_Ctrl_Eng_Main_FS_000
3. What is the base Tag?
UF2090:1:O.6
4. What Node is this?
Node 9
5. What physical slot position on the chassis is
it on?
Slot 2
6. What Module address is used?
ZF2091
7. Is it an Input or an Output?
Output
8. What channel is being used?
Channel 6
9. What Electrical schematic sheet is it on?
Sheet 37
10. What actually starts B321?
K2913 Normally Closed Contacts
11. What must be satisfied for K2913 to be

energized?
K2910_1 Normally Open Contacts closed,

plus an output from B321 (ZF2091 Channel
6)

12. What is K2910-1?
PLC Ok Relay (part of the Backup Relay

System

FUEL PROGRAM EXERCISE ANSWERS

1. What is the tag name for overspeed?
Tag name = KF_Ngp_Ospeed_SD
2. What routine is it in?
Routine = _210_Ngp_AL_SD
3. What is the setpoint?
Setpoint = 108%NGP
4. When does the Bleed Valve open & close?
Open = 78%NGP
Close = 80%NGP
5. What routine are they in?
Routine = _870_BV_Open_Cls_Ngp
6. What is the T5 Base for gas and liquid fuels?
Gas = 1250
Liq = 1250
7. What is the tag name for the T5 Base on liquid

fuel?
Tag name = T5_Base_L.Val

NOTES:



Solar Technical Training TT4 Chapter 2 Lesson 8 Analog Device Programming
TT4 Chapter 2 Lesson 8 Analog Device Programming
OBJECTIVES:
able to perform the following:
1. given a Turbotronic 4 controller program
or software docs, and electrical schematic,
determine the base tags for selected analog
inputs and outputs.
2. using the controller program or software docs,
determine the ranges, types of data and scaling
for selected analog inputs and outputs.
3. using the controller program or software docs,
identify any setpoints associated with selected
analog inputs.
4. describe the program’s functional responses to

selected setpoint detections.
INTRODUCTION
Analog input signals to the controller are generated by
end devices such as pressure transmitters, vibration
transducers, magnetic pickups, RTDs, thermocouples
and linear position sensors.
Analog output signals from the controller are directed
to actuators to position mechanical devices, such as
fuel control valves, anti-surge/bypass valves, and
guide vane or bleed air valve positioners.

TT4 Chapter 2 Lesson 8 Analog Device Programming Solar Technical Training
Each of these end devices, whether input devices or

output devices, has a range of operational capability
that is proportional to the controlling or measured
electrical signal associated with the device.
A pressure transmitter used in a typical
turbomachinery application, for example, may have a
pressure range of 0-100 psig that corresponds to an
electric output signal ranging from 4 to 20 mA. The
transmitter signal must be converted into a digital
value to be useful to the controller. This function is
accomplished by an Analog Input Module.
Similarly, analog outputs must be scaled from a range

of data generated by the Controller into a physical
electrical signal, again normally 4-20mA. This
function is accomplished by an Analog Output Module.
SCALING OF ANALOGS
Analog inputs are scaled (converted to engineering

units) using the following process:
Analogs are sent to and received from analog I/O

modules in integer form, with numeric ranges
according to the module type and selected range.
The algorithms in the control program utilize scaled

values (expressed in Engineering Units) to perform
the necessary calculations to monitor and control the
package. Therefore, input data must be converted
from unscaled counts (raw) values into scaled values
to enable the control algorithms to function correctly.
Outputs generated in the control algorithms must be

converted into unscaled integer form to be sent to
output modules. Floating Point (REAL) data types are
used for scaled values, andInteger data types are used
for unscaled data. These conversions are performed in
the Controller program, using standardized conversion
factors for the various types and ranges of I/O modules
and end devices.

Solar employs a Universal Equation to calculate these

conversion factors:
Figure 17.1 Analog Equation
where:
VEU = Value in Engineering Units
I = Signal current from transmitter = mA
IMIN = Minimum signal from transmitter (typically
4mA)
IMAX = Maximum signal from transmitter (typically
20 mA)
RMIN = Minimum value of transmitter range, in
Engineering Units
RMAX = Maximum value of transmitter range, in
Engineering Units
Example:
Most analog inputs are connected to 1794-IE8 Analog

Input modules, set to the 0-20 mA range.
The standard transmitter provides a 4 (IMIN)-20

(IMAX) mA signal, proportional to its range in
engineering units.
In this example, the transmitter range is 0 (RMIN)-100
(RMAX) psig.
In the 0-20 mA range, the 1794-IE8 module will
actually read inputs between 0 and 21 mA, and
will generate corresponding proportional outputs
between0 and 32,760.
Thus, I (signal current from the transmitter) can be

stated as: 32,760/21 =1560 counts per mA.

NOTE
The 0-20 mA range is used to facilitate
transmitter error detection. If the current
from the transmitter is below 3.5 mA (5460)
or above 20.5 mA (31,980), program logic will
annunciate a transmitter failure.
The factors to be used in the Universal Equation

then become:
I = N/1560
N = Raw integer value (ranging between 6240 and
31200)
IMIN = 4 mA, or 6240
IMAX = 20 mA, or 31,200
RMIN = 0 psig
RMAX = 100 psig
With these values, the equation becomes:
Figure 17.2 Analog Equation Using Counts
Since our offset is zero (i.e. the transmitter is ranged

0-100psig) we can simplify the equation that can be
used for the above example into the equation shown in
Figure 17.3.
Figure 17.3 Simplified Analog Equation
The equation and the conversion process are applicable

to any analog module or transmitter used by Solar.
However note that slightly different Raw Value ranges

may be used for different types of input modules, and
this should therefore be checked when scaling analogs.

STUDENT ACTIVITY
Using the above equations in Figure 17.1, Figure 17.2
and Figure 17.3, and a 0-100psig transmitter, complete
the following table for the different values specified.
Table 17.1 Analog Scaling Student Activity
VEU I RAW COUNTS
8mA
12mA
18.5mA
12480
18720
30000
SCALING ANALOGS IN RSLogix

Figure 17.4 Transmitter Scaling and Fail Detection
Logic
Figure 17.4 Transmitter Scaling and Fail Detection Logic
First we will examine the Compute Instruction that

is used to scale the input signal.

TP380 is an Alias for the raw value (number of counts)

from the transmitter. Firstly the offset of the input
module range is subtracted, and then the value is
divided by the number of counts per mA. This results
in a mA value directly proportional; to the range
(4-20mA) of the transmitter.
The actual range of the transmitter is specified by

the EU MIN and EU MAX of the UDT_ANALOG
as covered in the earlier lesson. These factors are
multiplied by the mA value obtained previously to
obtain a value of the transmitter input in Engineering
Units.
One final step is required the EU MIN from the

UDT_ANALOG is added to the result to allow for any
transmitter that is not scaled from zero. This gives a
final value in Engineering Units, and this is registered
as the VAL member of the UDT_ANALOG.
This VAL will now be referenced throughout the

program to generate alarms, shutdowns, etc. Figure
17.5 illustrates Header_Pressure.Val being used to
generate a shutdown.
Figure 17.5 Header Pressure Val Reference
STUDENT ACTIVITY
Using the cross-reference functions of the RSLogix
software, or the software docs, complete Table 17.2 for
five more instances of Header_Pressure.Val.

Table 17.2 Header_Pressure.Val.

INSTRUCTON ROUTINE RUNG DESCRIPTION
TYPE
LES _400_Pmp_Ctrl_Eng_Main_FS_000
2 GENERATING BACKUP PUMP FAIL
SHUTDOWN AT 4PSIG
The analog value is also required for display on the

HMI display. It must therefore become an Alias for an
element of the HMI_Analog_Array. This is completed
in the MOV instruction.
However, referring back to Figure 17.4, you will note
that an extra step is required to conform to Solar
conventions. The VAL from the UDT_ANALOG is
not directly Aliased to the HMI_Analog_Array. We

actually move it to an additional tag that has the

prefix AN, signifying an analog. This new tag then
becomes the Alias for the HMI_Analog_Array.
Although this creates one additional tag for each
analog, by complying with this convention we obtain
a much better organizational structure within the
Tag Databases.
Next we will examine the transmitter fail logic in
the top rung.
Solar standard logic requires a transmitter fail alarm

or shutdown to be annunciated if the transmitter
signal exceeds 20.5mA or becomes less than 2mA.
This accounts for the values of raw counts within the
LIM instruction.
Solar use a LIM instruction to monitor for transmitter

failure. In order for the shutdown NOT to be active
(i.e. the transmitter signal is healthy), the rung must
remain false. Table 17.3 uses information extracted
from the RSLogix Instruction Help file, and describes
the operation of the LIM instruction.
Table 17.3 LIM Instruction
LOW LIMIT TEST VALUE RUNG CONDITION
? HIGH LIMIT EQUAL TO OR BETWEEN THE LIMITS TRUE
? HIGH LIMIT NOT EQUAL TO OR OUTSIDE FALSE
THE LIMITS
? HIGH LIMIT EQUAL TO OR OUTSIDE THE LIMITS TRUE
? HIGH LIMIT NOT EQUAL TO OR INSIDE THE LIMITS FALSE
Referring to Table 17.2 we can see that if we have

the Low Limit as the higher number the rung will
remain false if the signal from the transmitter is
between the two limits.

The decision on whether a transmitter failure should

annunciate an alarm or a shutdown, and what type of
shutdown (i.e. Fast Stop or Cooldown Stop) is made
by the design engineer, and is largely based on the
actual function of the transmitter. For example if the
function of a transmitter is to generate a Fast Stop
shutdown then the failure of the transmitter would
normally also generate a Fast Stop shutdown.
In our example failure of the transmitter will latch

the OTL HMI_FSLO[2].19 with the alias tag:
FL_TP380_Fail.
ANALOG DATA ORGANIZATION

Note the tag: TP380is aliased to the base tag:
UF2080:5:I.Ch3Data. This defines the path through
the analog input module.
As mentioned previously Solar have created a
User-Defined Data Type called the UDT_ANALOG to
facilitate the scaling of all analog inputs. Figure 17.6
illustrates the Header_Pressure UDT_ANALOG from
the Lube Program Tag Database.
Figure 17.6 Header Pressure UDT

The scaled value resulting from the scaling
computation in Figure 17.4 is stored as the
VAL member of the UDT_ANALOG, in our case
Header_Pressure.Val, as a REAL (Floating Point)
value.
Header_Pressure.Valcan be referenced throughout
the Lube Program to generate alarms, shutdowns
or any other functions.
As mentioned above, the Header pressure is
also to be displayed on the HMI, and this is
accomplished by aliasing the tag to a member of
the HMI_Analog_Array. However this is not done
directly, due to Solar conventions. As explained
above we create an addition tag with the pre-fix AN
to signify an analog value, and then move the UDT

VAL to this new tag. The new tag is then Aliased

to the HMI_Analog_Array. This is purely done for
organizational reasons.
Figure 17.7 illustrates the aliasing of analog
values to the HMI_Analog_Array within the
Lube Program Tag Database. Note that our
new tag AN_Lube_Header_Pressure is aliased to
HMI_Analog_Array [66].
Figure 17.7 Aliasing of Analogs
Figure 17.8 illustrates a section of the

HMI_Analog_Array within the Controller Tag
Database. Note that HMI_Analog_Array [66] displays
no references to the Lube Oil Header Pressure other
than the Description field. In other words this is a
Base Tag so there is no entry within theAlias For field.
Figure 17.8 HMI Analog Array

STUDENT ACTIVITY
1. What instruction is used to scale an analog input

in a Solar RSLogix project?
_____________________________________________
2. What instruction is used to check a transmitter

for over-range or under-range?
_____________________________________________
3. What are the four members of the

UDT_ANALOG?
_____________________________________________
4. Describe how the VAL member of the

UDT_ANALOG is sent to the HMI for display.
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. What instruction is used to scale an analog input

in a Solar RSLogix project?
CPT (Compute)
2. What instruction is used to check a transmitter

for over-range or under-range?
LIM
3. What are the four members of the

UDT_ANALOG?
VAL
EU MAX
EU MIN
EU
4. Describe how the VAL member of the

UDT_ANALOG is sent to the HMI for display.
VAL is moved to a new tag with the prefix

an. This new tag is aliased to an element
of the HMI_Analog_Array.



Solar Technical Training TT4 Chapter 2 Lesson 9 Function Block Overview
TT4 Chapter 2 Lesson 9 Function Block Overview
OBJECTIVES:
Upon completion of this lesson, the student will be:
1. able to state the capabilities and limitations of
function block programming.
2. familiar with the layout and basic editing tools

available in function block programming.
INTRODUCTION
Function block programming is a graphics-oriented
method of organizing relatively complex
calculations and operations in a dynamic,
interactive system environment. This approach
provides easy-to-understand screen displays, with
comprehensive programming aids and help features.
Many of the available controller instructions can be

programmed in either ladder or function block logic.
Function block routines have full access to the
Controller Database and Program Database, and as
such share management of tagged memory elements.
Function block logic is created in function block
diagrams, much like a designer would draft the logic
with pencil and paper. The diagram is laid out in
standard drawing form, with grid coordinates and grid
lines to aid in placement and location of drawing
elements.

TT4 Chapter 2 Lesson 9 Function Block Overview Solar Technical Training
Instruction blocks are selected from a menu, inserted

in the diagram, and control parameters are entered to
complete the entry. A function block diagram can have
as many sheets as are necessary, although as we saw
previously Solar projects tend to be broken down into
relatively small routines, so Function Block routines
should normally be contained on one sheet.
Figure 18.1 illustrates a typical function block

diagram:
Figure 18.1 Typical Function Block

When a function block diagram is opened, an
instruction toolbar is available at the top of the editing
window - see Figure 18.2.
Figure 18.2 Function Block Instruction Menu
Tabs enable quick access to the various instruction

types, or the scroll buttons at the ends of the toolbar
can be used to locate the desired instruction.

In this example, the designer has used Wires to

interconnect the instructions in the desired scheme.
Inputs to the diagram that are connected this way are
called Input References (IREF), and outputs are called
Output References (OREF). The solid Wires connect
analogs, and the dashed Wiresconnect binary data.
Interconnects can also be facilitated without Wires if

desired; in this case the inputs are called ICON and
OCON. They can be used to connect
1. Elements in the same function block
2. Elements in different diagrams/pages
The symbols for these interconnects are illustrated in

Figure 18.3:
Figure 18.3 ICON and OCON

Just like in the ladder logic routines, tag properties for
any element in the diagram can be viewed by placing
the mouse pointer on the element. Figure 18.4 is an
example of the information window that pops up.
Figure 18.4 Tag Information

Instruction parameters are configured through the

Parameters dialog box, which is opened by clicking
the ellipsis in the upper right corner of the instruction
block (circled in Figure 18.5), or by right-clicking
anywhere in the block (see Figure 18.5):
Figure 18.5 Instruction Parameters Dialog Box

Parameters that cannot be modified are shaded on
the screen. Click the box in theVis column to view or
hide a parameter (note that required parameters
cannot be hidden).
When a function block diagram is created, the
program automatically sets the order of execution of
the function blocks. The example block is assigned
execution order 1. The execution order is as follows:
1. the controller latches all data values in IREFs.
2. the controller executes the other function blocks

in the order determined by how they are wired.
3. the controller writes outputs to the OREFs.

The program automatically assigns a tag to an

instruction block when it is created. The tag can be
modified by clicking the Tag tab on the parameters
dialog box and making the appropriate entries (see
Figure 18.6):
Figure 18.6 Tag Dialog Box

NOTES:

STUDENT ACTIVITY
1. What is the main purpose of Function Block

Routines?
_____________________________________________
_____________________________________________
2. Many ladder logic instructions can also be

programmed in Function Block Logic.
TRUE / FALSE
TRUE / FALSE
4. Function block inputs and outputs can be

connected either by wiring or by wireless
connectors.
TRUE / FALSE
5. Analog data in function block IREFs are wired in

dotted lines and Boolean data in solid lines.
TRUE / FALSE

NOTES:

ANSWER KEY
1. What is the main purpose of Function Block

Routines?
Function block routines are normally used

to perform complex calculations.

TRUE

TRUE
4. Function block inputs and outputs can be
connected either by wiring or by wireless
connectors.
TRUE
5. Analog data in function block IREFs are wired in

dotted lines and Boolean data in solid lines.
FALSE (the opposite is the case)



Solar Technical Training TT4 Chapter 2, Lesson 10 RSLogix5000 Online Functions
TT4 Chapter 2, Lesson 10 RSLogix5000

Online Functions
OBJECTIVES:
Upon completion of this lesson, the student will:
1. demonstrate the ability or knowledge required to

go online with an RSLogix 5000 Controller.
2. demonstrate the ability to set, enable and

remove forces in the ladder logic.
3. demonstrate the ability to make simple edits to
an RSLogix program when online.
INTRODUCTION
This lesson concludes the course by allowing the
student to go online with an RSLogix 5000 Controller
and perform some simple operations when on line.
NOTE
The availability of programming terminals
and either Turbotronic 4 Simulators or an
actual control system available for training
use will determine whether the exercises are
actually completed by the students. If these
facilities are not available the lesson will be
based on instructor lecture or demonstration.

TT4 Chapter 2, Lesson 10 RSLogix5000 Online Functions Solar Technical Training
CONFIGURING COMMUNICATION DEVICES

Various methods are available to communicate with
the RSLogix Controller. These include the following:
RS232 Serial Port
A serial cable is connected between the programming terminal
and the serial port on the front of the Controller.
DH+/RIO
A DH+ cable is connected between a PCMK card in the
programming terminal and a dedicated DH+/RIO module in
the Controller chassis.
Ethernet
An Ethernet Crossover Cable is connected between the
network connection of the programming terminal and a
dedicated Ethernet module in the Controller chassis.
ControlNet
A special cable is connected between a PCC card in the
programming terminal and one of the ControlNet modules
(CNBRs) in the Controller chassis.
Since all Solar projects will have at least two

ControlNet modules in the Controller chassis, and
obviously one Controller, during this lesson we will
cover the RS232 and ControlNet methods.
Whatever method is selected for communication, a
driver has to be set up to allow communications to be
established. This is achieved using RSLinx software.

RS232 SERIAL PORT DRIVER
1. Before configuring this driver connect a serial

cable between the programming terminal serial
port and the serial port on the front of the
Controller
2. Open RSLinx
3. Select Communications
4. Select Configure Drivers (see Figure 19.1)
Figure 19.1 RSLinx Driver Configuration
5. Use pull down menu to select driver type, select

RS-232 DF1 devices
6. Select Add New

7. Accept the default name and select OK (see

Figure 19.2)
Figure 19.2 Selecting RS232 Driver
1. A new dialog box will appear
2. Use the pull down menu to select the correct

Device select Logix 5550/compact Logix

3. Select Autoconfigure (see Figure 19.3)
4. RSLinx will automatically poll the Controller

and set the correct parameters
5. When completed selectOK
Figure 19.3 Autoconfigure RS232 Driver
CONTROLNET DRIVER
1. Open RSLinx
2. SelectCommunications
3. Select Configure Drivers
4. Use the pull down menu to select driver type

select 1784-PCC for Controlnet devices

5. Select Add New (see Figure 19.4)
Figure 19.4 Selecting ControlNet Driver
6. Accept the default name and select OK
7. check the Auto Address MAC ID and select OK

(see Figure 19.5)
Figure 19.5 ControlNet Driver Configuration

Both drivers will now be configured correctly, and

will appear in the RSLinx Configure Drivers list.
See Figure 19.6.
Figure 19.6 List of Configured Drivers
NOTE
The message in the Status field shown in
Figure 19.6 does not always reflect the
actual status of the driver. For example the
ControlNet Driver shows as Runningin the
Status field, but the other field shows the
actual status as Power Up. Always check the
information in the Name and Description
field when troubleshooting drivers in RSLinx.
RSLinx can now be minimized, or even closed down. It

will open automatically when attempting to go online
using RSLogix software.

GOING ONLINE
Communications Menu
Selecting the Communications option provides a list
of choices:
Figure 19.7 Communications Menu

If Who Active is clicked, a screen will appear showing
the configured communication paths; active nodes will
be identified and flashing symbols will highlight the
active paths. Figure 19.8 illustrates the active paths
with the RS232, DF1 Driver only.
Figure 19.8 Going Online RS232

The procedure to go online is simple to browse until a

valid path to the Controller is found. In the case of
RS232 the browsing is limited to the first level below
the DF1 Driver, since the connection is directly into
the Controller via the serial port. See Figure 19.8.
Whenever the Controller is highlighted using a valid
communications path theGo Onlineoption, which was
previously greyed out, will become available. Clicking
Go Online will then establish communications.
Figure 19.9 illustrates the same procedure for the

ControlNet driver. To connect with ControlNet a PCC
card must be installed in the programming terminal
and the cable attached to any of the RJ45 ports in the
ControlNet system. Normally this would be in the
front of one of the ControlNet Modules in the chassis,
but any of the ACNRs on the Nodes can also be used.
Figure 19.9 Going Online ControlNet
The valid path this time is more complex. First the

PCC-! Driver must be expanded and then the path
again takes the same route as the physical connection.
Therefore the next level is the CNBR (ControlNet
Module), followed by the Backplane in the Chassis;
and finally the Controller. Connection via an ACNR
would follow a different, and more complex path.
As with RS232 when a valid path to the Controller
has been established the Go Online option will become
available.

If repeatedly going online using the same path,

theSelect Recent Path option may be useful. If
Select Recent Path had been selected from the
Communications options, a list of recently configured
paths would have appeared. Placing the cursor on
a selected path that you know still to be valid and
clicking Go Online would have attached to the network
through the selected path. See Figure 19.10.
Figure 19.10 Select Recent Path

DOWNLOADING
We will assume for the moment that there is currently
no program in the Controller. The next step is
therefore to download a program to the Controller.
NOTE
DOWNLOAD = PROGRAMMING
TERMINAL TO CONTROLLER
UPLOAD = CONTROLLER TO
PROGRAMMING TERMINAL
After selecting Go Online in any of the above steps

the dialog box shown in Figure 19.11 will appear. If a
project is currently open in RSLogix then this will be
the Offline Project shown in Figure 19.11.
If no project is currently open then another dialog box

will appear prompting for a project selection. Simply
browse for the required RSLogix ACD file, which
should be located in C:\JOBS.
Selecting Download will place the Controller in

Program Mode (if the keyswitch is in the REM
position) and download either the open project or the
selected project. Figure 19.12 illustrates dialog box
which opens to request confirmation that a download
is required. Figure 19.13 illustrates the project in the
process of being downloaded.
Placing the Controller in Program Mode

will cause the Controller to lose control
over the turbine package, resulting in a
package shutdown.

Figure 19.11 Connected To Go Online
Figure 19.12 Download Confirmation

Figure 19.13 Downloading To The Controller

RUN MODE
When the project has been downloaded the Controller
will remain in the Remote Program Mode. See Figure
19.14. We know this for several reasons:
1. Remote Program indicated in the Controller
Status
2. Running not illuminated in the Controller Status
3. Power rails in the routines not highlighted green
Figure 19.14 Controller In Program Mode

Returning the Controller to the Run Mode will result

in the status shown in Figure 19.15.
1. Rem Run in the Controller Status
2. Running illuminated in the Controller Status

3. Power Rails highlighted green
This is accomplished by clicking on one of the

Controller icons in the Controller status toolbar, or by
making a selection from the Communications menu.
Figure 19.15 Controller In Run Mode

UPLOADING
If the Controller already has a program, and you
wish to go online, then Uploading would be the option
to choose.
Selecting Upload from the Communications menu will
cause the software to use the selected path to go online,
and the screen shown in Figure 19.16 will appear.
Figure 19.16 Upload Options

Clicking on the tabs will provide detailed information
about the controller. It is important to note that
the Offline Project must match (correlate with) the
Connected Controller for this function to complete. If
the names differ, upload will be disallowed.
If no offline file is open, as in the example in Figure
19.16, then clicking on theSelect File option will
allow you to browse the C:\JOBS directory to locate
and select the same file name as the project in the
Controller.
If however the same project does not already exist

on the programming terminal, you can specify a file
name and a location at this point, and RSLogix will
create an offline file as it uploads, according to your
specification.

File 19.17 illustrates the screen that appears once the

correct offline file has been selected in the C:\JOBS
directory. Note that since both the online (Controller)
file and the offline (programming terminal) file are
identical the system does not require an Upload
we can simply go online. IF however the files were
different we would Upload.
Figure 19.17 Upload Screen
As can be seen from the above, several different

options are available to go online, and some depend
on the correct procedures being followed in using the
Project CD to load the project to the programming
terminal before attempting to go online. This really
essential when Uploading from the Controller,
since the online file will already exist in the correct
directory, and therefore no conflicts should occur that
could affect the use of the Solar Project Tools.

In summary, the recommended procedure is:

No Project In The Controller
1. Use the project tools described in previous lessons to load the

project to the programming terminal.
2. Download to the Controller as detailed above.
Project In The Controller

1. Use the project tools described in the previous lessons to load
the project to the programming terminal.
2. Ensure that the revision is the same as the Controller project.
3. Connect to the Controller Go Online if possible.
4. Upload if necessary to the same directory as was created
using the project tools.

FORCING
Bit or Analog values can be forced (online only) using
the following procedures:
Determine the current state of forces by observing the

Forces drop-down list and the Force icon shown in
Figure 19.18.
Figure 19.18 Forcing Status

Forces are made in the routines by right clicking the

selected instruction and selecting either Force On or
Force Off. The force will not take effect immediately
unless the forces have already been enabled. This
is illustrated in Figure 19.19. Note that the three
options are:
1. Force On
2. Force Off
3. Remove Force
Figure 19.19 Creating A Force

If the drop-down list displays “Forces” and the icon

is Red, forces have been created but are not enabled.
If forcing is then enabled, the forces will take effect
immediately. See Figure 19.20.
Figure 19.20 Enabling Forces
If the drop-down list displays “Forces” and the icon

is Yellow and Red, forces are present and enabled.
Any added forces will take effect as soon as they are
created. See Figure 19.21. Note that ON has also
appeared next to the item forced.
Figure 19.21 Forces Enabled

If the drop-down list displays “No Forces: and the

icon is Yellow, forcing is enabled but no forces are
present. Added forces will take effect as soon as they
are created.
Extreme care should be taken when

creating a force. The user must fully
understand the effects of the force.

LOCKING THE CONTROLLER

One of the effects of the large number of methods to
connect to the Controller, is that these methods can be
used simultaneously, therefore the Controller may be
accessed by multiple users.
One of the effects of the large number of methods to
connect to the Controller, is that these methods can be
used simultaneously, therefore the Controller may be
accessed by multiple users.
In view of this a useful feature of RSLogix is the
ability to lock the Controller. This will only allow edits
to the program to be made by the user who has locked
the Controller. The Controller will be automatically
unlocked if that user comes off line.
To lock the Controller select the section of the Online
Toolbar with the padlock icon (see Figure 19.22). Note
that the icon shows an unlocked padlock and this
information is also displayed as text.
Simply selecting Lock Controller will initiate the
function the padlock icon will change to a locked
indication and the text will also indicate that the
Controller is locked. The Lock Controller option will
also change to Unlock Controller.

Figure 19.22 Locking the Controller

INTRODUCTION TO ONLINE EDITING

This short section will give a very brief introduction to
editing, mainly to demonstrate the toolbars available.
Advanced editing is carried out as part of the
Turbotronic 4 Maintenance and Programming Course.
The appearance and procedures differ from offline
editing, since when editing online additional steps
are required to verify the edits before finally
accepting them. When editing offline edits take effect
immediately.
To start a rung edit double click to the left of the rung
to be edited. Other methods are available using the
toolbars. See Figure 19.23.
Note that a duplicate of the selected rung appears.
The “i” to the left of the first rung signifies that this
is the rung to be inserted (i.e. the new rung). The “r”
to the left of the second rung signifies that this is
the rung to be replaced.
Also note the appearance of an additional toolbar
above the routine window. These are tools to be used
to test and accept the edits.
Figure 19.23 Starting A Rung Edit

Once an edit has been made the following procedure

should be followed to finalize the edit. Refer to Figure
19.24. Note that for the purposes of the example an
instruction has been added to the rung. The next
action is to Accept the Pending Program Edit by
selecting the tool icon indicated in Figure 19.24. A
dialog box will open requesting confirmation of the
edit. After selecting Yes the screen will change to that
Figure 19.24 Accept Pending Program Edit
Figure 19.25 Test Program Edits

Note that in Figure 19.25 the lower-case “i” and “r”
have changed to upper-case. Also note that the Accept
Pending Program Edits option is no longer available,
but that the next step is to Test Program Edits, as
illustrated in the screen capture. Just to the left of
this icon is an option to Cancel Pending Edits, if this is
required.

Figure 19.26 illustrates the screen when the edits are

being tested. Note that the green highlighted power
rail has changed from the original rung to the new
rung in other words this is the rung that is now being
scanned by the Controller.
If the edits are not required then the icon to the right
allows for Untest Program Edits. If the edits are
required then the final step is to Assemble Program
Edits, as indicated in Figure 19.26.
Figure 19.26 Assemble Program Edits
Figure 19.27 illustrates the routine with the edits

assembled, i.e. fully completed. The only remaining
step would be to use the standard Windows Save
function to save a copy of the edits in the programming
terminal offline file.
Figure 19.27 Completed Edits

NOTES:

STUDENT ACTIVITY
1. List four methods of communicating with an

RSLogix Controller.
_____________________________________________
_____________________________________________
_____________________________________________
_____________________________________________
2. What program is used to configure

communication drivers?
_____________________________________________
3. Loading a project from a Programming Terminal
to the Controller is:
Upload / Download
4. What action is required following the creation

of a force?
_____________________________________________
5. What three steps are required to finalize a

pending rung edit when editing online?
_____________________________________________
_____________________________________________
_____________________________________________

NOTES:

ANSWER KEY
1. List four methods of communicating with an

RSLogix Controller.
RS232 Serial Port
ControlNet
Ethernet
DH+ / RIO
2. What program is used to configure

communication drivers?
RSLinx
3. Loading a project from a Programming Terminal
to the Controller is:
Download
4. What action is required following the creation

of a force?
Enable the forces
5. What three steps are required to finalize a

pending rung edit when editing online?
Accept Pending Program Edits
Test Program Edits
Assemble Program Edits



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Technical Training

Course No. 3800

Solar Turbines Incorporated

PUBLICATION NUMBER: TR3800

© 2004 Solar Turbines Incorporated. All rights reserved.

1 TT4 CHAPTER 1 INTRODUCTION TO TURBOTRONIC

2 TT4 CHAPTER 1, LESSON 1 CONTROL SYSTEM CONCEPTS

3800 © 2004 Solar Turbines Incorporated. All rights reserved. v

3 TT4 CHAPTER 1 LESSON 2 CONTROL SYSTEM CONFIGURATION

4 TT4 CHAPTER 1, LESSON 3 LOGIX5000 CONTROLLER

5 TT4 CHAPTER 1, LESSON 4 I/O MODULES

6 TT4 CHAPTER 1, LESSON 5 COMMUNICATION NETWORKS & DEVICES

vi © 2004 Solar Turbines Incorporated. All rights reserved. 3800

7 TT4 CHAPTER 1, LESSON 6 OPERATOR INTERFACE DEVICES

8 TT4 CHAPTER 1, LESSON 7 SPECIAL FUNCTION DEVICES

9 TT4 CHAPTER 2 INTRODUCTION TO TT4 PROGRAMMING

3800 © 2004 Solar Turbines Incorporated. All rights reserved. vii

10 TT4 CHAPTER 2, LESSON 1 BASIC INSTRUCTION SET

11 TT4 MODULE 2, LESSON 2 INTRODUCTION TO SOLAR LOGIC

12 TT4 CHAPTER 2, LESSON 3 LOADING A PROGRAM TO

13 TT4 CHAPTER 2, LESSON 4 OFF-LINE PROGRAM MONITORING

14 TT4 CHAPTER 2, LESSON 5 RSLOGIX5000 FAMILIARIZATION

15 TT4 CHAPTER 2, LESSON 6 SOLAR PROJECT ORGANIZATION

viii © 2004 Solar Turbines Incorporated. All rights reserved. 3800

16 TT4 CHAPTER 2, LESSON 7 CONTROL LOGIC FAMILIARIZATION

17 TT4 CHAPTER 2 LESSON 8 ANALOG DEVICE PROGRAMMING

18 TT4 CHAPTER 2 LESSON 9 FUNCTION BLOCK OVERVIEW

19 TT4 CHAPTER 2, LESSON 10 RSLOGIX5000 ONLINE FUNCTIONS

3800 © 2004 Solar Turbines Incorporated. All rights reserved. ix

2.1 Control System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Information Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3 RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.4 Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.5 Pressure Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.6 Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.7 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.8 Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.9 Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.10 Flex I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

2.11 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.12 ControlLogix 5000-series Controller . . . . . . . . . . . . . . . . . . . . . . . 2.16

2.13 Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

2.15 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

2.16 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

2.17 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.18 Backup Relay System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

2.19 Backup Relay System Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

2.20 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.21 Communication Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.22 HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.23 Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

3.1 Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2 On-Skid Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

3.3 Off-Skid Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

3800 © 2004 Solar Turbines Incorporated. All rights reserved. xi

4.1 1756-series Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 ControlLogix Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3 ControlLogix Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

4.4 Standard Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.5 External High-Capacity Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4.6 RS-232 Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

5.1 1794-IB16 Discrete Input Module. . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.2 1794-OB16 Discrete Output Module . . . . . . . . . . . . . . . . . . . . . . . 5.6