Enhanced and Ethernet PLC-5 Programmable Controllers 1785-L11B, -L20B, -L30B, -L40B, -L40L, -L60B, -L60L, -L80B, -L20E, -L40E, -L80E, -L26B, -L46B, -L86B User Manual
Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices.
Summary of Changes Summary of Changes Changes to this Manual This user manual contains new and updated information. The black revision bars, as shown on the left, indicate the changes. For specific locations of the new information, refer to the table below.
Summary of Changes 2 Notes Publication 1785-UM012D-EN-P - July 2005
Table of Contents Preface Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related PLC-5 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terms Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 P-1 P-2 P-3 Chapter 1 Understanding Your Programmable Controller Using This Chapter . . . . . . . . . . .
Table of Contents 2 Chapter 4 Addressing I/O and Controller Memory Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 I/O Addressing Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Choosing an Addressing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Addressing Block-Transfer Modules. . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Addressing Summary . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Block-Transfer Programming Considerations . . . . . . . . . . . . . . . . . General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For Controller-Resident Local Racks . . . . . . . . . . . . . . . . . . . . . Monitoring Remote I/O Scanner Channels . . . . . . . . . . . . . . . . . . . Monitoring transmission retries . . . . . . . . . . . . . . . . . . . . . . . . . Addressing the I/O Status File . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 4 Monitoring General Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estimating DH+ Link Performance . . . . . . . . . . . . . . . . . . . . . . . . . Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Size and Number of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . Message Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Processing Time. . . . . . . . . . . . . . . . .
Table of Contents Using BOOTP to Configure Channel 2 for Controllers on Subnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Domain Name Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Embedded Web Server . . . . . . . . . . . . . . . . . . . . . . . . . . Generating User Provided Web Pages . . . . . . . . . . . . . . . . . . . Importing User Page Files to the PLC-5 Controller . . . . . . . . Using Multihop Messaging . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 6 Step 2 - Use the Programming Software to Enter or Edit the Data You Want to Force in the Extended Force Configuration Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Step 3 - Use the Programming Software to Enter Force Values for the Specified Data Table Files . . . . . . . . . . . . 13-8 Step 4 - Enable or Disable the Forces . . . . . . . . . . . . . . . . . . . . 13-8 Using Extended Forcing with Time-Critical Applications. . . . .
Table of Contents 7 Chapter 16 Using Main Control Programs Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Main Control Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding How the Controller Interprets MCPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring MCPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring MCPs. . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 8 Appendix C Maximizing System Performance Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Program Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Effects of False Logic versus True Logic on Logic Scan Time. . C-2 Effects of Different Input States on Logic Scan Time . . . . . . . . C-2 Effects of Different Instructions on Logic Scan Time . . . . . . . .
Table of Contents 9 ASCII Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-27 Bit and Word Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30 File, Program Control, and ASCII Instructions . . . . . . . . . . . . D-32 Appendix E Switch Setting Reference Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Controller Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 10 Appendix G Cable Reference Index Publication 1785-UM012D-EN-P - July 2005 Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Channel 0 Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Cable Specifications . . . . . .
Preface Using This Manual Purpose of This Manual The purpose of this manual is to help you design, operate and maintain an Enhanced and Ethernet PLC-5 programmable controller system. Use this manual to: • determine the features of the controllers and how you use them • design your PLC-5 system • operate and maintain your PLC-5 system Related PLC-5 Documentation The following documents contain additional information related to the procedures described in this document..
Preface 2 Terms Used in This Manual Become familiar with the following terms and definitions which are used throughout this manual.
Preface Manual Overview 3 This manual has three main sections: • Design • Operate • Maintain Section: For information about: Design An overview of the PLC-5 controllers’ capabilities and keyswitch Chapter 1 Understanding Your Controller Guidelines for selecting and placing I/O modules Chapter 2 Selecting and Placing I/O The proper environment for your PLC-5 system Chapter 3 Placing System Hardware Choosing addressing mode, assigning rack numbers, and understanding PLC-5 memory Chapter 4 Ad
Preface 4 Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 1 Understanding Your Programmable Controller Using This Chapter For Information About Lay Out the System Identifying controller components Programming features Using a controller channel as a remote I/O scanner Using a controller channel as a remote I/O adapter Using a PLC-5/40L, -5/60L programmable controller as an extended-local I/O scanner Lay Out the System Go to Page 1-1 1-2 1-10 1-11 1-12 1-14 Lay out the system by determining the network configuration and the placement of components in
1-2 Understanding Your Programmable Controller For a PLC-5 controller to control I/O modules, both the controller and the I/O modules must be directly attached to the same network. I/O Location Controller in Panel A, chassis 1 Controller in Panel B, chassis 1 Panel A, chassis 1 yes yes Panel A, chassis 2 yes no Panel A, chassis 3 yes no Panel B, chassis 1 yes yes Panel B, chassis 2 no yes Panel C, chassis 1 yes yes Evaluate what communications need to occur between controllers.
Understanding Your Programmable Controller 1-3 PLC-5/11, -5/20, and -5/26 Controller Front Panels PLC-5/11 Controller PLC-5/20 or -5/26 Controller battery indicator (red when the battery is low) controller RUN/FAULT indicator (green when running; red when faulted) keyswitch; selects controller mode force indicator (amber when I/O forces are enabled) channel 0 communication status indicator (green when the channel is communicating) channel 0-25-pin D-shell serial port; supports standard EIA RS-232C
1-4 Understanding Your Programmable Controller PLC-5/30 Controller Front Panell battery indicator (lights red when the battery is low) controller RUN/FAULT indicator (green when running; red when faulted) force indicator (amber when I/O forces are enabled) keyswitch; selects controler mode channel 0 communication status indicator (green when the channel is communicating) channel 0-25-pin D-shell serial port; supports standard EIA RS-232C and RS-423 and is RS-422A compatible 1 Use this port with ASCII o
Understanding Your Programmable Controller 1-5 PLC-5/40, -5/46, -5/60, -5/80, and -5/86 Controller Front Panel battery indicator (red when the battery is low) controler RUN/FAULT indicator (green when running; red when faulted) keyswitch; selects controller mode force indicator (amber when I/O forces are enabled) channel 0 communication status indicator (green when the channel is communicating) channel 2A status indicator (lights green and red) 8-pin mini-DIN, DH+ programming terminal connection parallel
1-6 Understanding Your Programmable Controller PLC-5/20E Controller Front Panel battery indicator (red when the battery is low) external transceiver fuse controller RUN/FAULT indicator (green when running; red when faulted) force indicator (amber when I/O forces are enabled) keyswitch; selects controller mode channel 0 communication status indicator (green when the channel is communicating) channel 2 Ethernet status indicator (green when functioning normally; red when not functioning) channel 2, Ethern
Understanding Your Programmable Controller 1-7 PLC-5/40E and -5/80E Controller Front Panels battery indicator (red when the battery is low) controller RUN/FAULT indicator (green when running; red when faulted) external transceiver fuse force indicator (amber when I/O forces are enabled) channel 0 communication status indicator (green when the channel is communicating) keyswitch; selects controller mode channel 2 Ethernet status indicator (green when functioning normally; red when not functioning) chann
1-8 Understanding Your Programmable Controller PLC-5/40L and -5/60L Controller Front Panels battery indicator (red when the battery is low) controller RUN/FAULT indicator (green when running; red when faulted) force indicator (amber when I/O forces are enabled) channel 0 communication status indicator (green when the channel is communicating) keyswitch; selects controller mode channel 2 extended-local I/O status indicator (green when functioning normally; red when not functioning) channel 2 communicati
Understanding Your Programmable Controller 1-9 Use the keyswitch to change the mode in which a controller is operating. If You Want to Turn the Keyswitch to • Run your program. Outputs are enabled. (Equipment being controlled by the I/O RUN addressed in the ladder program begins operation.) PROG • Force I/O. • Save your programs to a disk drive (during operation). • Enable outputs. R E M RUN • Edit data table values.
1-10 Understanding Your Programmable Controller Programming Features This table highlights the programming features of a PLC-5 programmable controller. This Capability Ladder logic Lets You program using a language that is representative of relay logic. Choose this language Subroutines Sequential Function Charts (SFCs) • if you are more familiar with ladder logic than with programming languages such as BASIC Your plant personnel may be more familiar with ladder logic; consider their needs as well.
Understanding Your Programmable Controller Using a Controller Channel as a Remote I/O Scanner 1-11 Configure a remote I/O channel for scanner mode to read and write I/O information between a controller and an I/O device remotely located from the controller. PLC-5/40 A controller with a channel configured for scanner mode acts as a supervisory controller for other controllers that are in adapter mode as well as remote I/O adapter modules.
1-12 Understanding Your Programmable Controller A controller transfers I/O data and status data using: • discrete transfers data transfers of 8 words per rack occur automatically on the remote I/O network • block-transfers special data transfers that require ladder logic instructions to achieve the transfer allow a transfer of a maximum of 64 words of data also used to communicate information between a scanner channel and an adapter-mode controller channel Using a Controller Channel as a Remote I/O Ada
Understanding Your Programmable Controller 1-13 For Enhanced and Ethernet programmable controller channels in adapter mode, you do not need ladder logic in the adapter controller for block-transfer instructions. You define the block-transfers via an adapter configuration screen and by defining block-transfer files.
1-14 Understanding Your Programmable Controller Using a PLC-5/40L, -5/60L Programmable Controller as an Extended-Local I/O Scanner Use the extended-local I/O link when you need I/O updates more quickly than is possible from remote I/O link. An extended-local I/O link provides faster scan and update time than a remote I/O link. The extended-local I/O link is limited to 30.5 cable-m (100 cable-ft). If an I/O chassis is located more than 30.5m from the controller, you must use a remote I/O link.
Chapter 2 Selecting and Placing I/O Using This Chapter For Information About Selecting I/O modules Selecting I/O module density Placing I/O modules in a chassis Selecting I/O Modules Go to Page 2-1 2-2 2-3 Select I/O modules to interface your PLC-5 controller with machines or processes that you determine while analyzing your plant operation. Use the following list and table as guidelines for selecting I/O modules and operator control interface(s).
2-2 Selecting and Placing I/O Guidelines for Selecting I/O Modules Choose this Type of I/O Module For these Types of Field Devices or Operations (examples) Discrete input module and block I/O module Selector switches, pushbuttons, photoelectric eyes, limit switches, circuit breakers, proximity switches, level switches, motor starter contacts, relay contacts, thumbwheel switches Input modules sense on/off or opened/closed signals. Discrete signals can be either ac or dc.
Selecting and Placing I/O Placing I/O Modules in a Chassis Place I/O modules in a chassis depending on the electrical characteristics of the module. The placement is made left to right, with the left-most position being closest in the chassis to the PLC-5 controller or the I/O adapter module. The placement order is as follows: Priority: Module placement priority: 1. block-transfer modules (all types) 2. dc input modules 3. dc output modules 4. ac input modules 5.
2-4 Selecting and Placing I/O Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 3 Placing System Hardware Using This Chapter For Information About Determining the proper environment Protecting your controller Avoiding electrostatic damage Laying out your cable raceway Laying out your backpanel spacing Grounding your system Determining the Proper Environment Go to Page 3-1 3-3 3-3 3-4 3-5 3-6 Place the controller in an environment with conditions that fall within these guidelines: Environmental Condition Operating temperature Storage temperature Relative humidity Accepta
3-2 Placing System Hardware Minimum spacing requirements for a controller-resident chassis: Mount the I/O chassis horizontally. Allow 153 mm (6 in) above and below the chassis. Allow 102 mm (4 in) on the sides of each chassis. Allow 51 mm (2 in) vertically and horizontally between any chassis and the wiring duct or terminal strips. Leave any excess space at the top of the enclosure, where the temperature is the highest.
Placing System Hardware Protecting Your Controller 3-3 You provide the enclosure for your controller system. This enclosure protects your controller system from atmospheric contaminants such as oil, moisture, dust, corrosive vapors, or other harmful airborne substances. To help guard against electromagnetic interference (EMI) and radio frequency interference (RFI), we recommend a steel enclosure. Mount the enclosure in a position where you can fully open the doors.
3-4 Placing System Hardware Laying Out Your Cable Raceway The raceway layout of a system reflects where the different types of I/O modules are placed in I/O chassis. Therefore, you should determine I/O-module placement prior to any layout and routing of wires. When planning your I/O-module placement, however, segregate the modules based on the conductor categories published for each I/O module so that you can follow these guidelines.
Placing System Hardware 3-5 Use 6.35 mm (0.25 inch) mounting bolts to attach the I/O chassis to the enclosure backpanel. Laying Out Your Backpanel Spacing Chassis Dimensions (Series B) 1771-A1B 1771-A2B 1771-A3B1 1771-A4B 591mm (23.25") 16-slot 1771 464mm (18.25") 337mm (13.25") 193mm (7.60") Side 12-slot 8-slot 210mm (8.25") 315mm (12.41") 4-slot 254mm (10") Power C onnector 171mm (6.75") 483mm (19.01") 229mm (9.01") 610mm (24.01") 16-slot 1771-A4B 12-slot 1771-A3B1 356mm (14.
3-6 Placing System Hardware I/O Chassis and External Power Supply Dimensions U se .25" dia mounting bolts (4 places) 315mm (12.41") 16-slot 591mm (23.25") 464mm (18.25") 337mm (13.25") 210mm (8.25") External Power Supply 91mm (3.6") 483mm (19.01") 610mm (24.01") 4-slot 16-slot 1771-A4B 12-slot 1771-A3B1 356mm (14.01") Clearance depth is 204mm (8") for 8 I/O connection points per module. Publication 1785-UM012D-EN-P - July 2005 8-slot 254mm (10") 229mm (9.
Placing System Hardware 3-7 Recommended Grounding Configuration for Remote I/O Systems Enclosure Grounding Electrode Conductor Ground Bus To Grounding Electrode System I/O Chassis Wall Ground Lug Nut Star Washer Ground Lug 15561 Required Grounding Configuration for Extended-Local I/O Systems Enclosure Enclosure Ground Bus Ground Bus To Grounding Electrode System (single point only) Extended-Local I/O Cables I/O Chassis Wall I/O Chassis Ground Stud Ground Lug Nut Star Washer Ground Lug 18585 P
3-8 Placing System Hardware Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 4 Addressing I/O and Controller Memory Using This Chapter For Information About I/O addressing concept Choosing an addressing mode Addressing block-transfer modules Addressing summary Assigning racks Understanding PLC-5 controller memory Addressing Effectively Using I/O Memory I/O Addressing Concept Go to Page 4-1 4-3 4-7 4-7 4-8 4-10 4-16 4-24 Since the main purpose of a programmable controller is to control inputs and outputs of field devices like switches, valves, and thermocouples, these i
4-2 Addressing I/O and Controller Memory The figure below shows the relationship between an I/O terminal and its location in controller memory.
Addressing I/O and Controller Memory Choosing an Addressing Mode 4-3 For each I/O chassis in your system, you must define how many I/O chassis slots make up an I/O group (1 word each in the input image table and output image table); this choice is the chassis’ addressing mode. Choose from among these available modes: 2-slot addressing 2 I/O chassis slots = 1 I/O group = 1 input image word and 1 output image word = 16 input bits and 16 output bits.
4-4 Addressing I/O and Controller Memory 18-and 16-point Example 1-slot addressing (1 I/O chassis slot = 1 I/O group = 1 input image word and 1 output image word = 16 input bits and 16 output bits.
Addressing I/O and Controller Memory 4-5 32-point Example 1-slot addressing (1 I/O chassis slot = 1 I/O group = 1 input image word and 1 output image word = 16 input bits and 16 output bits.) 01 32-point input module Controller memory Rack x Output Image Table Word # 0 32-point I/O modules use the entire word of their group and borrow the entire word of the next group. See 1 .
4-6 Addressing I/O and Controller Memory When planning your system design, consider the densities of the I/O modules you are using and choose an addressing mode that most efficiently uses controller memory. Example of Efficient I/O Image Table Use. 2-slot addressing (2 I/O chassis slot = 1 I/O group = 1 input image word and 1 output image word = 16 input bits and 16 output bits.
Addressing I/O and Controller Memory Addressing Block-Transfer Modules 4-7 Block-transfer modules occupy 8 bits in the controller’s I/O image table. Since all block-transfer modules are bidirectional, they cannot be used to complement either input or output modules.
4-8 Addressing I/O and Controller Memory Assigning Racks The number of racks in a chassis depends on the chassis size and the addressing mode: If Using this Chassis Size 4-slot 8-slot 12-slot 16-slot 2-slot Addressing, Results In 1/4 rack 1/2 rack 3/4 rack 1 rack Group together 1/4 racks and 1/2 racks Publication 1785-UM012D-EN-P - July 2005 1 1 1 2 2 2 3 17 1/2-slot Addressing, Results In 1 rack 2 racks 3 racks 4 racks When assigning rack numbers, use the following guidelines: TIP Rack Address
Addressing I/O and Controller Memory 4-9 When assigning remote I/O rack numbers, use these guidelines: TIP • A single remote I/O scanner channel can support up to 32 devices but only 16 rack numbers. For more information, see chapter 6. • Limit the number of remote I/O rack numbers to those that your PLC-5 controller can support. • The PLC-5 controller and the 1771-ASB adapter module automatically allocate the next higher rack number(s) to the remaining I/O groups of the chassis.
4-10 Addressing I/O and Controller Memory Understanding PLC-5 Controller Memory Controller memory is divided into two basic areas: Storage Areas Description Data All of the data the controller examines or changes is stored in files in data storage areas of memory.
Addressing I/O and Controller Memory 4-11 Understanding Data Storage (Data-Table Files) The controller divides data storage into: Integer Data Table Files File # Integer File 7 • Types that let you specify different formats and ranges to accommodate different types of data. For more information on the different types of data files, see on page 13. File 999 Words (Sample Data) Integer Files • You can create multiple files of a given type. Files let you group and organize logically related data.
4-12 Addressing I/O and Controller Memory TIP You might also want to leave room for future expansion when grouping data. Do this by leaving gaps between: • data blocks within a file • groups of sequentially numbered files • modules in an I/O chassis IMPORTANT TIP If you plan to edit your program online in Run mode, you must allocate unused data table files/elements and program files because you cannot create user memory while in run mode.
Addressing I/O and Controller Memory 4-13 Addressing File Types The following two tables show the available file types and the amount of memory used by each.
4-14 Addressing I/O and Controller Memory Data Table File Types and Memory Usage for PLC-5 Controllers Series E/Revision C and Earlier File Type File-Type File Maximum Size of File Identifier Number 16-bit Words and Structures PLC-5/11, -5/20, -5/20E PLC-5/30 PLC-5/40, -5/40E, -5/40L PLC-5/60, -5/60L, -5/80, -5/80E Memory Used in Overhead for Each File (in 16-bit Words) Memory Used (in 16-bit Words) per Word, Character, or Structure Output image O 0 32 64 128 192 6 1/word Input image I 1
Addressing I/O and Controller Memory 4-15 Valid Data Types/Values Are: This Data Type/Value Immediate (program constant) Integer Float Block Message PID String SFC status Accepts Any Value between -32768 and 32767 (Constants greater than 1024 use 2 storage words of memory; floating point constants use 3 words of memory.) Integer data type: integer, timer, counter, status, bit, input, output, ASCII, BCD, control (e.g., N7:0, C4:0, etc.) Floating point data type (valid range is + 1.175494e-38 to +3.
4-16 Addressing I/O and Controller Memory Valid formats for addressing data files are: Addressing If You Want to Access Input or output bit in the I/O image table Bit, word, sub-member, data block, file, or I/O image bit A component within a logical address by substituting the value in another address An address offset by some number of elements A substitute name for an address Use this Addressing Format I/O image address Logical address Indirect address And See Page 4-16 4-17 4-18 Indexed address Sy
Addressing I/O and Controller Memory 4-17 Specifying Logical Addresses The format of a logical address corresponds directly to the location in data storage: # X F : e . s / b Where Is the # File address.
4-18 Addressing I/O and Controller Memory To Specify the Address of a Use these Parameters Bit within a binary file B 3 / 2 4 5 Bit Delimiter Bit Number Binary files are bit stream continuous files, and therefore you can address them in two ways: by word and bit, or by bit alone. Bit within a structure file R 6 : 7 . D N File Type File Number File Delimiter Structure Number Member Delimiter Member Mnemonic You can also use mnemonics to address members at the word or bit level.
Addressing I/O and Controller Memory 4-19 When you specify indirect addresses, follow these guidelines: • You can indirectly address the file number, word number, or bit number. • The substitute address must be one of the following types: N, T, C, R, B, I, O, or S. Any T, C, or R address must be a word-length sub-member address, such as T4:0.ACC. • Enter the pointer address in brackets [ ]. Example N[N7:0]:0 Explanation The file number is stored in integer address N7:0. N7:[C5:7.
4-20 Addressing I/O and Controller Memory Specifying Indexed Addresses The controller starts operation at the base address plus the offset. Store the offset value in the offset word in the controller’s status file. You can manipulate the offset word in your ladder logic. The indexed address symbol is the # character. Place the # character immediately before the file-type identifier in a logical address. Enter the offset value in the status file S:24. All indexed instructions use S:24 to store an offset.
Addressing I/O and Controller Memory 4-21 Specifying Symbolic Addresses When you specify symbolic address, follow these guidelines: • Start the name with an alphabetic character (not a number). • The symbol must begin with a letter and can contain as many as 10 of the following characters: – – A-Z (upper and lower case) – – 0-9 – – underscore (_) • You can substitute a symbolic address for word or bit addresses.
4-22 Addressing I/O and Controller Memory Optimizing Instruction Execution Time and Controller Memory For the best instruction-execution performance, store your most frequently used addresses as shown below: TIP Address bit instructions between the end of the input image file and physical word 256. Bit addresses located in words greater than 256 require one extra word in the controller's memory for storage and execute 0.16ms slower than bit addresses stored in words 0-255.
Addressing I/O and Controller Memory 4-23 The following examples illustrate these concepts: Bit address example If your data table map looks like this: O I B T C R N 32 32 64 32 32 32 32 1 OTE An address used in an OTE instruction stored here: occupies one word in the controller's memory executes at a rate 0.48µs 256 1 2 OTE XX The same address stored here: occupies two words in the controller's memory executes at a rate 0.
4-24 Addressing I/O and Controller Memory The PLC-5 controller automatically allocates both an input and output memory location to each I/O location. I/O modules generally only use either the inputs or the outputs. To more effectively use I/O memory, you can use these methods of placing I/O modules. Effectively Using I/O Memory Use 2-slot 1-slot complementary I/O chassis Application Install 16-point I/O modules as an input module and output module pair in an I/O group.
Chapter 5 Communicating with Controller-Resident I/O Using This Chapter For Information About Introduction to PLC-5 controller scanning Program scanning Transferring data to controller-resident I/O Configuring the system for controller-resident I/O Go to Page 5-1 5-2 5-3 5-4 This chapter explains how to configure the controller to communicate with resident I/O: 1. Set the I/O chassis switch for the addressing mode. 2. Set the rack address. The rack address defaults to 0.
Communicating with Controller-Resident I/O The controller performs two primary operations: program scanning where - logic is executed - housekeeping is performed I/O scanning - where input data is read and output levels are set Extendedlocal I/O Data Exchange Data Exchange I/O Image Table Remote I/O Buffer Update I/O image Data Exchange During logic scan, inputs are read from and outputs are written to the I/O image table.
Communicating with Controller-Resident I/O Transferring Data to Controller-Resident I/O 5-3 A PLC-5 controller transfers discrete and block-transfer data with controller-resident I/O. Transferring Discrete Data to Controller-Resident I/O a b The controller scans controller-resident local I/O synchronously and sequentially to the program scan. I/O Image Table The controller-resident rack exchanges discrete I/O information with the I/O image table during housekeeping.
5-4 Communicating with Controller-Resident I/O If your application cannot support this configuration, condition the immediate I/O instructions with the control bits of the adjacent block-transfer module. This technique helps make certain that an adjacent block-transfer module is not performing a block-transfer while an immediate I/O instruction is executing in its adjacent input module.
Chapter 6 Communicating with Remote I/O Using This Chapter For Information About Selecting devices that you can connect Introduction to remote I/O Designing a remote I/O link Configuring a controller channel as a scanner Communicating to a remote I/O node adapter Transferring block data Block-transfers of remote I/O data Block-transfer sequence with status bits Block-transfer programming considerations Monitoring remote I/O scanner channels Addressing the I/O status file Go to Page 6-2 6-3 6-4 6-6 6-11
6-2 Communicating with Remote I/O Selecting Devices That You Can Connect The following table lists some of the devices you can use on a remote I/O link: Category Product Catalog Number Other Controllers (in adapter mode) enhanced PLC-5 controllers 1785-LxxB Ethernet PLC-5 controllers 1785-LxxE ControlNet PLC-5 controller 1785-LxxC VMEbus PLC-5 controllers 1785-VxxB extended-local PLC-5 controllers 1785-LxxL classic PLC-5 controllers 1785-LTx Other Controllers (in adapter mode) Direct Co
Communicating with Remote I/O Introduction to Remote I/O 6-3 A remote I/O system lets you control I/O that is not within the controller’s chassis. A PLC-5 controller channel, in scanner mode, transfers discrete and block-transfer data with remote I/O devices. An example remote I/O system looks like this: PLC-5/40 A PLC-5 controller channel acting as a scanner The scanner channel maintains a list of all the full and partial racks connected to that channel, which is the scan list.
6-4 Communicating with Remote I/O Follow these steps for setting up a remote I/O system: For this Step 1.configure the remote I/O adapter devices 2.layout and connect the remote I/O link cable See the device’s user manual • page 6-4 for design • chapter 3 for cable routing information • your controller’s installation information (For enhanced PLC-5 controllers, see publication 1785-IN062; for Ethernet PLC-5 controllers publication 1785-IN063) page 6-6 3.
Communicating with Remote I/O 6-5 Cable Design Guidelines Specify 1770-CD (Belden 9463) cable. Connect a remote I/O network using a daisy chain or trunk line/drop line configuration. TIP Trunk line/drop line considerations: Verify that your system’s design plans specify cable lengths within allowable measurements.
6-6 Communicating with Remote I/O I/O Link Devices that Require 150Ω Termination Resistors Device Type Scanners Catalog Number 1771-SN 1772-SD, -SD2 1775-SR 1775-S4A, -S4B 6008-SQH1, -SQH2 Adapters 1771-AS 1771-ASB 1771-DCM Miscellaneous 1771-AF Configuring a Controller Channel as a Scanner Series All A All Use this table to help you determine the controller channels you can configure as a remote I/O scanner: Controller PLC-5/11 PLC-5/20 PLC-5/20E PLC-5/30 PLC-5/40E PLC-5/40L PLC-5/60L PLC-5/80E PLC
Communicating with Remote I/O 6-7 Define an I/O Status File The I/O status file stores data for the controller’s I/O rack configuration tables. The I/O status from each remote I/O rack requires two words. These two words store the reset, present, inhibit, and fault bits for each rack. To define an I/O status file, enter an unused integer file number (9-255) in the I/O status file field (S:16) of the controller configuration screen. If you do not want to use I/O rack configuration tables, enter 0.
6-8 Communicating with Remote I/O ATTENTION In this Field Diagnostic file Define The file containing the channel’s status information: Assign a unique diagnostic file to each channel. Do not assign a diagnostic file that is the I/O status file you assigned or any other used integer file. Unpredictable machine damage can result.
Communicating with Remote I/O 6-9 Specify the Scan List A scan list is a map of the I/O devices being scanned by the scanner channel. For the channel to communicate with the I/O devices connected to it, you must create a scan list. To Create a scan list Do the Following Make sure the controller is in Remote Program or Program mode. 1.Make sure that you defined an I/O status file on the controller configuration screen (see page 6-7). 2.Accept any edits made to the channel configuration. 3.
6-10 Communicating with Remote I/O TIP If you need multiple updates to an I/O device during an I/O scan, you can enter a logical address in the scan list more than one time. Do not assign the same partial or full rack address to more than one channel in scanner mode. Each channel must scan unique partial and/or full rack addresses.
Communicating with Remote I/O Communicating to a Remote I/O Node Adapter 6-11 A scanner channel exchanges discrete data with remote I/O node adapters like 1771-ASB modules via the remote I/O buffer. Remote I/O Scan and Program Scan Loops.
6-12 Communicating with Remote I/O Troubleshooting Remote I/O Communication Difficulties Follow these steps to make sure the controller can communicate with devices on remote I/O links. 1. Put the controller in program mode. Go into the memory map and find two unused file numbers. The controller will use these files. Do not create the files, just record which file numbers you will use. 2. Go to the controller status screen and make sure all rack inhibit bits are zeroed (0). 3.
Communicating with Remote I/O 6-13 In addition to discrete data, the controller can also exchange block data with remote I/O. Block-transfer instructs the controller to interrupt normal I/O scanning and transfer as many as 64 words of data to/from a selected I/O module. The figure below shows how the scanner-mode controller handles a block-transfer.
6-14 Communicating with Remote I/O As shown in the previous figure, the controller has the following storage areas for block-transfers: Maximum Number of Active Buffers Per Remote I/O Channel PLC-5/60, -5/60L, -5/80, -5/80E PLC-5/40, -5/40L, -5/40E PLC-5/30 PLC-5/20, -5/20E PLC-5/11 23 31 39 43 43 Placing the controller in program mode, cancels block-transfers in the active buffers and in the waiting queues.
Communicating with Remote I/O 6-15 Block-Transfer Minor Fault Bits Minor Fault S:17/0Block-transfer queue full to remote I/O S:17/1 through S:17/4Queue full - channel xx Description There is a possibility that the PLC-5 controller might temporarily be unable to initiate multiple consecutive user-programmed block-transfers. For any block-transfer which temporarily can’t be processes, the PLC-5 controller sets minor fault bit S:17/0 and skips that block-transfer instruction.
6-16 Communicating with Remote I/O If you split remote rack addresses between scanner channels, block-transfers to lower priority scanner channels do not function properly. Scanner channels have priority according to the following order: 1A, 1B, 2A, then 2B.
Communicating with Remote I/O 6-17 The following figure describes the different states of the block-transfer status bits. Block-Transfer Sequence with Status Bits Start ladder logic Detects that a rung containing a block-transfer is enabled and sets the enable .EN bit and resets the .ST, .DN, .ER, and .EW status bits. The processor sends the block-transfer request to the I/O scanner, sets the .EW bit, and resumes the program scan.
6-18 Communicating with Remote I/O B Did the block-transfer complete without errors? no Sets the error .ER bit (12). yes Sets the done .DN bit (13). no Was the block-transfer a BTR? Is the block-transfer continuous? (the .CO bit is set.) yes Re-initializes the block-transfer. go to yes Copies data from the active buffer to the block-transfer file in the data table.
Communicating with Remote I/O 6-19 C Is the block-transfer for a local I/O module? no Block-transfer is for a module in a remote rack. yes no Is the timeout .TO bit (08) set? Sets the no response .NR bit (09). Continues to request the block-transfer until the watchdog timer expires (4 s). yes Continues to request the block-transfer for 0-1 s before setting the .ER bit (12). no Is the timeout .TO bit (08) set? Re-initializes the request until the watchdog timer expires (4 s).
6-20 Communicating with Remote I/O • When performing block-transfers (controller-resident local or remote I/O) in any PLC-5 controller, clear the output image table corresponding to the block-transfer module rack location before changing to run mode. If you do not clear the output image table, then you encounter block-transfer errors because unsolicited block-transfers are being sent to the block-transfer module (i.e.
Communicating with Remote I/O 6-21 • Do not program IIN or IOT instructions to a module in the same physical module group as a BT module unless you know a block-transfer is not in progress. If you must do this, then use an XIO instruction to examine the .EN bit of the block-transfer instruction to condition the IIN and IOT. Monitoring Remote I/O Scanner Channels To monitor channels configured as a scanner, use the scanner mode status screen in your programming software.
6-22 Communicating with Remote I/O Status Field Location Description Rack Address This field indicates the rack number of the remote racks being scanned by the scanner channel: can only scan rack 3 (PLC-5/11 controller) 1-3 octal (PLC-5/20, -5/20E controller) 1-7 octal (PLC-5/30 controllers) 1-17 octal (PLC-5/40, -5/40L, 5/40E controllers) 1-27 octal (PLC-5/60, -5/60L, -5/80, -5/80E controllers) If complementary I/O is enabled (on the scanner mode configuration screen), the complement of a rack is iden
Communicating with Remote I/O 6-23 Monitoring messages Status Field Location Description Messages Tab (Messages = SDA messages + SDN messages) Messages sent word 1 Displays the number of messages sent by the channel. Messages sent with error word 3 Displays the number of messages containing errors sent by the channel. Messages received word 0 Displays the number of error-free messages received by the channel.
6-24 Communicating with Remote I/O Addressing the I/O Status File During program execution you can address words and fault bits within the I/O status file. The following figure shows the arrangement of the words in the I/O status file for a given remote or extended local I/O rack. The example status file used for the figures in this section is integer file 15.
Communicating with Remote I/O 6-25 Bit Layout Diagrams for the First Word Allotted to a Remote I/O Rack or an Extended-Local I/O Rack N15:14 15 Present Bits 14 13 12 11 10 09 Fault Bits 08 07 Not Used 06 05 04 03 02 01 00 Not Used This Bit Corresponds to Fault Bits 00 first 1/4 rack starting I/O group 0 01 second 1/4 rack starting I/O group 2 02 third 1/4 rack starting I/O group 4 03 fourth1/4 rack starting I/O group 6 Present Bits 08 first 1/4 rack starting I/O group 0 09
6-26 Communicating with Remote I/O Bit Layout Diagrams for the Second Word Allotted to a Remote I/O Rack or an Extended Local I/O Rack N15:15 15 Reset Bits 14 13 12 11 10 09 Inhibit Bits 08 07 Not Used 06 05 04 03 02 01 00 Not Used This Bit: Corresponds to: Inhibit Bits 00 first 1/4 rack starting I/O group 0 01 second 1/4 rack starting I/O group 2 02 third 1/4 rack starting I/O group 4 03 fourth1/4 rack starting I/O group 6 Reset Bits 08 first 1/4 rack starting I/O group 0
Chapter 7 Communicating with a PLC-5 Adapter Channel Using This Chapter For Information About: Go to Page: Configuring communication to a PLC-5 adapter channel 7-2 Programming discrete transfers 7-10 Programming block-data transfers 7-10 Monitoring the status of the adapter channel 7-17 Monitoring the status of the supervisory controller 7-18 Monitoring remote I/O adapter channels 7-19 This chapter explains how to configure the controller to communicate with an adapter channel: 1.
Communicating with a PLC-5 Adapter Channel Configuring Communication to a PLC-5 Adapter Channel Because a PLC-5 controller adapter channel is more intelligent than a 1771-ASB module, data communication and configuration tasks are handled differently for adapter channels. The supervisory controller or scanner channel and the adapter-mode controller channel automatically transfer discrete data and status between themselves via the supervisory controller’s remote I/O scan.
Communicating with a PLC-5 Adapter Channel 7-3 Specify an Adapter Channel’s Communication Rate, Address, and Rack Size Use this table to help you determine the controller channels you can configure as a remote I/O adapter: Controller Channels that Support Remote I/O Adapter PLC-5/11 1A PLC-5/20 PLC-5/20E 1B PLC-5/30 PLC-5/40E 1A, 1B PLC-5/40L PLC-5/80E PLC-5/60L PLC-5/40 PLC-5/80 1A, 2A, 1B, 2B PLC-5/60 To select a channel as an adapter, use the adapter mode configuration screen in your pr
7-4 Communicating with a PLC-5 Adapter Channel In this Field Define By Doing the Following Diagnostic file The file containing the adapter channel’s Cursor to the field and enter an integer file number (9-999). status information ATTENTION: Assign a unique diagnostic file to each channel. Do not assign a diagnostic file that is the I/O status file you assigned or any other used integer file. Unpredictable machine damage can result.
Communicating with a PLC-5 Adapter Channel In this Field Define By Doing the Following Last rack Notifies the supervisory controller that this is the last chassis Select the check box if this is the last rack. 7-5 This information is important when the supervisory controller is a PLC-2 controller. Starting group The starting group number of the rack Cursor to the field and enter the number Valid entries are: 0, 2, 4 or 6.
7-6 Communicating with a PLC-5 Adapter Channel Configure the discrete transfer configuration file as an integer file. Although the PLC-5 controller allows you to use the input or output areas, reserve these for real I/O on scanner channels. In doing so, you are avoiding a possible conflict if you later attempt to add a rack that uses the same I/O image space. IMPORTANT Do not configure the adapter channel’s discrete transfer configuration input destination file to be the data table input image.
Communicating with a PLC-5 Adapter Channel 7-7 Discrete Data and Block-Transfer Status .
7-8 Communicating with a PLC-5 Adapter Channel If data from the supervisory controller is intended to control outputs of the adapter-mode controller channel, write ladder logic in the adapter-mode controller to move the data from its input destination file to its output image. Use XIC and OTE instructions for bit data; use move and copy instructions for word data.
Communicating with a PLC-5 Adapter Channel 7-9 To create the discrete transfer configuration files, use the adapter mode configuration screen in your programming software. specify the discrete transfer configuration files IMPORTANT The controller determines the number of words used by the file according to the rack size you specified. In this Field Define By Doing the Following Input destination The location where the scanner (host device) places output words into the adapter’s input file 1.
7-10 Communicating with a PLC-5 Adapter Channel Programming Discrete Transfers in Adapter Mode Typically, each output instruction in one controller should have a corresponding input instruction in the other controller. The rack number of the adapter mode controller-channel determines the addresses that you use.
Communicating with a PLC-5 Adapter Channel 7-11 Configure Block-Transfer Requests To configure block-transfers to adapter-mode controller channel, use the adapter mode configuration screen in your programming software. 1. Define the BTW control and BTR control files you need. These control files must already exist (appear on the memory map) or the edit will result in an error. Each control word must contain a unique block-transfer control address to properly transmit block-transfers. A.
7-12 Communicating with a PLC-5 Adapter Channel A block-transfer write of 10 words from file 24, element 10 with BT control file for group 0, module 0 of BT12:000 looks like: EXAMPLE Adapter Mode Configuration screen Group 0 Module BTW control 0 BTR control BT02:000 BT000:000 Data Monitor screen Address BT12:000 EN ST DN ER CO EW NR TO RW RLEN DLEN FILE ELEM R G M 0 0 0 0 0 0 0 0 0 10 0 24 10 0 0 0 Publication 1785-UM012D-EN-P - July 2005
Communicating with a PLC-5 Adapter Channel 7-13 Program multiple block-transfers to an adapter-mode controller channel by matching block-transfer instructions in the supervisory controller to control files in the adapter. Supervisor Program In this example, the first block transfer in the supervisor uses the BTR control word listed in group 0 module 0, which is BT010:000.
7-14 Communicating with a PLC-5 Adapter Channel If you want to transfer controller-resident local I/O data of the adapter mode controller channel to a supervisory controller or if you want to transfer data from the supervisory controller to controller-resident local I/O of the adapter mode controller channel, you must use MOV or COP instructions within the adapter-mode controller channel to move the data in or out of the data file used in the adapter block-transfer control file.
Communicating with a PLC-5 Adapter Channel 7-15 Example Bidirectional Repeating Block Transfer in PLC-5/250 Supervisory Controller Read data from adapter-mode processor Enter the following parameters in the block-transfer instructions in the supervisory processor. Set the length to 0. Use the remote I/O rack number for which you configure the adapter-mode processor. Use the group and module numbers for which the adapter-mode processor is configured. Condition the use of BTR data with a "data valid" bit.
7-16 Communicating with a PLC-5 Adapter Channel Each group/module that is programmed as an adapter channel block transfer uses one byte in the adapter channel’s input destination file. For example: Adapter Channel’s Input Destination File Example Integer File Scanner’s Output Image Table d for status.
Communicating with a PLC-5 Adapter Channel 7-17 Do not program a block-transfer to group 0, module 1 since this area of the discrete transfer configuration file is used for communication status exchanges between the supervisory controller and the adapter-mode controller channel.
7-18 Communicating with a PLC-5 Adapter Channel When this Bit(s) Is It Indicates 10 octal (8 decimal) 0 adapter-mode controller is in run mode 1 adapter-mode controller is in program or test mode and 15 octal (13 decimal) 10 octal (8 decimal) and 15 octal (13 decimal) Write ladder logic in the supervisory controller to monitor the rack-fault bits for the rack that the adapter-mode controller channel is emulating to determine the status of the remote I/O link.
Communicating with a PLC-5 Adapter Channel Monitoring Remote I/O Adapter Channels 7-19 To monitor channels that are configured to support adapter mode, use the adapter mode status screen. The data displayed is stored in the diagnostic file you defined in the adapter mode configuration screen of your programming software. Status Field Location Description Messages sent word 1 Displays the number of messages sent by the channel.
7-20 Communicating with a PLC-5 Adapter Channel Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 8 Communicating with Extended-Local I/O Using This Chapter For Information About Go to Page Selecting devices that you can connect 8-1 Cabling 8-2 Addressing and placing I/O 8-2 Transferring data 8-4 Configuring the controller as an extended-local I/O scanner 8-9 Monitoring extended-local I/O status 8-12 This chapter explains how to configure the controller to communicate with extended-local I/O: 1. Configure channel 2 for extended-local I/O. 2. Define a diagnostic file. 3.
8-2 Communicating with Extended-Local I/O Cabling The maximum cable length for an extended-local I/O system is 30.5 cable-m (100 cable-ft). Connect extended-local I/O adapters by using any of these cables: Cable Length Catalog Number 1 m (3.3 ft) 1771-CX1 2 m (6.6 ft) 1771-CX2 5 m (16.5 ft) 1771-CX5 IMPORTANT You cannot connect or splice extended-local I/O cables to form a custom cable length.
Communicating with Extended-Local I/O 8-3 PLC-5/40L Controller with 16-rack Addressing Capability (Split Between Extended-Local I/O and Remote I/O) Processor-resident local I/O racks 0 1 2 Extended-local I/O racks 3 4 5 6 7 10 11 Remote I/O racks 12 13 14 15 16 17 Note: Racks numbers do not need to be consecutive per channel. For example, remote I/O racks can be numbered 6, 7, 14, 15, 16, and 17, while extended-local I/O racks can be numbered 4, 5, 10, 11, 12, and 13.
8-4 Communicating with Extended-Local I/O • You cannot configure more than one rack to have the same starting rack number and module group; that is, you cannot use chassis to chassis complementary I/O. Follow these guidelines when you plan your extended-local I/O system. • Do not configure controller input interrupts (PIIs) for inputs in an extended-local I/O chassis. The PII inputs must be in the controller-resident local I/O rack.
Communicating with Extended-Local I/O 8-5 Discrete Data Transfer The processors scan the extended-local I/O chassis during the housekeeping portion of the program scan. Extended-local I/O discrete data is exchanged between the processor’s data table image and the I/O in the extended-local I/O chassis.
8-6 Communicating with Extended-Local I/O The time in ms that it takes to scan extended-local I/O chassis depends on the number of 1771-ALX adapter modules and the number of extended- local I/O racks. The formula used to calculate the total time to scan extended-local I/O chassis is: extended-local I/O scan time = (0.32 ms x A)+(0.
Communicating with Extended-Local I/O 8-7 Calculating Block-Transfer Completion Time You can calculate two types of block-transfer timing: • worst-case calculation for the completion of all block-transfers in the system • the time to perform a block-transfer for any one block-transfer module in the system This formula assumes: block-transfer instructions are consecutively placed in the logic program block-transfer modules in the I/O chassis are ready to perform when operations are requested Calculating W
8-8 Communicating with Extended-Local I/O Example Calculations: Here is an example system that provides sample calculations of a worst case block-transfer completion time and the completion time of the modules in chassis 2.
Communicating with Extended-Local I/O 8-9 • If you are using block-transfer to a 2760-RB module located in the extended-local rack, make sure you do not set the timeout bit in the block-transfer control file. Configuring the Controller as an Extended-Local I/O Scanner To configure the extended-local I/O (channel 2), use the extended-local I/O configuration screen.
8-10 Communicating with Extended-Local I/O How Chassis Size and Backplane Addressing Determine the Quantity of I/O Racks If You are Using this Chassis Size And 2-Slot Addressing (Single Density) Or 1-Slot Addressing (Double Density) Or 1/2-Slot Addressing (Quad Density) 4-slot 1/4 logical rack 1/2 logical rack 1 logical rack 8-slot 1/2 logical rack 1 logical rack 2 logical racks 12-slot 3/4 logical rack 11/2 logical rack 3 logical racks 16-slot 1 logical rack 2 logical racks 4 logical r
Communicating with Extended-Local I/O For this Field A Scan List Contains Scan rack address 1-17 octal (PLC-5/40L controllers) 8-11 1-27 octal (PLC-5/60L controllers) Starting group number 0, 2, 4, or 6 Chassis size 4-slot, 8-slot, 12-slot, 16-slot Backplane addressing 1-slot, 2-slot, or 1/2-slot Range Automatically calculated based upon rack address, starting module group and chassis size. An asterisk (*) after a range indicates the last valid rack entry.
8-12 Communicating with Extended-Local I/O Use the following table for information about creating/modifying your scan list: To: Do the Following Create a scan list Make sure the controller is in Remote Program or Program mode. 1.Make sure that you defined an I/O status file on the controller configuration screen. 2.Accept any edits made to the channel configuration. 3.Use the autoconfiguration function If you have errors when you accept edits, clear the scan list and accept edits again.
Communicating with Extended-Local I/O 8-13 Status Field Location Description Channel retry word 0 Displays the number of times extended local I/O scanner tried and failed to communicate with all adapters on the channel. This value is the sum of all adapter retry counts. Retry word 10 word 20 word 30 etc. word 160 Displays the number of retries for the corresponding rack entry (word numbers are in multiples of 10). Entry 1 Entry 2 Entry 3 etc.
8-14 Communicating with Extended-Local I/O Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 9 Communicating with Devices on a DH+ Link Using This Chapter For Information About Go to Page Selecting devices that you can connect 9-1 Link design 9-2 Configuring the channel for DH+ communication 9-3 Selecting Devices That You Can Connect 1 Using the global status flag file 9-5 Monitoring DH+ communication channels 9-7 Estimating DH+ link performance 9-12 Application guidelines 9-17 You can use a DH+ link for data transfer to other PLC-5 controllers or higher level computers
9-2 Communicating with Devices on a DH+ Link Devices that You Can Connect Product Catalog Number Required Cables Application ControlLogix Data Highway Plus Remote I/O 1756-DHRIO Interface Module Allows communication between PLC-5 controllers over different networks, such as Data Highway Plus, ControlNet and Ethernet 1770-CD Data Highway or Data Highway Plus (RS-232C or RS-422-A) Interface Module 1770-KF2 Connects an asynchronous (RS-232C) device to a Data Highway or DH+ network 1770-CD Data Hi
Communicating with Devices on a DH+ Link IMPORTANT 9-3 If you select the baud rate as 230.4 kbps, and you are using the serial port or a PLC-5 coprocessor, use channel 2 for better overall system performance. For proper operation, terminate both ends of a DH+ link by using the external resistors shipped with the programmable controller. Selecting either a 150Ω or 82Ω terminator determines how many devices you can connect on a single DH+ link.
9-4 Communicating with Devices on a DH+ Link To configure a channel to support a DH+ link, use the DH+ configuration screen in your programming software. configure the channel for DH+ This Field Specifies Configure by Doing the Following Diagnostic file The file containing the channel’s status information Enter an integer file number (10-999). The system creates an integer file 40 words long. ATTENTION: Assign a unique diagnostic file to each channel.
Communicating with Devices on a DH+ Link This Field Specifies Global status flag file The file where you want to store token Cursor to the field, type an integer file number (10-999), and press pass data [Enter]. The system creates an integer file 64 words long. 9-5 Configure by Doing the Following ATTENTION: When you change the controller from run or test to program mode, the controller writes zeroes in the global status flags file. Any information previously in this file is lost.
9-6 Communicating with Devices on a DH+ Link This process lets each station automatically see the newly updated data. You can create ladder logic to monitor and interpret this data according to your application. The Global Status Flag data for each node address on your DH+ link is stored in the word address corresponding to the octal node address.
Communicating with Devices on a DH+ Link Monitoring DH+ Communication Channels 9-7 Use the DH+ status screen in your programming software to monitor channels that are configured to support a DH+ link. The data displayed is stored in the diagnostic file defined on the DH+ configuration screen in your programming software. Note that this screen does not display the active node table, which is also stored in the diagnostic file.
9-8 Communicating with Devices on a DH+ Link Monitoring Data Sent with Acknowledgment Status Field Word(s) Description Received 19 Number of error-free SDA messages that the station received. Received SAP off 23 Number of SDA messages that the station received but could not process because its service access point (SAP) was off. This counter should always be 0. Received but full 22 Number of SDA messages that the station could not receive because of lack of memory.
Communicating with Devices on a DH+ Link 9-9 Status Field Word(s) Description Transmit confirm 24 Number of SDA messages successfully sent to and acknowledged by the addressed station Transmit NAK full 30 Number of times the station received a NAK to a message because the destination station was full This indicates that messages are being sent to the receiving station faster than the PLC-5 controller can process them.
9-10 Communicating with Devices on a DH+ Link Monitoring Data Sent without Acknowledgment Status Field Word(s) Description Received 35 Number of valid SDN messages received Transmit failed 33 Number of SDN messages sent by the station that were in error This error should never be seen.
Communicating with Devices on a DH+ Link 9-11 Monitoring General Status Status Field Word(s) SDA or SDN transmit retry 28 Description Total number of SDA or SDN messages that were re-transmitted. Some reasons why the station would retry a message are: the ACK was lost or corrupted on an SDA message, indicating a possible noise problem the original message was NACKed Duplicate node 17 Number of times the station has detected the same station address as itself on the network.
9-12 Communicating with Devices on a DH+ Link Status Field Word(s) Description Linear scan failed 16 Number of times the station solicited every station number without getting a response. See started linear scan below for more information. Token retry 13 Number of times the station had to re-transmit a token pass. The station re-transmits a token pass if it detects that the station it passed the token to did not receive the token. Noise can cause this to occur.
Communicating with Devices on a DH+ Link 9-13 Nodes Nodes affect transmission time in the following ways: • During one complete token rotation, each node on the DH+ link receives the token whether or not it has something to send. • Each node spends from 1.5 ms (if it has no messages to send) to 38 ms (maximum time allotted) with the token, assuming there are no retries, as shown below. Min. 1.5 ms with the token Station 1 DH+ link Station 5 Station 2 Max.
9-14 Communicating with Devices on a DH+ Link The number of messages a station has to send also affects throughput time. For example, if a station has three messages queued and a fourth is enabled, the fourth message may have to wait until the previous three are processed. Message Destination Throughput times vary depending on whether a receiving station can process the message and generate a reply before it receives the token. The figure below assumes that station 1 wants to send a message to station 4.
Communicating with Devices on a DH+ Link 9-15 In the following figure, station 4 has had time to process the message and generate a reply. However, in , station 2 does not have sufficient time to process a MSG reply. 1. In this figure, we assume that station 1 wants to send the identical message as shown in Figure but to station 2. Station 1 has the token. Station 1 sends the message to station 2 and then passes the token on to station 2. 2.
9-16 Communicating with Devices on a DH+ Link Test Setup One to 22 PLC-5 controllers were used with one personal computer online. Each PLC-5 controller executes 1K of ladder logic. Initial testing was done with one PLC-5 controller writing data to another PLC-5 controller. The response time was recorded. Additional PLC-5 controllers were added to the network, each writing the same amount of data to a PLC-5 controller at the next highest station address.
Communicating with Devices on a DH+ Link 9-17 The following figure shows the effect of a personal computer on message response time under various configurations.
9-18 Communicating with Devices on a DH+ Link Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 10 Communicating with Devices on a Serial Link Using This Chapter For Information About: Go to Page: Choosing between RS-232C, RS-422A, and RS-423 10-1 Configuring the controller serial port 10-2 Using channel 0 10-2 Cabling 10-5 Configuring channel 0 10-6 Monitoring channel 0 status 10-22 If you are using PLC-5 controllers in Supervisory Control and Data Acquisition (SCADA) applications, see the SCADA System Selection Guide, publication AG-SG001.
10-2 Communicating with Devices on a Serial Link Configuring the Controller Serial Port Channel 0 is the serial port and is configurable for RS-232C, RS-423, or RS-422A compatible communication. Use switch assembly SW2 to specify the serial port configuration. To set the controller switch, see chapter 23 or look on the side label of the controller, which shows the switches in switch assembly SW2 and a table listing the settings.
Communicating with Devices on a Serial Link 10-3 In system mode, you can send data to a device using: • the message (MSG) instruction; or • ASCII write instructions (send as an ASCII string) All data is encapsulated inside a DF1 protocol packet; therefore, the controller can communicate only with peripheral devices that support the DF1 protocol.
10-4 Communicating with Devices on a Serial Link Master Station to Remote Station Communication Methods A PLC-5 master station can communicate with remote stations in two ways: Method Option Name Principal Benefits initiating polling packets to remote stations standard according to their position on a polling list communication mode This is the communication mode used most often in point-to-multipoint configurations. Polling packets are formed independently of any user-programming.
Communicating with Devices on a Serial Link 10-5 Polling Inactive Priority Stations Through the channel configuration feature of your programming software, you can choose to poll one or all of the inactive priority stations when the PLC-5 controller is in master mode on channel 0. The default selection is to poll one inactive priority station during each polling sequence.
10-6 Communicating with Devices on a Serial Link Configuring Channel 0 Use switch assembly SW2 controllers to specify RS232-C, RS422A (compatible), or RS423 communications for channel 0.
Communicating with Devices on a Serial Link This Field Specifies Configure by Doing the Following Diagnostic file The file containing the channel’s status information Enter an integer file number (10-999). 10-7 ATTENTION: Assign a unique diagnostic file to each channel. Do not assign a diagnostic file that is the I/O status file you assigned or any other used integer file. Unpredictable machine operation can result.
10-8 Communicating with Devices on a Serial Link This Field Specifies Configure by Doing the Following Stop bits Match the number of stop bits to the device with which you are communicating Select 1, 1.5, or 2. Control line Select the mode in which the driver operates. Select a method appropriate for your system’s configuration: If you are not using a modem, choose NO HANDSHAKING. If you are using a full-duplex modem, choose FULL-DUPLEX.
Communicating with Devices on a Serial Link 10-9 Configure Channel 0 as a Slave Station To configure channel 0 for DF1 slave communication, use the system mode configuration screen in your programming software. configure the serial communications as system slave specify the details This Field Specifies: Configure by Doing the Following Diagnostic file The file containing the channel’s status information Enter an integer file number (10-999).
10-10 Communicating with Devices on a Serial Link This Field Specifies: Configure by Doing the Following User mode char. The character for the mode attention character (above) Enter a character. If the attention character you want to use is a control character, specify the ASCII equivalent. When the controller encounters the attention character and the user mode character, the controller sets channel 0 communication to user mode. The remote mode change option must be ENABLED.
Communicating with Devices on a Serial Link 10-11 This Field Specifies: Configure by Doing the Following RTS send delay The amount of time that elapses between the assertion of the RTS signal and the beginning of the message transmission Enter a value 0-255. Limits are defined in 20 ms intervals. For example to wait 40 ms, type 2. The recommended time elapse is 0, unless you are using a modem that automatically returns the CTS as soon as it receives the RTS.
10-12 Communicating with Devices on a Serial Link Configure Channel 0 as a Master Station To configure channel 0 for DF1 master communication, use the system mode configuration screen in your programming software. configure the serial communications as system master specify the details This field Specifies Configure by Doing the Following Diagnostic file The file containing the channel’s status information Enter an integer file number (10-999).
Communicating with Devices on a Serial Link 10-13 This field Specifies Configure by Doing the Following User mode char. The character for the mode attention character (above) Enter a valid attention character. If the attention character you want to use is a control character, specify the ASCII equivalent. When the controller encounters the attention character and the user mode character, the controller sets channel 0 communication to user mode. Note that the remote mode change option must be ENABLED.
10-14 Communicating with Devices on a Serial Link This field Specifies Configure by Doing the Following RTS off-delay The time delay between the time the Enter a value 0-255. Limits are defined in 20 ms intervals. For example end of the message transmission and to wait 40 ms, type 2. The recommended time elapse is 0, unless you are the RTS is de-asserted using a modem that automatically returns the CTS as soon as it receives the RTS.
Communicating with Devices on a Serial Link 10-15 This Field Specifies Configure by Doing the Following Master message transmit The current value of channel 0 master If you want the master station to: message transmit send all of the master station-initiated MSG instructions to the remote stations before polling the next remote station in the poll list, choose Between Station Polls This method makes certain that master station-initiated messages are sent in a timely and regular manner (after every rem
10-16 Communicating with Devices on a Serial Link To define a polling scheme using standard mode, you must specify the following on the DF1 master configuration screen in your programming software: Configuration Parameter Definition Polling mode How you want the master to poll the station lists. Master message transmit When you want the master to send messages. Normal poll file An integer file in which you place the station addresses of the remote stations. The default size is 64 words.
Communicating with Devices on a Serial Link 10-17 To create station lists, place each station address in an individual word in a poll file (normal and/or priority) starting at word 2.
10-18 Communicating with Devices on a Serial Link Configure Channel 0 for User Mode (ASCII Protocol) To configure channel 0 for user mode, use the user mode configuration screen in your programming software. configure the serial communications as user (ASCII) specify the details This Field Specifies Configure by Doing the Following Diagnostic file The file containing the channel’s status information Enter an integer file number (10-999). ATTENTION: Assign a unique diagnostic file to each channel.
Communicating with Devices on a Serial Link 10-19 This Field Specifies Configure by Doing the Following User mode char. The character for the mode attention character (above) Enter a valid attention character. If the attention character you want to use is a control character, specify the ASCII equivalent. When the controller encounters the attention character and the user mode character, the controller sets channel 0 communication to user mode. The remote mode change option must be ENABLED.
10-20 Communicating with Devices on a Serial Link This Field Specifies Configure by Doing the Following Delete mode Select how the controller responds to Select Ignore, CRT, or Printer. If you select Ignore, the controller ignores a delete character. the delete character. If you select CRT or Printer, the controller ignores the character it received immediately before the delete character. The controller then sends a signal to the CRT or printer to erase the deleted character.
Communicating with Devices on a Serial Link 10-21 Configure Channel 0 for a Communication Mode Change You can configure channel 0 so that it switches from one communication mode to another upon receiving a control command. You define a mode attention character and either a system or user mode character.
10-22 Communicating with Devices on a Serial Link Monitoring Channel 0 Status The channel 0 status screens display the information stored in the diagnostic file you specified when you configured channel 0.
Communicating with Devices on a Serial Link 10-23 System Mode (DF1 Master) Status Screen Descriptions of System Mode Status Screen Fields Status Field Word Bit Description DCD recover 11 Displays the number of times the controller detects the DCD-handshaking line has gone low to high. Messages sent 1 Displays the total number of DF1 messages sent by the controller (included message retry). Messages received 2 Displays the number of messages the controller received with no error.
10-24 Communicating with Devices on a Serial Link Status Field Word Bit Description DTR 0: 4 Displays the status of the DTR handshaking line (asserted by the controller) DSR 0: 2 Displays the status of the DSR handshaking line (received by the controller) RTS 0: 1 Displays the status of the RTS handshaking line (asserted by the controller) CTS 0: 0 Displays the status of the CTS handshaking line (received by the controller) DCD 0: 3 Displays the status of the DCD handshaking line (receive
Chapter 11 Communicating with Devices on an Ethernet Network Using This Chapter Media and Cabling For Information About Go to Page Media and cabling 11-1 Assigning your IP address 11-2 Network addressing 11-2 Configuring channel 2 for Ethernet communication 11-2 Using advanced Ethernet functions 11-9 Using domain name service 11-15 Using the embedded web server 11-16 Using multihop messaging 11-29 Communicating with ControlLogix devices 11-32 Interpreting error codes 11-33 Interpr
11-2 Communicating with Devices on an Ethernet Network Assigning Your IP Address Contact your network administrator or the Network Information Center for a unique IP address to assign to your PLC-5/20E, -5/40E, or 5/80E controller. Network Addressing Because the Ethernet PLC-5 controller uses the TCP/IP protocol, each controller on the network requires a unique IP address. The IP address is software-configurable using either the BOOTP protocol or your programming software.
Communicating with Devices on an Ethernet Network 11-3 You can manually configure channel 2 for Ethernet communication using your programming software over a DH+ or serial link Enter the IP address and toggle the BOOTP enable field to No. Enter further configuration information in the appropriate fields. See the following table on the next page. IMPORTANT BOOTP enabled is the factory default.
11-4 Communicating with Devices on an Ethernet Network Ethernet Channel 2 Configuration Fields This Field Specifies Configure by Doing the Following Diagnostic file The file containing the channel’s status information. Enter an integer file number (10-999). The system creates an integer file 44 words long. ATTENTION: Assign a unique diagnostic file to each channel. Do not assign a diagnostic file that is the I/O status file you assigned or any other used file. Unpredictable machine action can result.
Communicating with Devices on an Ethernet Network This Field Specifies Configure by Doing the Following The broadcast address to which the controller should respond. See page 11-9 for information about advanced network functions, including the use of broadcast addressing. 11-5 Advanced Functions Broadcast Address This function does not allow for sending one message simultaneously to multiple PLC-5E controllers. Subnet Mask The controller’s subnet mask.
11-6 Communicating with Devices on an Ethernet Network To enable BOOTP, use the Ethernet channel 2 configuration screen in your programming software. Specify YES for BOOTP Enable. IMPORTANT If you change this field from NO to YES, the change does not take effect until you cycle power. Specify further configuration information using this screen.
Communicating with Devices on an Ethernet Network IMPORTANT 11-7 If BOOTP is disabled, or no BOOTP server exists on the network, you must use PLC-5 programming software to enter/change the IP address for each controller. Editing the BOOTPTAB Configuration File IMPORTANT Be sure you know the Ethernet hardware address of the module. You will enter it in this file.
11-8 Communicating with Devices on an Ethernet Network C. Replace xxyy with the last four digits of the hardware address. Use only valid hexadecimal digits (0-9, A-F); do not use the hyphens that separate the numbers. (You will find the hardware address on a label affixed to the printed circuit board of the Ethernet PLC-5 controller.) 3. Save, close, and make a backup copy of this file. EXAMPLE In this example there are three Ethernet PLC-5 controllers and an HP 9000 personal computer.
Communicating with Devices on an Ethernet Network Using Advanced Ethernet Functions 11-9 Configure the following advanced communication characteristics using the Ethernet channel 2 configuration screen: • broadcast address • subnet mask • gateway address If You are Using See Page Broadcast addressing 11-9 Subnet masks and gateways 11-11 IMPORTANT If BOOTP is enabled, you can’t change any of the advanced Ethernet communications characteristics.
11-10 Communicating with Devices on an Ethernet Network In most cases, you can leave the broadcast address at the default setting. Configure this Field By Doing the Following Broadcast Address Cursor to the field, and enter an address of the following form: a.b.c.dWhere: a, b, c, d are between 0-255 (decimal) If you change the default and need to reset it, type 0.0.0.0.
Communicating with Devices on an Ethernet Network 11-11 Using Subnet Masks and Gateways If your network is divided into subnetworks that use gateways or routers, you must indicate the following information when configuring channel 2: • subnet mask • gateway address A subnet mask is a filter that a node applies to IP addresses to determine if an address is on the local subnet or on another subnet.
11-12 Communicating with Devices on an Ethernet Network Manually Configuring Channel 2 for Controllers on Subnets If you are manually configuring channel 2 for a controller located on a subnet, see refer to the table below to configure the subnet mask and gateway address fields for each controller via your programming software. Ethernet Channel 2 Configuration Screen Advanced Functions This Field Specifies Configure by Doing the Following Subnet Mask The controller’s subnet mask.
Communicating with Devices on an Ethernet Network 11-13 Using BOOTP to Configure Channel 2 for Controllers on Subnets Configure the BOOTPTAB file according to the subnet mask and gateway address for each PLC-5E controller on the link. See the example below and the corresponding BOOTPTAB file on the next page. IMPORTANT Because BOOTP requests are seen only on the local subnet, each subnet needs its own BOOTP server and BOOTPTAB file.
11-14 Communicating with Devices on an Ethernet Network The BOOTPTAB files that correspond to this example looks like: # # # # # # # Legend: gw ha ht ip sm vm tc -------- gateways hardware address hardware type host IP address subnet mask BOOTP vendor extensions format template host #Default string for each type of Ethernet client defaults5E: ht=1:vm=rfc1048:sm=255.255.255.0 #Entries for Ethernet PLC-5 controllers: iota1:\ tc=defaults5E:\ gw=130.151.194.1:\ ha=0000BC1C1234:/ ip=130.151.194.
Communicating with Devices on an Ethernet Network Using Domain Name Service 11-15 DNS allows an Internet Protocol (IP) address in symbolic form to be converted into the equivalent numeric IP address. For the PLC-5 controller, this conversion is a service provided by a remote host on the network. With this release of Ethernet PLC-5 controllers and release 5.20 or greater of RSLogix programming software, you may enter the symbolic form of the IP address as the IP address in the Message Block.
11-16 Communicating with Devices on an Ethernet Network Using the Embedded Web Server To use the embedded web server: 1. Go online at your controller IP address (for example, www.cle.ab.com). The 1785-ENET Ethernet Programmable Controllers main page appears: 2. Click on the first item, Module Information. The Module Information page appears and displays specific controller information: 3. At the bottom of the Module Information page, click on TCP/IP Configuration.
Communicating with Devices on an Ethernet Network 11-17 The TCP/IP Configuration page appears and displays TCP/IP parameters: 4. At the bottom of the TCP/IP configuration page, click on Diagnostic Information. The Diagnostic Information page appears and displays two lists of statistics pages: The first list contains Network Stack Statistics. These pages present information about the TCP/IP stack. 5. For example, under Network Stack Statistics, click on the first entry General Ethernet Counters.
11-18 Communicating with Devices on an Ethernet Network This page displays general messaging statistics: Use the information on this page when troubleshooting the network.
Communicating with Devices on an Ethernet Network 11-19 Details of each counter on the General Ethernet Counters page are described in the following table.
11-20 Communicating with Devices on an Ethernet Network The second list contains Application Level Statistics.
Communicating with Devices on an Ethernet Network 11-21 Each file contains a hyperlink that takes you to the specific Data Table Monitor page for that file. 8. On the bottom of the Data Table Memory Map page, click on DT Monitor. The Data Table Monitor page appears and displays a table that shows the contents of the selected PLC-5 data table file: The available and default display formats depend on the data type of the file.
11-22 Communicating with Devices on an Ethernet Network Generating User Provided Web Pages You can use a text editor to generate up to 16 user provided web pages. The pages are stored in consecutive ASCII files of the PLC-5 controller. The channel configuration feature of RSLogix5 (release 5.
Communicating with Devices on an Ethernet Network 11-23 • you can reference other WWW servers and display images from other sources without affecting your usage of data table memory (except for the size of the HTTP reference) Referencing Data Table Memory - reference data table memory locations by placing custom tags into your HTML source which specify the data table location and optional formatting information.
11-24 Communicating with Devices on an Ethernet Network HTML Examples - the following examples shows an HTML code segment in bold with a short description of what you would see on a web browser: The input image word is I:0 is (this segment displays the value of the first word of the input image table in the default format of octal with bold type) The time values in T4:0 are (this segment will display the values of the timer in T4:0 in the default format of a table) I:0 is
Communicating with Devices on an Ethernet Network 11-25 Referencing Data Table Memory - the Data Table locations in the Custom Data Table Monitor are referenced by placing custom tags into the ASCII file of the controller. The format of the custom tag is: The items surrounded with {} are sometimes optional, whereas the items surrounded by [] are always optional. You must always specify the basic file reference.
11-26 Communicating with Devices on an Ethernet Network Fixed display formats - float files are always output in floating point format (“C”%g format). String files are always output as a null terminated text string. Binary files are always output as four binary nibbles. ASCII files are displayed in a memory dump format. Importing User Page Files to the PLC-5 Controller Use RSLogix5 to import user page files to the PLC-5 ASCII files: 1.
Communicating with Devices on an Ethernet Network 11-27 7. Click on the User Provided Pages link to view the User Provided Pages menu, as shown in the following example: 8. Click on the User Provided Page # to display that specific page. 9. Click on the link under the file heading to display an ASCII dump of the ASCII file.
11-28 Communicating with Devices on an Ethernet Network 10. Select the User Provided Page #4 to display the following screen: 11. Click on [+]A22 to display the following screen: You can change the radix display of N7:0 through N7:2: 1. Go back to the Custom Data Table Monitor page. 2. In the Address column, click on N:70 to display the radix selection page: 3. Click on a radio button to select the desired radix type.
Communicating with Devices on an Ethernet Network 11-29 To see the Sample Extended Format page: 1. Go back to the Custom Data Table Monitor page. 2. In the Address column, click on the + before the T4:0 to display the Sample Extended Format: This completes the Embedded Web Server enhancements and descriptions. Corrected anomalies and previous controller enhancements are described on the following pages.
11-30 Communicating with Devices on an Ethernet Network Keep in mind these considerations: • RSLogix programming software on ControlNet and DH+ links cannot see the controllers on an Ethernet link. • The RSLinx DDE server on a ControlNet link cannot poll data from the controllers on an Ethernet link. • The RSLinx DDE server on a ControlNet link cannot accept unsolicited data from controllers on an Ethernet link.
Communicating with Devices on an Ethernet Network Scenario 11-31 Multihop Path originating PLC-5 with Ethernet interface to ControlLogix controller in chassis 1 originating PLC-5 with Ethernet interface to PLC-5 (station 76) on DH+ link (link 12) Note: Both 1756-DHRIO modules need routing tables that show a path to both link 12 and the link ID that is configured for the Ethernet port of the originating PLC-5 controller.
11-32 Communicating with Devices on an Ethernet Network Comparing Multihop and Non-Multihop Messages Over Ethernet When an outbound connection's inactivity timer has expired and a MSG is pending on that connection, the MSG receives an error. On a multihop connection, the error is 0x18 (Broken Connection). On a non-multihop connection, the error is 0x16 (Connection Timeout). For non-multihop connections, the Connection Inactivity Timeout is user configurable.
Communicating with Devices on an Ethernet Network Interpreting Error Codes 11-33 When the controller detects an error during the transfer of message data, the controller sets the .
11-34 Communicating with Devices on an Ethernet Network Code - Hexadecimal Description (word 1 of the control block) (displayed on the data monitor screen) Interpreting Ethernet Status Data Publication 1785-UM012D-EN-P - July 2005 9000 Remote node cannot buffer command B000 Controller is downloading so it is inaccessible F001 Controller incorrectly converted the address F002 Incomplete address F003 Incorrect address F006 Addressed file does not exist in target controller F007 Destination f
Communicating with Devices on an Ethernet Network 11-35 Monitoring general Ethernet status Status Field Bytes Displays the Number of In Octets 28-31 Octets received on the channel Out Octets 32-35 Octets sent on the channel In Packets 36-39 Packets received on the channel, including broadcast packets Out Packets 40-43 Packets sent on the channel, including broadcast packets Excessive collisions 56-59 Frames for which a transmission fails due to excessive collisions Excessive deferrals
11-36 Communicating with Devices on an Ethernet Network Monitoring Ethernet commands Status Field Bytes Displays the Number of Sent 0-3 Commands sent by the channel Received 4-7 Commands received by the channel Monitoring Ethernet replies Status Field Bytes Displays the Number of Sent 8-11 Replies sent by the channel Received 12-15 Replies received by the channel Sent with error 16-19 Replies containing errors sent by the channel Received with error 20-23 Replies containing errors
Communicating with Devices on an Ethernet Network Ethernet PLC-5 Performance Considerations 11-37 Actual performance of an Ethernet PLC-5 controller varies according to: • • • • size of Ethernet messages frequency of Ethernet messages network loading the implementation of and performance of your controller application program The following charts show performance of the Ethernet PLC-5 controller, depending on packet size.
11-38 Communicating with Devices on an Ethernet Network Performance: Ethernet PLC-5 Controller to Ethernet PLC-5 Controller PLC-5 Controller Typed Write - Packet Size Publication 1785-UM012D-EN-P - July 2005
Chapter 12 Protecting Your Programs Using This Chapter For Information About Go to Page Passwords and privileges 12-2 Defining privilege classes 12-3 Assigning a privilege class to a channel or offline file 12-4 Assigning a privilege class to a node 12-4 Assigning read/write privileges to a program file 12-5 Assigning read/write privileges to a data file 12-5 Using protected controllers 12-6 Read this chapter for an overview of: • • • • • defining privilege classes assigning a privilege
12-2 Protecting Your Programs About Passwords and Privileges The passwords and privileges function supported by enhanced and Ethernet PLC-5 controllers helps you protect your programs by restricting access to controller files and functions. You can assign a privilege class to a node, channel or file. The privilege class defines the level of access (read or write) or type of function (I/O forcing, memory clearing) the PLC-5 controller allows.
Protecting Your Programs 12-3 • Node C has Class 3 access to channel 2A, based on the node privilege the controller has assigned it IMPORTANT If node privileges had not been assigned in this example, the node would have had the same privilege class as that assigned to its channel. Follow these guidelines when using the passwords and privileges: • You must define the passwords and privileges information for each controller in your system.
12-4 Protecting Your Programs For example, set your privilege classes as follows on the channel privileges screen of your programming software (an X indicates that the privilege is enabled): Privileges \ Privilege Class Names Modify Privileges Data Table File Create/Delete Program File Create/Delete Logical Write Physical Write Logical Read Physical Read Mode Change I/O Force SFC Force Clear Memory Restore On-line Editing Modify passwords Assigning a Privilege Class to a Channel or Offline File Class1 X
Protecting Your Programs Assigning Read/Write Privileges to a Program File 12-5 You can assign read and write privileges for each program file in a controller. These privileges limit the access of users to view or change your program files.
12-6 Protecting Your Programs Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 13 Programming Considerations Using This Chapter For Information About Go to Page Forcing 13-1 Extended forcing 13-2 Using special programming routines 13-10 Priority scheduling for interrupts and MCPs 13-11 Defining and programming interrupt routines 13-15 Forcing Forcing I/O lets you turn specific input and output bits on or off for testing purposes. Forcing bits on or off or forcing SFC transitions lets you simulate operation or control of a device.
13-2 Programming Considerations With the controller-resident local rack set for 1/2-slot addressing, you cannot force the input bits for the upper word of any slot that is empty or that has an 8-point or 16-point I/O module. For example, if you have an 8-point or a 16-point I/O module in the first slot of your local rack (words 0 and 1 of the I/O image table, 1/2-slot addressing), you cannot force the input bits for word 1 (I:001) on or off.
Programming Considerations 13-3 The 1771 read command type of the CIO instruction operates in the same manner as the BTR instruction; the 1771 write command type of the CIO instruction operates in the same manner as the BTW instruction. For simplicity, the following descriptions and examples of extended forcing refer to the BTR instruction (for BTR and 1771 read command type of CIO instructions) and the BTW instruction (for BTW and 1771 write command type of CIO instructions).
13-4 Programming Considerations For BTR instructions using non-configured data tables, the .DN bit indicates when data is valid in the BTR data file. When you configure files in the extended force configuration table, the .DN bit indicates that the data is in the BTR data buffer. The BTR data is not forced and moved into the BTR data file until the next housekeeping period. Delay using the BTR data until the scan after the .DN bit is set.
Programming Considerations 13-5 Using Protected Controllers If you are using a PLC-5 protected controller, you must configure forcing online since, by their design, protected controllers cannot download forcing operations. This protects controller operation from possible force operations programmed in offline mode. For more information about protected controllers, see the PLC-5 Protected Controller Supplement, publication 1785-6.5.13.
13-6 Programming Considerations Step 1 - Select Which Group of Data You Want to Force IMPORTANT Group the data in the extended force configuration table so that you separate read date from write data.
Programming Considerations 13-7 Step 2 - Use the Programming Software to Enter or Edit the Data You Want to Force in the Extended Force Configuration Table The extended force configuration table lets you specify as many as four groups of block-transfer data words to force. Each group can contain as many as 256 words of block-transfer data. When you plan your forcing, you can group together multiple block-transfer instructions until you reach the 256-word maximum for each group.
13-8 Programming Considerations Step 3 - Use the Programming Software to Enter Force Values for the Specified Data Table Files The block-transfer forcing screens include a function that lets you change the radix among binary, octal, HEX/BCD, and ASCII. If you select the binary radix, the display is similar to the I/O forcing display. The programming software displays forces differently, depending on the selected radix: Radix Force Screen Display binary no force . (period) off 0 on 1 no force .
Programming Considerations 13-9 To ensure that the received BTR data table file has been properly updated before you use the data, do the following: 1. Enable the input conditions of the BTR rung. 2. Wait for the BTR done bit to be set. 3. Allow time for housekeeping to force and send the changed data from the block-transfer data buffer to the block-transfer data table file. BTR.
13-10 Programming Considerations 4. Ensure that data does not change in the block-transfer data table output file until the BTW is complete.
Programming Considerations 13-11 Deciding When to Use Special Routines If a Portion of Logic Should Execute Immediately on detecting conditions that require a startup Immediately on detecting a major fault Example Use Restart the system after Power-Up Routine the system has been shut down Shut down plant floor Fault Routine devices safely upon detecting a major fault or At a specified time interval Send critical status to a supervisory controller via DH+ after detecting a major fault Monitor machine
13-12 Programming Considerations This scheduling determines what controls the program execution path. For example, if a PII is currently executing, it cannot be interrupted by an STI until the PII is completed (since the PII has scheduling priority over the STI). If an MCP is executing and a fault routine is called, however, the MCP’s execution will be interrupted because fault routines have priority over the MCPs.
Programming Considerations 13-13 Completed State Program has completed execution or has not yet started execution Ready State Program would be executing if it were of a higher priority; all programs pass through this state; there can be several programs in this state at any given time Waiting State Program is ready for execution but is waiting for some event to occur (such as an input to transition or a timer to complete) Rescheduling Operation Waiting State While block-transfer to remote rack occurs,
13-14 Programming Considerations Influencing Priority Scheduling Use the UID (user interrupt disable) and UIE (user interrupt enable) instructions to influence user program scheduling. They can be used to protect important portions of ladder logic that must be executed through to completion. The UID/UIE instructions are designed to be used in pairs.
Programming Considerations Defining and Programming Interrupt Routines 13-15 For information about configuring and programming these routines, see the appropriate chapter: For Information About See Chapter Power-up routines 14 Fault routines 15 Main control programs (MCPs) 16 Selectable timed interrupts (STIs) 17 Controller input interrupts (PIIs) 18 Publication 1785-UM012D-EN-P - July 2005
13-16 Programming Considerations Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 14 Preparing Power-Up Routines Using This Chapter Setting Power-Up Protection For Information About: Go to Page Setting power-up protection 14-1 Allowing or inhibiting startup 14-2 Defining controller power-up procedure 14-2 You can configure your controller so that if a power-loss is experienced while in run mode, the controller does not come back up in run mode. User control bit S:26/1 defines whether power-up protection (e.g., fault routine) is executed upon power-up.
14-2 Preparing Power-Up Routines Allowing or Inhibiting Startup Major fault bit S:11/5 controls whether you can power up the controller in run mode after a loss of power. Do not confuse this bit with user control bit S:26/1. This Bit Tells the Controller user control S:26/1 whether or not to scan a fault routine upon power up before returning to normal program scan. major fault S:11/5 whether or not to fault at the end of scanning the fault routine.
Preparing Power-Up Routines 14-3 To set and reset bits: 1. Cursor to the bit location. 2. Set by entering 1; reset the bit by entering 0. Use this Bit To 0 Control controllers that are using SFCs This bit determines if the SFC restarts or resumes at the last active step after a power loss. 1 Select power-loss protection If this bit is set and a power loss occurs, the controller sets major fault bit 5 and executes a fault routine you define before it returns to normal program scan.
14-4 Preparing Power-Up Routines Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 15 Preparing Fault Routines Using This Chapter For Information About Understanding the Fault Routine Concept See Page Understanding the fault routine concept 15-1 Understanding controller-detected major faults 15-2 Defining a fault routine 15-4 Defining a watchdog timer 15-5 Programming a fault routine 15-6 Monitoring faults 15-11 Fault routines execute when a PLC-5 controller encounters a major fault during program execution.
15-2 Preparing Fault Routines • returns to the current ladder program file if the controller can recover from the fault • enters fault mode if the controller cannot recover from the fault For example, this rung includes an instruction that causes a major fault: B A C Causes a major fault [ [ In this example, the processor runs the fault routine after detecting the fault.
Preparing Fault Routines 15-3 To decide how to set this switch, evaluate how the machines in your process will be affected by a fault. For example: • how will the machine react to outputs remaining in their last state or to outputs being automatically de-energized? • what is each output connected to? • will machine motion continue? • could this cause the control of your process to become unstable? To set this switch, see Appendix E.
15-4 Preparing Fault Routines The outputs in the faulted rack remain in their last state or they are de-energized, based on how you set the last state switch in the I/O chassis. ATTENTION If outputs are controlled by inputs in a different rack and a remote I/O rack fault occurs (in the inputs rack), the inputs are left in their last non-faulted state. The outputs may not be properly controlled and potential injury to personnel and damage to the machine may result. Be sure you have recovery methods.
Preparing Fault Routines 15-5 To define a controller fault routine: For more information about fault codes, see the documentation for your programming software. Defining a Watchdog Timer The watchdog timer (S:28) monitors the program scan. If the scan takes longer than the watchdog timer value, a fault routine is initiated and executed. The timer is the maximum time (in ms) for the watchdog; or if you use an SFC, it is the maximum time for a single pass through all the active steps.
15-6 Preparing Fault Routines Avoiding Multiple Watchdog Faults If you encounter a memory loss fault or watchdog major fault, it may be because multiple watchdog faults occurred while the controller was busy servicing a ladder-related major fault. The memory loss fault occurs when the fault queue, which stores a maximum of six faults, becomes full and cannot store the next fault.
Preparing Fault Routines 15-7 Setting an Alarm If you need an alarm to signal the occurrence of a major fault, put this rung first in your fault routine program: alarm output and combine it with a counter. You can also set an alarm in your fault routine to signal when the fault routine clears a major fault. Clearing a Major Fault You can clear a major fault with one of these methods: • Turn the keyswitch on the PLC-5 controller from REM to PROG to RUN.
15-8 Preparing Fault Routines 6. If the controller finds a match, the FSC instruction sets the found (.FD) bit in the specified control structure. 7. Use a MOV instruction to clear the fault in S:11. In the following figure, #N10:0 is the reference file.
Preparing Fault Routines 15-9 Follow these guidelines when creating fault routines: • Store initial conditions and reset other data to achieve an orderly start-up later. • Monitor the shutdown of critical outputs. Use looping if needed to extend the single fault routine scan time up to the limit of the controller watchdog timer so your program can confirm that critical events took place.
15-10 Preparing Fault Routines Using Ladder Logic to Recover from a Fault If you have the appropriate fault routine and ladder logic to perform an orderly shutdown of the system, you may want to configure an I/O rack fault as a minor fault. You can program ladder logic in several ways to recover from an I/O rack fault. Ways to Recover from a Rack Fault Method Description User-generated major fault The program jumps to a fault routine when a remote I/O rack fault occurs.
Preparing Fault Routines 15-11 Block-Transfers in Fault Routines If the controller runs a fault routine that contains block-transfer instructions, the controller performs these block-transfers immediately upon completing any block-transfers currently in the active buffer, ahead of block-transfer requests waiting in the queue. The block-transfers in a fault routine should be between the controller and local I/O only.
15-12 Preparing Fault Routines Monitoring Major/Minor Faults and Fault Codes When a fault occurs, the controller status screen in your programming software displays program file and rung number indicators that point to where the fault occurred. Interpreting Major Faults Displaying a Description of the Major Faults • The status text that appears corresponds to the most significant fault when the cursor is not on the major fault status word.
Preparing Fault Routines 15-13 For a description of the minor faults in word 1 (S:10) and word 2 (S:17), see Appendix B. Monitoring Status Bits Two types of status bits display information about your system: global status bits and multiple chassis status bits. Each bit represents an entire rack, no matter how many chassis make up a rack. (Remember that you can have a maximum of four chassis configured as quarter racks to make up one I/O rack.
15-14 Preparing Fault Routines Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 16 Using Main Control Programs Using This Chapter For Information About Selecting Main Control Programs Go to Page Selecting main control programs 16-1 Understanding how the controller interprets MCPs 16-2 Configuring MCPs 16-3 Monitoring MCPs 16-5 You can have as many as 16 control programs active at one time. Each of these programs is called a “main control program” (MCP). You can define one MCP for each particular machine or function of your process.
16-2 Using Main Control Programs Understanding How the Controller Interprets MCPs The MCPs are scheduled to execute in the order in which you specify on the Crocessor Configuration screen. You can configure: • an I/O image update and housekeeping after each MCP is completed (default parameter), or • the controller to skip the I/O scan and run the next MCP After the last MCP is completed, all MCPs are then repeated in the same order. Note that the watchdog setpoint covers one scan of all MCPs.
Using Main Control Programs 16-3 If the MCP is a The Following Occurs: Ladder-logic program 1.All rungs are executed—from the first rung to the last, with all timers, counters, jumps, and subroutines active. 2.After the END instruction in the ladder program, the controller initiates an I/O update—reading local inputs, writing local outputs, reading remote buffers, and writing remote outputs to the buffer. 3.The controller starts the next MCP. Structured-text program 1.Code is executed normally. 2.
16-4 Using Main Control Programs In this Field Do the Following Status File Program file Specify the program file numbers for MCPs A-P and the order in which the S:80-S:127 MCPs should be run. This configuration is read before the MCP is executed; if you make a change to the configuration screen regarding an MCP, that change takes effect on the next execution of the MCP. You can change the MCP information on the Controller Configuration screen or through ladder logic.
Using Main Control Programs IMPORTANT Monitoring MCPs 16-5 If you plan to use SFC subcharts, make sure you define something for MCP A - even an empty ladder file is sufficient. If a MCP is undefined, the controller faults on the second SFC scan with major fault code 71 SFC subchart is already executing. The program scan times for each MCP are stored in the controller status file, including the previous and maximum scan time.
16-6 Using Main Control Programs Notes Publication 1785-UM012D-EN-P - July 2005
Chapter 17 Using Selectable Timed Interrupts Using This Chapter For Information About Using a Selectable Timed Interrupt Go to Page Using a selectable timed interrupt 17-1 Defining a selectable timed interrupt 17-3 Monitoring selectable timed interrupts 17-4 A selectable timed interrupt (STI) tells the controller to periodically interrupt program execution (due to elapsed time) to run an STI program once to completion.
17-2 Using Selectable Timed Interrupts Online editing affects the performance of an STI routine. The STI cannot interrupt the controller while it is managing its memory due to the online edits being made. The STI input must be on for an amount of time slightly greater than the actual time required to complete the online edits. If not, the STI does not execute. STI Application Example Periodically check the status of PLC-5 family controllers on the DH+ communication link.
Using Selectable Timed Interrupts 17-3 The block-transfers in an STI should only be between the controller and local I/O. Remote block-transfer instructions in an STI cause the controller to resume executing the user program while waiting for the block-transfer to complete. If you want the STI to run to completion before returning to your main logic program, include an UID and UIE instruction pair in your STI program file. Place the block-transfer instruction inside of a UID/UIE pair.
17-4 Using Selectable Timed Interrupts For example, you could enter a 7 in S:31 and a 15 in S:30. This causes the controller to execute ladder file 7 every 15 ms. You can use only one STI at any one time. However, you can enable or disable the interrupt, change to a different interrupt file, or change the time between interrupts. Use ladder logic to change the values in word S:30 and word S:31 as needed.
Chapter 18 Using Processor Input Interrupts Using This Chapter For Information About Using a Processor Input Interrupt Go to Page Using a processor input interrupt 18-1 Defining a processor input interrupt 18-5 Monitoring processor input interrupts 18-5 A processor input interrupt (PII) specifies when an event-driven input causes the controller to interrupt program execution and run a PII program file once to completion.
18-2 Using Processor Input Interrupts Writing PII Ladder Logic Follow these rules when you write ladder logic for a PII. • Store the PII program in a ladder file. • Make sure the input condition (to cause the interrupt) doesn’t occur faster than the execution time of the PII program. If a second identical input condition occurs before the interrupt program has finished executing for the first input condition, a PII overlap occurs and the controller sets a minor fault bit at S:10/12.
Using Processor Input Interrupts 18-3 As shown in the following figure, the PII program must: • count 100 tablets per group • set an output at the 100th tablet • reset the counter for the next group C4:0.CU U CTU COUNT UP Counter Preset Accum CU C4:0 100 DN Output C4:0 DN C4:0 RES Output CLR CLEAR Destination S:51 The output image bit remains set until the next count.
18-4 Using Processor Input Interrupts IMPORTANT When the controller runs an PII with a block-transfer instruction to a remote chassis, the MCP resumes processing while waiting for the block-transfer to complete unless a UIE/UID instruction pair is used. PII configuration changes are not put into effect until the controller goes from program to run or test mode. Design Considerations Consider the following guidelines when planning PIIs. • Do not use 2-slot addressing when using PIIs.
Using Processor Input Interrupts Defining a Controller Input Interrupt 18-5 To define a PII, use the controller configuration screen in your programming software. In this PII Configuration Field Preset Status File Address Do the Following Enter a preset value to determine how many conditions you want to occur before the interrupt. Valid range is 0 - 32,767. S:50 If you want the interrupt to occur every time, enter a 0 or 1.
18-6 Using Processor Input Interrupts Monitoring Controller Input Interrupts Use the controller status screen in your programming software to monitor PIIs. Status File Address This PII Field Stores Events since last interrupt Displays the number of PII events (the input conditions that caused the interrupt) since the last interrupt. S:52 PII changed bits Displays the bit transitions that caused the interrupt. You can use this information to condition other rungs in your ladder program.
Appendix A System Specifications Controller Specifications For all controller-related specifications, please refer to the related installation instructions: • Enhanced PLC-5 Controllers Installation Instructions, publication 1785-IN062 • Ethernet PLC-5 Programmable Controllers Installation Instructions, publication 1785-IN063 To get this documentation, you can either: • view or download an electronic version from the internet at www.rockwellautomation.
A-2 System Specifications Memory and Channel Specifications Controller/ Cat. No.
System Specifications Controller/ Cat. No.
A-4 System Specifications Battery Specifications Enhanced and Ethernet PLC-5 programmable controllers use 1770-XYC batteries that contain 0.65 grams of lithium. Battery Life Estimates In these Controllers At this Temperature Power Off 100% Power Off 50% Battery Duration Aafter the LED Lights1 PLC-5/11B, -5/20B and -5/20E 60°C 256 days 1.4 years 11.5 days 25°C 2 years 4 years 47 days 60°C 84 days 150 days 5 days 25°C 1 year 1.
System Specifications Area Description ControlNet PLC-5 controllers EEPROM memory cannot be loaded to a non-ControlNet PLC-5 controller if the EEPROM was saved on a ControlNet PLC-5 controller. A-5 EEPROM memory cannot be loaded to a ControlNet PLC-5 controller if the EEPROM was burned on a non-ControlNet PLC-5 controller.
A-6 System Specifications Notes Publication 1785-UM012D-EN-P - July 2005
Appendix B Processor Status File Processor status data is stored in data file 2. For more information about any of these topics, see the description in this manual or the documentation for your programming software.
B-2 Processor Status File This Word Stores S:2Switch setting information S:2/00 through S:2/05 Channel 1A DH+ station number S:2/06 Channel 1A DH+ baud rate 057.6 kbps 1230.
Processor Status File B-3 S:3-10 This Word Stores S:3 to S:6 Active Node table for channel 1A WordBitsDH+ Station # 30-1500-17 40-1520-37 50-1540-57 60-1560-77 S:7 Global status bits: (See also S:27, S:32, S:33, S:34, and S:35) • S:7/0-7 • S:7/8-15 rack fault bits for racks 0-7 unused S:8 Last program scan (in ms) S:9 Maximum program scan (in ms) S:10Minor fault (word 1) See also S:17 S:10/00 Battery is low (replace in 1-2 days) S:10/01 DH+ active node table has changed S:10/02 STI delay t
B-4 Processor Status File S:11 This Word Stores S:11major fault word Publication 1785-UM012D-EN-P - July 2005 S:11/00 Corrupted program file (codes 10-19). See major fault codes (S:12). S:11/01 Corrupted address in ladder program (codes 20-29). See major fault codes (S:12). S:11/02 Programming error (codes 30-49). See major fault codes (S:12). S:11/03 Controller detected an SFC fault (codes (71-79). See major fault codes (S:12).
Processor Status File B-5 This word stores the following fault codes: S:12 This Fault Code Indicates this Fault And the Fault Is 00-09 Reserved for user-defined fault codes. Recoverable: You can use user-defined fault codes to identify different types of faults or error conditions in your program by generating your own recoverable fault.
B-6 Processor Status File This Fault Code Indicates this Fault And the Fault Is 30 You tried to jump to one too many nested subroutine files Non-recoverable 31 You did not enter enough subroutine parameters 32 You jumped to an invalid (non-ladder) file The fault routine will be executed but cannot clear major fault bit 2.
Processor Status File This Fault Code Indicates this Fault And the Fault Is 70 The controller detected duplicate labels Non-recoverable 71 The controller tried to start an SFC subchart that is already running 72 The controller tried to stop an SFC subchart that isn’t running 73 The controller tried to start more than the allowed number of subcharts 74 SFC file error detected 75 The SFC has too many active functions 76 SFC step loops back to itself.
B-8 This Fault Code Processor Status File Indicates this Fault And the Fault Is 90 Sidecar module extensive memory test failed.
Processor Status File B-9 S:13-S:24 This Word: Stores S:13 Program file where fault occurred S:14 Rung number where fault occurred S:15 VME status file S:16 I/O status File S:17Minor fault (word 2) See also S:10.
B-10 Processor Status File S:26-S:35 This Word Stores S:26User control bits S:26/00 Restart/continuous SFC: when reset, controller restarts at first step in SFC. When set, controller continues with active step after power loss or change to RUN S:26/01 Start-up protection after power loss: when reset, no protection. When set, controller sets major fault bit S:11/5 when powering up in run mode. S:26/02 Define the address of the local rack: when reset, local rack address is 0.
Processor Status File IMPORTANT B-11 Setting inhibit bits in the processor status file (S:27, S:33, or S:35) does not update inhibit bits in the I/O status file.
B-12 Processor Status File This Word Stores S:68 Installed memory card type: 0 - No memory card installed 1 - 1785-ME16 2 - 1785-ME32 3 - 1785-ME64 4 - 1785-ME100 5 - 1785-CHBM 6 - 1785-RC 7-15 - Reserved When the 1785-RC module is installed, the eight least-significant bits indicate the memory card’s status: Bit 3 is set when the memory card is installed Bit 2 is set when contact is detected closed Bit 1 is set when the relay is driven open Bit 0 is set when 120V ac is present on the memory card When
Appendix C Maximizing System Performance Using This Chapter For Information About Go to Page Program scan C-1 Calculating throughput C-5 Input and output modules delay C-6 I/O backplane transfer C-6 Remote I/O scan time C-6 Controller time C-11 Example calculation C-12 Performance effects of online operations C-12 Inserting ladder rungs at the 56K-word limit C-13 Using program control instructions C-14 For information about the time that it takes the controller to execute a specific i
C-2 Maximizing System Performance Effects of False Logic versus True Logic on Logic Scan Time The rung below—which changes states from one program scan to the next— will change your scan time by about 400 µs. I:000 LN NATURAL LOG Source 00 Dest N7:0 5 F8:20 1.609438 If I:000/00 is Then the Rung is On True, and the controller calculates the natural log. A natural log instruction takes 409 µs to execute. Off False, and the controller scans the rung but does not execute it. It takes only 1.
Maximizing System Performance C-3 If you use subroutines, program scan times can vary by the scan time of entire logic files. Effects of Different Instructions on Logic Scan Time Some instructions have a much greater effect on logic scan time than others based on the time that it takes to execute each instruction. Program scan time is also affected by the construction of your ladder rungs. The size of the rung and the number of branches can cause the scan time to fluctuate greatly.
C-4 Maximizing System Performance Because the first program scan takes 28 ms, the STI actually occurs 12 ms into the second program scan (28 + 12 = 40, which is the time for the second STI to occur). This example points out that when the STI time period is different than the program scan time, the STI occurs in different places in the program scan. Also note that, due to fluctuations in program-scan times, multiple STIs may be executed during one scan and no STIs during other scans.
Maximizing System Performance C-5 Putting Block-Transfer Modules in Controller-Resident Chassis Because controller-resident racks cannot be updated until after active block-transfers are completed, putting block-transfer modules in the controller-resident chassis can affect housekeeping by a worst-case time of approximately 100 µs per one word of block-transfer data. Note that this estimate is based on a worst-case scenario. Typically, the effect, if any, on housekeeping will be minimal.
C-6 Maximizing System Performance All input and output modules have a “delay time,” which is the time that it takes the module to transfer information to/from the I/O backplane through the I/O module to/from the field device. Input and Output Modules Delay Depending on the type of modules you are using, these delay times vary; but, the times must be taken into account when calculating system throughput. Choose modules that perform the function that you need with the lowest possible delay times.
Maximizing System Performance C-7 These three factors affect the remote I/O scan time: • communication rate • number of rack entries • block-transfers Communication Rate The communication rate determines the time it takes for the scanner to communicate with each individual entry in its scan list. The following table lists the amount of time required to communicate to a device at each communication rate. Communication Rate (kbps): Time (ms): 57.6 10 115.2 7 230.
C-8 Maximizing System Performance Block-Transfers A block-transfer is an interruption of the normal remote I/O scan in order to transfer a block of data to a specific I/O module. Most of the time that the controller spends in performing the block-transfer is for the handshaking that occurs between the controller and the block-transfer module. This handshaking is embedded in the discrete I/O transfer and has no effect on the remote I/O scan.
Maximizing System Performance C-9 Calculating Worst-Case Remote I/O Scan Time Since it is impossible to predict within which remote I/O scan a block-transfer will occur, you only can calculate the worst-case remote I/O scan time. To calculate the worst case time: 1. Determine the normal I/O time (without block-transfers) 2. Add the time of the longest block-transfer to each entry in the scan list. (The controller can only perform one block-transfer per entry in the scan list per I/O scan.
C-10 Maximizing System Performance However, if rack 2 has the most time-critical I/O, use the configurable scan list to specify: rack 1 rack 2 rack 3 rack 2 rack 4 rack 2 Using this scan list, rack 2 is scanned every other rack. The list has 6 entries, so the normal I/O scan time is 6 x 10 ms = 60 ms. Since rack 2 is scanned every other rack, however, the rack 2 effective scan time is 2 x 10 ms = 20 ms. The remaining racks are scanned every 60 ms.
Maximizing System Performance C-11 To optimize your system layout for block-data transfers, use an arrangement similar to the following: System Optimized for Block-Data Transfer Adapter BT BT Adapter PLC Adapter With this arrangement, a block-transfer to each BT module can occur in a single discrete I/O scan.
C-12 Maximizing System Performance The worst-case controller time is: Variable Value periodic input buffer update from remote I/O buffer 10 ms one program scan to guarantee inputs received xx ms one program scan to guarantee outputs received xx ms 0.18 ms times number of racks xx ms total For a 3-rack system with a 20 ms program scan, the worst-case controller time is: 10 + 20 + 20 + (0.18 ∗ 3) = 50.54 ms.
Maximizing System Performance C-13 The amount of time that the messaging and block-transfers can be delayed is proportional to the size (K words) of the ladder file. The following table lists the performance effects (when using any of the 6200 Series PLC-5 Programming Software releases that support the controller you are using).
C-14 Maximizing System Performance Using Program Control Instructions Scan time can increase based on how you use JMP/LBL instructions and FOR/NXT instructions. Using JMP/LBL Instructions Keep in mind these issues when programming JMP/LBL instructions: Instruction Consideration JMP The execution time required for a JMP instruction depends on the program file that contains the JMP instruction. The estimated execution time for a JMP instruction is: 8.9 + (file_number − 2) ∗ 0.
Appendix D Instruction Set Quick Reference Using This Chapter If You Want to Read About Relay instructions D-2 Timer instructions D-3 Counter instructions D-4 Compare instructions D-5 Compute instructions D-7 Logical instructions D-14 Conversion instructions D-15 Bit modify and move instructions D-16 File instructions D-17 Diagnostic instructions D-19 Shift register instructions D-20 Sequencer instructions D-21 Program control instructions D-22 Process control and message instru
D-2 Instruction Set Quick Reference Relay Instructions Instruction Description Examine On XIC Examine data table bit I:012/07, which corresponds to terminal 7 of an input module in I/O rack 1, I/O group 2. If this data table bit is set (1), the instruction is true. Examine Off XIO Examine data table bit I:012/07, which corresponds to terminal 7 of an input module in I/O rack 1, I/O group 2. If this data table bit is reset (0), the instruction is true.
Instruction Set Quick Reference D-3 Timer Instructions Instruction TON TIMER ON DELAY Timer T4:1 1.0 Time Base Preset 15 Accum 0 Description Timer On Delay TON Status Bits: EN - Enable TT - Timer Timing DN - Done If the input conditions go true, timer T4:1 starts incrementing in 1-second intervals. When the accumulated value is greater than or equal to the preset value (15), the timer stops and sets the timer done bit.
D-4 Instruction Set Quick Reference Instruction Description RTO RETENTIVE TIMER ON Timer T4:10 1.0 Time Base Preset 10 Accum 0 Retentive Timer On RTO Status Bits: EN - Enable TT - Timer Timing DN - Done Timer Reset RES T4:1 ( RES ) If the input conditions go true, timer T4:10 starts incrementing i 1-second intervals as long as the rung remains true. When the rung goes false, the timer stops. If the rung goes true again, th timer continues.
Instruction Set Quick Reference Instruction Description Count Down CTD CTD COUNT DOWN Counter Preset Accum D-5 If the input conditions go true, counter C5:1 starts counting, decrementing by 1 every time the rung goes from false-to-true. When the accumulated value is less than the preset value (10), the counter resets the counter done bit.
D-6 Instruction Set Quick Reference Instruction Description Compare CMP CMP COMPARE Expression N7:5 = N7:10 xxx xxxxxxxxxxxxx Source A Source B Publication 1785-UM012D-EN-P - July 2005 If the expression is true, this input instruction is true. The CMP instruction can perform these operations: equal (=), less than (<), less than or equal (<=), greater than (>), greater than or equal (>=), not equal (<>), and complex expressions (up to 80 characters).
Instruction Set Quick Reference D-7 Compute Instructions Instruction Description Compute CPT CPT COMPUTE Dest N7:3 3 The CPT instruction can perform these operations: add (+), subtract (-), multiply (*), divide (|), convert from BCD (FRD), convert to BCD (TOD), square root (SQR), logical and (AND), logical or (OR), logical not (NOT), exclusive or (XOR), negate (-) clear (0), and move, X to the power of Y (**), radians (RAD), degrees (DEG), log (LOG), natural log (LN), sine (SIN), cosine (COS), tangent
D-8 Instruction Set Quick Reference Instruction Description Arc sine ASN ASN ARCSINE Source Dest F8:17 0.7853982 When input conditions go true, take the arc sine of the value in F8:17 and store the result in F8:18. Status Bit F8:18 0.9033391 C Description always resets V sets if overflow is generated; otherwise resets Z sets if the result is zero; otherwise resets always resets S ATN ARCTANGENT Source F8:21 0.
Instruction Set Quick Reference Instruction Description Clear CLR CLR CLR Dest D9:34 0000 Cosine COS COS COSINE Source Dest D-9 F8:13 0.7853982 When the input conditions are true, clear decimal file 9, word 3 (set to zero). Status Bit Description C always reset V always reset Z always set S always reset When input conditions go true, take the cosine of the value in F8:13 and store the result in F8:14. Status Bit F8:14 0.
D-10 Instruction Set Quick Reference Instruction Description Natural log LN LN NATURAL LOG Source Dest N7:0 5 When input conditions go true, take the natural log of the va in N7:0 and store the result in F8:20. Status Bit F8:20 1.
Instruction Set Quick Reference Instruction Description Negate NEG NEG NEGATE Source Dest N7:3 3 N7:12 -3 Dest When the input conditions are true, take the opposite sign of the Source (N7:3) and store the result in the Destination (N7:12). This instruction turns positive values into negative values and negative values into positive values.
D-12 Instruction Set Quick Reference Instruction Description Sort SRT SRT SORT File Control Length Position #N7:1 R6:0 4 0 STD STANDARD DEVIATION File #N7:1 Dest N7:0 Control R6:0 Length 4 Position 0 Publication 1785-UM012D-EN-P - July 2005 When the input conditions go from false-to-true, the values in N7:1, N7:2, N7:3.and N7:4 are sorted into ascending order.
Instruction Set Quick Reference Instruction Description Subtract SUB SUB SUBTRACT Source A Source B Dest N7:3 3 N7:4 1 N7:12 2 Dest When the input conditions are true, subtract the value in Sour B (N7:4) from the value in Source A (N7:3) and store the result the Destination (N7:12).
D-14 Instruction Set Quick Reference Logical Instructions Instruction Description AND AND BITWISE AND Source A Source B Dest D9:3 3F37 D9:4 00FF D9:5 0037 Source ASource BResult 000 100 010 111 NOT Operation NOT NOT Source A D9:3 00FF D9:5 FF00 Dest BITWISE INCLUSIVE OR Source A D9:3 3F37 Source B D9:4 00FF Dest D9:5 3FFF XOR BITWISE EXCLUSIVE OR D9:3 Source A 3F37 Source B D9:4 3F37 Dest D9:5 0000 Status Bit When the input conditions are true, the controller performs a NOT (takes the opposite
Instruction Set Quick Reference D-15 Conversion Instructions Instruction Description Convert from BCD FRD FRD FROM BCD Source Dest D9:3 0037 N7:12 37 Convert to BCD TOD TOD TO BCD Source Dest N7:3 44 D9:5 0044 DEG RADIANS TO DEGREE Source F8:7 0.7853982 Dest F8:8 45 Convert to Degrees DEG When the input conditions are true, convert the BCD value in the Source (D9:3) to a integer value and store the result in the Destination (N7:12).
D-16 Instruction Set Quick Reference Instruction Description RAD DEGREES TO RADIAN N7:9 Source Dest Convert to Radians RAD 45 F8:10 0.785398 When the input conditions are true, convert degrees (the value in Source A) to radians and stores the result in the Destination (Source times p/180).
Instruction Set Quick Reference Instruction D-17 Description BTD BIT FIELD DISTRIB Source N7:3 0 Source bit 3 Dest N7:4 0 Dest bit 10 Length 6 Bit Distribute BTD When the input conditions are true, the controller copies the number of bits specified by Length, starting with the Source bit (3) of the Source (N7:3), and placing the values in the Destination (N7:4), starting with the Destination bit (10).
D-18 Instruction Set Quick Reference Instruction Description File Copy COP COP COPY FILE Source Dest Length #N7:0 #N12:0 5 When the input conditions are true, the controller copies the contents of the Source file (N7) into the Destination file (N12). The source remains unchanged. The COP instruction copies the number of elements from the source as specified by the Length. As opposed to the MOV instruction, there is no data type conversion for this instruction.
Instruction Set Quick Reference D-19 Diagnostic Instructions Instruction FBC FILE BIT COMPARE Source #I:031 #B3:1 Reference Result #N7:0 Cmp Control R6:4 Length 48 Position 0 Result Control R6:5 Length 10 Position 0 DDT DIAGNOSTIC DETECT Source #I:030 Reference #B3:1 Result #N10:0 Cmp Control R6:0 Length 20 Position 0 Result Control R6:1 Length 5 Position 0 Description File Bit Compare FBC Status Bits: EN - Enable DN - Done Bit ER - Error Bit IN - Inhibit Bit FD - Found Bit When the input conditions go
D-20 Instruction Set Quick Reference Shift Register Instructions Instruction Description BSL BIT SHIFT LEFT File #B3:1 R6:53 Control Bit Address I:022/12 Length 5 BSR BIT SHIFT RIGHT File #B3:2 Control R6:54 Bit Address I:023/06 Length 3 N60:1 #N60:3 R6:51 64 0 Publication 1785-UM012D-EN-P - July 2005 Bit Shift Right BSR Status Bits: EN - Enable DN - Done Bit ER - Error Bit UL - Unload Bit Status Bits: EN - Enable Load DN - Done Bit EM - Empty Bit FIFO Unload FFU FFU FIFO UNLOAD FIFO Dest Control
Instruction Set Quick Reference Instruction Description LIFO Load LFL LFL LIFO LOAD Source LIFO Control Length Position N70:1 #N70:3 R6:61 64 0 Status Bits: EN - Enable Load DN - Done Bit EM - Empty Bit LIFO Unload LFU LFU LIFO UNLOAD LIFO Dest Control Length Position D-21 #N70:3 Status Bits: N70:2 EU - Enable R6:61 Unload 64 DN - Done Bit 0 EM - Empty Bit When the input conditions go from false-to-true, the controller loads N70:1 into the next available element in the LIFO file #N70:3, as pointed
D-22 Instruction Set Quick Reference Instruction Description Sequencer Output SQO SQO SEQUENCER OUTPUT File #N7:1 Mask 0F0F Dest O:014 Control R6:20 Length 4 Position 0 # Status Bits: EN - Enable DN - Done Bit ER - Error Bit When the rung goes from false-to-true, the SQO instruction increments to the next step in the sequencer File (#N7:1). The data in the sequencer file is transferred through a Mask (0F0F) to the Destination (O:014) for every scan that the rung remains true.
Instruction Set Quick Reference Instruction D-23 Description Jump to Subroutine JSR If the input conditions are true, the controller starts running a subroutine Program File (90). The controller passes the Input Parameters (N16:23, N16:24, 231) to the subroutine and the RET instruction passes Return Parameters (N19:11, N19:12) back to the main program, where the controller encountered the JSR instruction. Subroutine SBR The SBR instruction is the first instruction in a subroutine file.
D-24 Instruction Set Quick Reference Instruction SFR SFC Reset Prog File Number Restart Step At ( EOT ) Description SFC Reset SFR The SFR instruction resets the logic in a sequential function chart. When the SFR instruction goes true, the controller performs a lastscan/postscan on all active steps and actions in the selected file, and then resets the logic in the SFC on the next program scan. The chart remains in this reset state until the SFR instruction goes false.
Instruction Set Quick Reference D-25 Process Control, Message Instructions Instruction Description PID PID Control Block Proc Variable Tieback Control Output PD10:0 N15:13 N15:14 N20:21 Proportional, Integral, The control block (PD10:0) contains the instruction information and Derivative for the PID. The PID gets the process variable from N15:13 and PID sends the PID output to N20:21. The tieback stored in N15:14 handles the manual control station.
D-26 Instruction Set Quick Reference Instruction Description Block Transfer Read BTR BTR BLOCK TRANSFER READ Rack 1 Group 0 Module 0 Control Block BT11:100 Data File N10:110 Length 40 Continuous Y If the input conditions go from false to true, a block transfer read is initiated for the I/O module located at rack 1, group 0, module 0. The Control Block (BT11:100, 6-word file) contains status for the transfer. The Data File (N10:110) is where the data read from the module is stored.
Instruction Set Quick Reference D-27 ASCII Instructions Status Bits: EN - EnableEM - Empty Bit DN - Done BitEU - Queue ER - Error BitFD - Found Bit Instruction ABL ASCII TEST FOR LINE Channel 0 Control R6:32 Characters Description ASCII Test for Line ABL If input conditions go from false-to-true, the controller reports the number of characters in the buffer, up to and including the end-of-line characters and puts this value into the position word of the control structure (R6:32.POS).
D-28 Instruction Set Quick Reference Instruction AEX STRING EXTRACT Source ST38:40 Index 42 Number 10 Dest ST52:75 AIC INTEGER TO STRING CONVERSION Source 876 ST38:42 Dest AHL ASCII HANDSHAKE LINE Channel 0 AND Mask 0001 OR Mask 0003 Control R6:23 Channel Status Description ASCII String Extract AEX If input conditions are true, the controller extracts 10 characters starting at the 42nd character of ST38:40 and store the result in ST52:75.
Instruction Set Quick Reference Instruction ASC STRING SEARCH Source ST38:40 Index 35 Search ST52:80 Result 42 ASR ASCII STRING COMPARE Source A ST37:42 ST38:90 Source B AWA ASCII WRITE APPEND Channel 0 Source ST52:76 Control R6:32 String Length 50 Characters Sent AWT ASCII WRITE Channel 0 Source ST37:40 Control R6:23 String Length 40 Characters Sent D-29 Description ASCII String Search ASC If input conditions are true, search ST52:80 starting at the 35th character, for the string found in ST38:40.
D-30 Instruction Set Quick Reference Bit and Word Instructions Category Relay Code Title Execution Time (µs) Integer Execution Time Words of (µs) Memory (1) Floating Point True False True False XIC examine if closed .32 .16 1(2) XIO examine if open .32 .16 12 OTL output latch .48 .16 12 OTU output unlatch .48 .16 12 OTE output energize .48 .48 12 branch end .16 .16 1 Branch Timer and Counter TON TOF RTO next branch 1 branch start 1 timer on(0.01 base) 3.
Instruction Set Quick Reference Category Arithmetic Code Title Execution Time (µs) Floating Point True False True False Words of Memory (1) ADD add 6.1 1.4 14.9 1.4 4-7 SUB subtract 6.2 1.4 15.6 1.4 4-7 MUL multiply 9.9 1.4 18.2 1.4 4-7 DIV divides 12.2 1.4 23.4 1.4 4-7 SQR square root 9.9 1.3 35.6 1.3 3-5 NEG negate 4.8 1.3 6.0 1.3 3-5 CLR clear 3.4 1.1 3.9 1.1 2-3 AVE average file 152+E25.8 30 162+E22.
D-32 Instruction Set Quick Reference File, Program Control, and ASCII Instructions Category Code Title Time (µs) Integer Time (µs) Floating Point True False True Words of Memory(1) False File Arithmetic and Logic FAL all 11 + (S[2.3 + i])E 6.16 + Wi[0.16] 11 + (Σ[2.3 + i])E 6.16 + Wi[0.16] 3-5 +Wi File Search and Compare FSC all 11 + (S[2.3 + i])E 6.16 + Wi[0.16] 11 + (Σ[2.3 + i])E 6.16 + Wi[0.16] 3-5 +Wi File COP copy 16.2+E[0.72] 1.4 17.8+E[1.44] 1.
Instruction Set Quick Reference Category Sequencer Code Title Time (µs) Floating Point True False True Words of Memory(1) False SQI sequencer input 7.9 1.3 5-9 SQL sequencer load 7.9 3.5 4-7 SQO sequencer output 9.7 3.7 5-9 1.1 2 1.1 2 0.
D-34 Instruction Set Quick Reference Category Code Time (µs) Integer Time (µs) Floating Point False label 0.16 0.16 END end negligible TND temporary end 1 EOT end of transition 1 AFI always false 0.16 0.16 1 ONS one shot 3.0 3.0 2-3 OSR one shot rising 6.2 6.0 4-6 OSF one shot falling 6.2 5.8 4-6 FOR/ NXT for next loop 8.1+ L[15.9]+ (file# - 2) * 0.96 5.3 + N[0.75] FOR 5-9 NXT 2 BRK break 11.3 + N[0.75] 0.
Instruction Set Quick Reference Category Code Title Time (µs) Integer True Process Control PID False True Words of Memory(1) False PID loop control 5-9 Independent Gains Time (µs) Floating Point D-35 3.
D-36 Instruction Set Quick Reference Category Code Title Time (µs) Integer True ACB AEX (1) • 214 • 150 1.4 3-5 1.9 4-7 1.9 5-9 • 237 + C[2.6] • 179 + C[5.5] • 226 + C[1.1] • 159 + C[2.2] set or reset lines • PLC-5/11, -5/20, and -5/20E • PLC-5/30, -5/40, -5/40E, -5/40L -5/60, -5/60L, -5/80, and -5/80E 5-9 • 318 • 526 • 213 • 157 Use the larger number for addresses beyond 2048 words in the controller’s data table.
Instruction Set Quick Reference Category Code Title Time (µs) Integer True ASCII(2) AIC integer to string • PLC-5/11, -5/20, and -5/20E • PLC-5/30, -5/40, -5/40E, -5/40L -5/60, -5/60L, -5/80, and -5/80E ARD False 3-5 4-7 • 315 • 380 • 214 • 149 4-7 • 316 • 388 • 214 • 151 1.9 5-9 • 222 + C[1.7] • 151 + C[3.
D-38 Instruction Set Quick Reference Category Code Title Time (µs) Integer True ASCII(2) AWA False write with append • PLC-5/11, -5/20, and -5/20E • PLC-5/30, -5/40, -5/40E, -5/40L -5/60, -5/60L, -5/80, and -5/80E AWT Time (µs) Floating Point • 319 • 345 • 215 • 154 4-7 • 318 • 344 • 215 • 151 (1) Use the larger number for addresses beyond 2048 words in the controller’s data table. (2) Timing for ASCII instructions is the time for the instruction to queue-up for processing in channel 0.
Appendix E Switch Setting Reference Using This Chapter For this Switch Setting 1 Go to Page Enhanced and Ethernet PLC-5 switch 1 for defining the controller’s DH+ address E-2 Enhanced and Ethernet PLC-5 switch 2 for defining the controller’s serial port electrical interface E-3 I/O chassis containing a PLC-5 controller E-4 I/O chassis containing a 1771-ASB, remote I/O adapter module E-5 I/O chassis configuration plug for defining an external or slot power supply E-6 1771-ASB not using comple
E-2 Switch Setting Reference Controller Switches Switch 1 Side View of PLC-5/11, -5/20, -5/26, -5/20E controllers Switch Assembly SW1 Side View of PLC-5/30, -5/40, -5/46, -5/40L, -5/60, -5/60L, -5/80, -5/86, -5/40E, and -5/80E controllers Switch Assembly SW1 toggle pushed down on 1 2 3 4 5 6 7 1 2 3 4 5 6 7 toggle pushed up off To Select DH+ Baud Rate for Channel 1A: DH+ address DH+ baud rate Switch DH+ Station Number 1 2 3 4 5 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 2
Switch Setting Reference E-3 Switch 2 Bottom View of PLC-5/11, -5/20, -5/26, and -5/20E processors Switch Assembly SW2 Bottom View of PLC-5/30, -5/40, -5/46 -5/40L, -5/60, -5/60L, -5/80, -5/86, -5/40E, and -5/80E processors Switch Assembly SW2 Front of Processor Front of Processor Side View toggle pushed toward bottom on toggle pushed toward top off 1 2 3 4 5 6 7 8 9 10 12 3 4 5 6 7 8 9 10 To Specify: Set Switches: 1 2 3 4 5 6 7 8 9 10 RS-232C on on on off off on on off on off
E-4 Switch Setting Reference I/O Chassis Backplane PLC-5 Controller in the I/O Chassis Switch Last State 1 on Outputs of this I/O chassis remain in their last state when a hardware failure occurs. 1 off Outputs of this I/O chassis are turned off when a hardware failure occurs.
Switch Setting Reference E-5 1771-ASB Remote I/O Adapter or 1771-ALX Extended-Local I/O Adapter Switch Last State 1 Always Off on Outputs of this I/O chassis remain in their last state when a communication fault is detected by this I/O adapter. 1 off Outputs of this I/O chassis are turned off when a communication fault is detected by this I/O adapter. Switch Processor Restart Lockout 2 on Processor can restart the I/O chassis after a communication fault.
E-6 Switch Setting Reference ATTENTION If you set this switch to the ON position, when a communication fault is detected, outputs connected to this chassis remain in their last state to allow machine motion to continue. We recommend that you set switch 1 to the OFF position to de-energize outputs wired to this chassis when a fault is detected.
Switch Setting Reference E-7 Remote I/O Adapter Module (1771-ASB Series C and D) without Complementary I/O Pressed in at top ON (closed) Pressed in at bottom OFF (open) S W -1 O 1 N O F F 2 3 I/O Rack Number (see next page) 4 5 6 7 8 S W -2 O 1 N O F F 2 3 4 5 6 First I/O Group Number (see below) Link Response: ON*for series B emulation OFF*for unrestricted Switch Communication Rate 1 2 ON OFF 57.6 Kbps OFF OFF 115.2 Kbps OFF ON 230.
E-8 Switch Setting Reference (1771-ASB Series C and D) I/O Rack Number without Complementary I/O Rack Publication 1785-UM012D-EN-P - July 2005 1 2 3 4 5 6 01 on on on on on off 02 on on on on off on 03 on on on on off off 04 on on on off on on 05 on on on off on off 06 on on on off off on 07 on on on off off off 10 on on off on on on 11 on on off on on off 12 on on off on off on 13 on on off on off off 14 on on off of
Switch Setting Reference Extended-Local I/O Adapter Module E-9 (1771-ALX) Switch SW1 SW-1 1 2 3 4 5 6 7 8 SW-2 Not Used OPEN First I/O Group Number I/O Rack Number Rack: 1 2 3 4 5 6 01 on on on on on off 02 on on on on off on 03 on on on on off off 04 on on on off on on 05 on on on off on off 06 on on on off off on 07 on on on off off off 10 on on off on on on 11 on on off on on off 12 on on off on off on 13 on on off on
E-10 Switch Setting Reference (1771-ALX) Configuration Plug 1. Lay the module on its right side. The configuration plugs are visible on the lower rear of the module. 2. Set the configuration plug as shown below according to your application. Configuration Plug Do not place a jumper on this set of pins.
Appendix F Troubleshooting Using This Chapter For Information About Troubleshooting: 1 Go to Page: PLC-5 controller F-2 Remote I/O system F-6 Extended-local I/O system F-9 Unexpected PLC-5 controller operation when entering run mode F-10 Publication 1785-UM012D-EN-P - July 2005
F-2 Troubleshooting PLC-5 Controller BATT PROG R E M RUN General Problems Indicator Color Description Probable Cause Recommended Action PROC Green (steady) Controller is in run mode and fully operational Normal operation No action required Green (blinking) Controller memory is being transferred to EEPROM Normal operation No action required Red (blinking) Major fault • RSLogix 5 download in progress • Run-time error During RSLogix 5 download, this is normal operation - wait for download
Troubleshooting Indicator Color Description Probable Cause Recommended Action FORCE Amber (steady) SFC and/or I/O forces enabled Normal operation No action required Amber (blinking) SFC and/or I/O forces present but not enabled Off SFC and/or I/O forces not present Off No transmission on channel 0 Normal operation if channel is not being used Green (blinking) Transmission on channel 0 Normal operation if channel is being used COMM F-3 Publication 1785-UM012D-EN-P - July 2005
F-4 Troubleshooting Controller Communication Channel Troubleshooting Indicator Color Channel Mode A or B Remote I/O Scanner Active Remote I/O link, all adapter modules are present and not faulted Green (steady) Description Probable Cause Recommended Action Normal operation No action required Remote I/O Adapter Communicating with scanner DH+ Green (blinking rapidly or slowly) Remote I/O Scanner At least one adapter is faulted or has failed DH+ Red (steady) Controller is transmitting or receiving
Troubleshooting F-5 Extended-Local I/O Troubleshooting Indicator Color Channel Mode Description 2 Extended local I/O Scanner active extended-local I/O normal operation link, all adapter modules are present and not faulted no action required at least one adapter is faulted or has failed • restore power to the rack green (steady) PLC-5/40L and -5/60L processors only BATT PROG green (blinking rapidly or slowly) PROC R E M Probable Cause Recommended Action • power off at extended-local I/O rack
F-6 Troubleshooting BATT PROG Ethernet Transmit LED PROC R E M FORCE RUN COMM The PLC-5 Ethernet interface contains an Ethernet Transmit LED that lights (green) briefly when the Ethernet port is transmitting a packet. It does not indicate whether or not the Ethernet port is receiving a packet.
Troubleshooting Indicators Active Description Probable Cause F-7 Recommended Action Adapter I/O Fault Rack Blink alternately Off Adapter module not Controller restart lockout switch on actively controlling I/O(2) chassis backplane switch assembly on(3) Adapter module in controller restart lockout mode (adapter to scanner link is normal) Press reset button to clear lockout feature or cycle power; if after repeated attempts indicators are still blinking, check: • push button not wired properly to fi
F-8 Troubleshooting Troubleshooting Guide for the 1771-ASB Series C and D Adapter Module (continued) Indicators Active Adapter I/O Fault Rack Off Off On Description Probable Cause Recommended Action I/O chassis fault. (1) No communication on link. Problem exists between: Cycle power to the chassis to clear a problem resulting from high noise.
Troubleshooting F-9 Extended-Local I/O System Troubleshooting Guide for the 1771-ALX Adapter Module ACTIVE ADAPTER FAULT I/O RACK FAULT Indicators Description Probable Cause Recommended Action Active Adapter I/O Fault Rack On Off Off Normal indication; remote adapter is fully operational Off On Off Local adapter fault (1) Local adapter not operating; it will stay in fault mode until fault is corrected Cycle power to the chassis to clear the adapter fault.
F-10 Troubleshooting Unexpected Operation when Entering Run Mode If unexpected operation occurs whenever your controller enters run mode, be sure to examine the prescan operation of the instructions in this section. These instructions execute differently during prescan than they do during a normal scan. The prescan function is an intermediate scan between the transition from program to run modes, during which all rungs are scanned as false.
Troubleshooting F-11 This Instruction: Executes These Actions During Prescan: FOR Ladder instructions within the FOR/NXT loop are prescanned. MSG If the SFC startover bit is cleared and the CO bit is cleared, then all non-user configuration bits 15, 14, 13, 12, 10, and 9 are cleared in both the INT and MG file types. The MG file type also clears bits 11, 7, 6, 5, 4, 2, 1, and 0. ONS The programmed bit address of the instruction is set to inhibit false triggering when the first run-mode scan begins.
F-12 Troubleshooting Notes Publication 1785-UM012D-EN-P - July 2005
Appendix G Cable Reference Using This Chapter For Information About Channel 0 Pin Assignments Pin RS-232C Go to Page Channel 0 pin assignments G-1 Serial cable pin assignments G-2 Connecting diagrams G-3 Programming cable specification G-5 Ethernet cable connections G-9 The side label of the controller shows a table listing channel 0 (RS-port) pin assignments. This table shows the same information: RS-422A RS-423 Pin 1 C.GND C.GND C.GND 14 2 TXD.OUT TXD.OUT+ TXD.OUT 15 3 RXD.
G-2 Cable Reference The following diagrams show the pin assignments for the cables you need for serial port communications.
Cable Reference G-3 Connecting Diagrams 1784-CP5 with -CP7 adapter cable #1 Terminal 1770-KF2 PLC-5 controller 9-Pin Serial Port Workstation Terminal 1784-CAK 1785-KE Series B 1770-CD PLC-5 Note: 1785-KE Series A uses 1785-CP5 cable and 1785-CP7 adapter with the Enhanced and Ethernet PLC-5 Programmable Controllers 1784-CP10 To channel 0 of the PLC-5 controller Terminal cable #4 modem Terminal phone line 1784-CP7 1784-CP5 PLC-5 controller cable #6 1770-KF2 modem cable #4 Terminal mod
G-4 Cable Reference 1784-CP5 cable #2 Terminal 1784-CP7 1770-KF2 PLC-5 controller 25-Pin Serial Port Workstation Terminal 1784-CXK 1785-KE Series B 1770-CD PLC-5 controller Note: 1785-KE Series A uses 1785-CP5 cable and 1785-CP7 adapter with the Enhanced and Ethernet PLC-5 controller 1784-CP11 Terminal cable #6 To channel 0 of the PLC-5 controller modem Terminal phone line PLC-5 controller 1784-CP6 cable #6 1770-KF2 cable #6 Terminal modem modem phone line To channel 0 of the PLC-5
Cable Reference G-5 The specifications for each Allen-Bradley cable used for DH+ communications are shown on the following pages. Refer to the following table for the exact location.
G-6 Cable Reference Cable - 1784-CP6 Connects Workstation Using 1784-KT, -KT/2, -KL, or -KL/B to Controller 62 61 Clear 22 43 1 A 62 Pin 1 21 Pin 6 Pin 3 8-Pin Mini-DIN Controller 62-Pin D-Shell Workstation 38 37 36 35 34 33 32 31 Clear Shield Blue Shield Blue 8 7 6 5 4 3 2 1 Controller 3 2 1 62-Pin D-Shell Workstation 18378 Cable and Adapter - 1784-CP7 Connects to Controller via 9-pin D-Shell of a 1784-CP, -CP5, or -PCM5 cable Clear 5 1 9 6 Pin 1 Pin 6 9-Pin D-Shell 8-Pin Mini-DIN Co
Cable Reference G-7 Cable Adapter - 1784-CP8 Connects a Workstation Using a 1784-KT, -KT2, or -KL Card to a Permanent DH+ Network 1 2 SH 1 2 3 3-position terminal connector 33 3-position terminal connector Workstation (front) 62-position sub-miniature connector 34 35 Network (back) 36 Blue 2 Shield SH Clear 1 62-position 37 sub-miniature connector 1770-CD Twinax Cable 60 61 62 19816 Cable - 1784-CP10 Connects Workstation to Controller Using Serial Port 3.
G-8 Cable Reference Cable - 1784-CP11 Controller to Workstation Using a Serial Port 3.2m (10 ft) 1 14 25 14 13 25 25-pin D-Shell Workstation Female 25-pin D-Shell Controller Male TXD 2 GND 7 3 7 RXD 3 2 RTS 4 CTS 5 4 5 RTS CTS DSR 6 DCD 8 6 8 DSR DCD DTS 20 20 DTR 1 13 19871 Cable - 1784-PCM5 Controller to Workstation (using a 1784-PCMK) 124.
Cable Reference Ethernet Cable Connections Transceiver G-9 The Ethernet port connects to either a thin-wire or thick-wire network via a 15-pin transceiver or Medium Access Unit (MAU) connection.
G-10 Cable Reference The controller connects to the transceiver using a standard transceiver cable, which is also known as an Access Unit Interface (AUI) cable. Allen-Bradley has two lengths of transceiver cables and four kits consisting of transceivers and cables. Catalog Number Description 5810-TER Thinwire Ethernet terminating resistors 5810-TC02/A Thick-wire 2.0 m (6.5 ft) transceiver cable 5810-TC15/A Thick-wire 15.0 m (49.2 ft) transceiver cable 5810-TAS/A (kit) Thin-wire transceiver and 2.
Index Numerics 1/2slot addressing 4-3, E-4, E-5 1770KF2 9-2 1771AF 6-6 1771ALX 8-1, E-5, F-9 1771AS 6-6 1771ASB 6-6, 6-11, E-5, F-6 1771CD 9-2 1771DCM 6-6 1771KRF 9-2 1771SN 6-6 1772SD, SD2 6-6 1775S4A, S4B 6-6 1775SR 6-6 1784CAK G-5 1784CP 9-2, G-6 1784CP10 G-2, G-5, G-7 1784CP11 G-2, G-5, G-8 1784CP2 9-2 1784CP3 9-2 1784CP5 9-2, G-5, G-6 1784CP6 9-2, G-5, G-6 1784CP7 G-5, G-6 1784CP8 G-5, G-7 1784KL 9-2, G-5, G-6, G-7 1784KT 9-2, G-5, G-6, G-7 1784KT2 9-2, G-5, G-6, G-7 1784KTK1 G-5 1784PCM5 9-2, G-5, G-6
2 Index blocktransfer 2-3, 4-7, 5-3, 5-4, 6-13, 6-14, 6-15, 6-16, 6-17, 6-19, 6-20, 7-7, 7-10, 7-11, 7-14, 8-6, 8-7, 15-11, 17-2, 18-3, C-8, C-12, D-25 BOOTP disabling 11-4 example 11-8 hardware address 11-8 IP address 11-7 using 11-5 broadcast addressing 11-9 C cables Belden 9463 6-3 communication interfaces G-5 DH+ link 9-2 Ethernet 11-1, G-9 extendedlocal I/O 8-2 pin assignments G-2 programming 9-2 raceway layout 3-4 reference G-1 remote I/O 6-5 routing conductors 3-4 serial 10-5 calculating process
Index I/O status file 6-7 main control programs 16-4 PII 18-5 pointtopoint 10-6 processorresident rack 5-4 remote I/O adapter channel 7-2, 7-3 remote I/O scanner channel 6-6 serial port 10-2, 10-6 startup procedure 14-3 STI 17-3 connections Ethernet G-9 control bits 14-3 controller documentation A-1 controller specifications A-1 controlling outputs 15-3 conversion instructions D-15 cooling 3-1 counter instructions D-4 D daisy chain 6-5, 9-2 data block 4-11 data file addressing 4-13 range of values 4-15 re
4 Index DH+ link cable lengths 9-2 communicating with devices 9-1 configuring channels 9-3 default address 9-3 defining the processor address 9-4 design tip 9-17 diagnostic counters 9-12 estimating performance 9-12 global status flag file 9-5 internal processing time 9-15 message destination 9-14 monitoring status 9-12 nodes/timing 9-13 planning cabling 9-2 response time test results 9-16 size and number of messages 9-13 terminating 9-3 token passing 9-13 transmission rate 9-4 troubleshooting F-4 diagnost
Index startup 14-2 testing 15-11 using 15-1 watchdog timer 15-5 when to use 13-11 faulted program state 13-12 faults blocktransfer, minor 6-15 clearing 15-7, 15-12 detecting major 15-2 extendedlocal I/O rack 15-3 major 15-1, 15-12 major and minor 15-11 minor 15-12 monitoring 15-12 processorresident local I/O rack 15-3 remote I/O chassis 15-3 remote I/O rack 15-4 status information 15-11 file instructions D-17 files 4-15 data storage 4-11 read/write privileges 12-5 floating point valid value range 4-15 forc
6 Index indicators 1771ALX F-9 1771ASB F-6 communication F-4 Ethernet F-5, F-6 extendedlocal I/O F-5 PLC5/11,5/20 1-3 PLC5/20E 1-6 PLC5/30 1-4 PLC5/40, 5/60, and 5/80 1-5 PLC5/40E and 5/80E 1-7 PLC5/40L, 5/60L 1-8 processor F-2 indirect address 4-18 instructions ASCII D-27 bit modify D-16 blocktransfer D-25 compare D-5 compute D-7 conversion D-15 counter D-4 diagnostic D-19 file D-17 logical D-14 memory bit and word instructions D-30 file, program control, and ASCII D-38 message D-25 move D-16 PID D-25
Index file, program control, and ASCII instructions D-38 gapping 4-12 optimizing 4-22 program files 4-15 protection E-4 memory card diagnostics B-12 memory module transfer E-4 message instruction D-25 messagebased communication 10-4 messages DH+ link 9-13 editing online C-12 Ethernet error codes 11-33 minor faults 15-12 mnemonic addressing 4-18 modes adapter 1-12 addressing 4-3 extendedlocal 1-14 keyswitch 1-9 scanner 1-11 monitoring adapter channel status 7-17 DH+ channel status 9-12 Ethernet channel stat
8 Index polling schemes 10-16 techniques 10-4 power supplies mounting dimensions 3-6 powerup routines 13-10, 13-11, 14-1, 14-3 priority scheduling 13-11 privilege class assigned to channel 12-4 assigned to node 12-4 assigned to offline file 12-4 privileges assigning class to channels 12-4 assigning class to offline files 12-4 assigning to data files 12-5 assigning to program files 12-5 defining classes 12-3 guidelines for assigning 12-3 types of 12-2 process control instructions D-25 Processor specifica
Index communication rate C-7 configuration overview 6-1 configuration steps 6-12 data transfer 6-11 design C-10, C-11 faults 15-3 how blocktransfers affect scan time C-8 I/O status file 6-7 introduction 6-3 maximum devices 6-4 number of rack entries in scan list C-7 optimizing scan time C-9 possible devices 6-2 programming blocktransfers 7-10 rack fault 15-4 scan list 6-3, 6-9 scan time C-6 scanner channel configuration 6-6 status 6-21 switch settings E-7 system setup 6-4 terminating the link 6-5 troublesh
10 Index SFC transitions forcing 13-2 SFCs 1-10 shift register instructions D-20 site preparation conductor categories 3-4 raceway layout 3-4 routing conductors 3-4 slave communication 10-3, 10-9 spacing chassis 3-1 Specification battery A-2 Specifications A-1 specifications A-1 standard communication 10-4 startup 14-2 status adaptermode channel 7-17 remote I/O 6-21 supervisory processor 7-18 status bits monitoring 15-13 status file processor B-1 size 4-13 status information main control program scan 16-5
Index file, program control, and ASCII instructions D-38 global status flags file C-5 housekeeping C-4 input states C-2 instructions C-3 internal processing 9-15 nodes 9-13 optimizing for remote I/O C-9 prescan F-10 program scan 5-2, 5-3 to extendedlocal I/O 8-5 using interrupts C-3 token passing 9-13 transceivers G-9 troubleshooting communications F-4 Ethernet F-5 extendedlocal I/O F-5, F-9 processor F-2 remote I/O F-6 trunk line/drop line 6-5, 9-2 type data storage 4-11 11 U UID/UIE influencing process
12 Index Publication 1785-UM012D-EN-P - July 2005
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