Allen-Bradley 747-L532, 1747-L524, 1747-L541, 1747-L542, 1747-L543 Installation And Operation Manual

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MANUFACTURER DATA SHEET

PLC-CPU

Manufacturer:

Allen-Bradley/Rockwell

Model Number:

SLC500

See www.geomartin.com for additional PDF datasheets

Martin Part Numbe r:

E-014624-00

VendorPartNumber: 1747-L524

PDF File: Doc_000074_Cover.pdf

This page is intentio n allyleft blank

Allen-Bradley

SLC 500t Modular Hardware Style

Installation

(Cat. Nos. 1747-L511, 1747-L514, 1747-L524, 1747-L531, 1747-L532, 1747-L541, 1747-L542, 1747-L543, 1747-L551, 1747-L552, and 1747-L553)

and Operation Manual

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

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

Allen-Bradley publication SGI-1.1, Safety Guidelines for the

Application, Installation, and Maintenance of Solid-State Control

(available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

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

Throughout this manual we use notes to make you aware of safety considerations:

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or

death, property damage or economic loss.

Attention statements help you to:

• identify a hazard

• avoid the hazard

• recognize the consequences

Important: Identifies information that is critical for successful

application and understanding of the product.

PLC, PLC–2, PLC–3, and PLC–5 are registered trademarks of Rockwell Automation. SLC, SLC 500, SLC 5/01, SLC 5/02, SLC 5/03, SLC 5/04, SLC 5/05, PanelView, PanelView 550, PanelView 900, RediPANEL, ControlView, PBASE, DH+, DTAM, DeviceNet, and Dataliner are trademarks of Rockwell Automation. RSLogix 500 and RSLinx are trademarks of Rockwell Software, Inc. Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation. IBM is a registered trademark of International Business Machines, Incorporated. Multimodem is a trademark of Multi–Tech Systems, Inc. Procomm is a registered trademark of Datastorm Technologies, Inc. Tandy is a trademark of the Tandy Corporation. Gateway 2000 is a trademark of Gateway 2000, Inc. Toshiba is a trademark of Toshiba America, Inc. Compaq is a registered trademark of Compaq Computer Corporation. Deskpro is a trademark of Compaq Computer Corporation. Intel is a trademark of Intel Corporation.

6–8

Installing Your Hardware Components

Installing Your Power Supply

If you have multiple chassis configurations, install the chassis interconnect cable before installing the power supply. (See page 6–10.) Also, the power supply terminals accept two #14 AWG wires and are marked as shown in the figure on page 6–8. To install the power supply, do the following:

1. Align the circuit board with the card guide on the left side of the

chassis. Slide the power supply in until flush with the chassis.

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2. Fasten the power supply to the chassis with the two Phillips head

screws.

3. Place the jumper to match the input voltage. (This does not apply

to 1746-P3 or 1746-P5, which do not have a jumper.)

ATTENTION: Make jumper selection before applying power. Hazardous voltage is present on

exposed pins when power is applied.

Installing Your Hardware Components

6–9

Fuse

Jumper Selection

100/120 Volts

200/240 V

Jumper Selection

85–132V ac

170–265V ac

olts

1746-P1 and -P2

POWER

User Power

PWR OUT +24V dc

PWR OUT COM 120/240V ac V ac NEUT

CHASSIS GROUND

PWR OUT +24V dc

PWR OUT COMMON

85–132V ac JUMPER 170–265V ac

L185–132/170–265

Fuse

1746-P3

POWER

User Power

NOT USED NOT USED + 24V dc dc NEUT CHASSIS GROUND

PWR OUT +24V dc PWR OUT COM

+125V dc dc NEUT CHASSIS GROUNDCHASSIS GROUND

L2

NEUTRAL

1746-P4 1746-P5

CHASSIS GROUND

4. Remove the warning label from the top of the power supply.

5. Connect line power to the power supply.

ATTENTION: If you have a 1746-P3, see page 3–5

for special grounding considerations.

On the 1746-P1 and -P2 power supply, use the PWR OUT + 24 VDC and PWR OUT COM terminals to power sensors. The terminals provide an isolated, nonfused, 200 mA, 24V dc power supply.

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6–10

Installing Your Hardware Components

Installing Your Chassis Interconnect Cable

Two cables are available to link modular hardware chassis. Catalog Number 1746-C7 cable is 152.4 mm (6 in.) in length and used when connecting chassis side-by-side. Catalog Number 1746-C9 is

914.4 mm (36 in.) in length and used to link one chassis below the other.

ATTENTION: Do not use any other cables than those provided. Longer cables could affect the integrity of

data communications between the chassis, possibly causing unsafe operation. Also, make sure the cable is properly secured to protect against the effects of shock and vibration.

Install the chassis interconnect cable before installing the power supply in multiple chassis configurations.

The cables are “keyed” for proper installation. The end of the cable that plugs into the right socket in the chassis has the “key” on the top of the connector. The opposite end of the cable has the “key” on the inside of the connector for insertion into the expansion chassis.

To remove the cable, move the tabs on the socket outward and the connector pops out.

ATTENTION: The expansion cable must always exit the right end of the chassis with the processor. Refer to

the following figures.

Chassis 1

P S

Chassis 2

CORRECT INSTALLATION

Chassis 1

P S

Chassis 2

INCORRECT INSTALLATION

Chassis 1

P S

Chassis 2

INCORRECT INSTALLATION

Chassis 1

P S

Chassis 2

INCORRECT INSTALLATION

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Chapter 7

Wiring Your I/O Modules

This chapter describes how to wire your I/O modules. It covers the following:

• defining sinking and sourcing

• preparing your wiring layout

• features of an I/O module

• recommendations for wiring I/O devices

• wiring your I/O modules

• octal label kit installation

• using removable terminal blocks

Defining Sinking and Sourcing

Sinking and sourcing are terms used to describe a current signal flow relationship between field input and output devices in a control system and their power supply.

• Field devices connected to the positive side (+V) of the field

power supply are sourcing field devices.

• Field devices connected to the negative side (DC Common) of the

field power supply are called sinking field devices.

To maintain electrical compatibility between field devices and the programmable controller system, this definition is extended to the input/output circuits on the discrete I/O modules.

• Sourcing I/O circuits supply (source) current to sinking field

devices.

• Sinking I/O circuits receive (sink) current from sourcing field

devices.

Europe: DC sinking input and sourcing output module circuits are the commonly used options.

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Chapter 10

Troubleshooting

In this chapter, you will learn about:

• calling Allen-Bradley for assistance

• tips for troubleshooting your control system

• troubleshooting the SLC 5/01 and SLC 5/02 processors

• troubleshooting the SLC 5/03, SLC 5/04, and SLC 5/05

processors

• troubleshooting your input modules

• troubleshooting your output modules

Calling Allen-Bradley for Assistance

If you need to contact Allen-Bradley or local distributor for assistance, it is helpful to obtain the following (prior to calling):

• processor type, series letter, operating system (OS) number

(obtained from the status file), firmware (FRN) number (see label on side of processor module)

• processor LED status

• processor error codes (found in S:6 of status file)

• hardware types in system (I/O modules, chassis)

• revision of programming device (on the main menu of the

Hand-Held Terminal or programming software)

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10–2

Troubleshooting

Tips for Troubleshooting Your Control System

When troubleshooting, pay careful attention to these general warnings:

ATTENTION: Have all personnel remain clear of the controller and equipment when power is applied. The

If installation and start-up procedures detailed in chapters 6, 7, and 8 were followed closely, your SLC controller will give you reliable service. If a problem should occur, the first step in the troubleshooting procedure is to identify the problem and its source.

problem may be intermittent and sudden unexpected machine motion could result in injury. Have someone ready to operate an emergency-stop switch in case it becomes necessary to shut off power to the controller equipment. Also, see NFPA 70E Part II for additional guidelines for safety related work practices.

Never reach into a machine to actuate a switch since unexpected machine motion can occur and cause injury.

Remove all electrical power at the main power disconnect switches before checking electrical connections or inputs/outputs causing machine motion.

The SLC 500 controller has been designed to simplify troubleshooting procedures. By observing the diagnostic indicators on the front of the power supply, processor unit and I/O modules, the majority of faults can be located and corrected. These indicators, along with error codes identified in the programming device user manual and programmer’s monitor, help trace the source of the fault to the user’s input/output devices, wiring, or the controller.

Removing Power

Before working on a SLC 500 modular system, always remove the power supply input power at the main power disconnect switch.

The power LED on the power supply indicates that DC power is being supplied to the chassis. The LED could be off when incoming power is present.

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Troubleshooting

10–3

Replacing Fuses

When replacing a fuse, be sure to remove all power from the system.

Program Alteration

There are several causes of alteration to the user program, including extreme environmental conditions, Electromagnetic Interference (EMI), improper grounding, improper wiring connections, and unauthorized tampering. If you suspect the memory has been altered, check the program against a previously saved program on an EEPROM, UVPROM or Flash EPROM module.

Troubleshooting the SLC 5/01 and SLC 5/02 Processors

To receive the maximum benefit of this troubleshooting section, we recommend you follow these steps:

1. Identify the status of your processor LEDs. See chapter 5 for a

description of LEDs and their different states.

2. Using the tables on the following pages, match your processor

and power supply LEDs with the status LEDs located in the first column.

3. Once the status LEDs are matched to the appropriate table,

simply move across the table identifying error description and probable causes.

4. Follow the recommended action steps for each probable cause

until the error is corrected.

5. If recommended actions do not correct the error, contact your

local Allen-Bradley sales office or distributor.

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10–4

Troubleshooting

Identifying SLC 5/01 and SLC 5/02 Processor Errors

The following LEDs and tables provide you with information regarding error messages, possible cause(s) for the error, and recommended action to take to resolve the error.

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

The Following

Error Exists

Inadequate System Power

Probable Cause Recommended Action

1. Verify proper line voltage and connections on the

No Line Power

power terminals.

2. Verify proper 120/240V power supply jumper selection. See page 6–8.

1. Check the incoming power fuse, check for proper Power Supply Fuse Blown

incoming power connections. Replace fuse.

2. If fuse blows again, replace the power supply. See

page 9–8 on fuse replacement.

1. Remove line power to power supply. Remove

several output modules from the chassis. Wait five minutes. Reapply power.

Power Supply Overloaded

2. If condition reoccurs, re-calculate module

configuration power required and verify proper power supply selection. See page 2–11. This problem can occur intermittently if power supply is slightly overloaded when output loading and temperature varies.

1. Recheck other probable causes. Defective Power Supply

2. Monitor the line power to chassis power supply for

possible transient or shorting.

3. Replace the power supply.

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

Inadequate System Power

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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The Following

Error Exists

Probable Cause Recommended Action

Improper Line Power Voltage Selection

Verify proper 120/240V power supply jumper selection. See page 6–8.

Troubleshooting

10–5

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

The Following

Error Exists

Processor Not in Run Mode

Probable Cause Recommended Action

1. Verify selected processor mode.

Either Improper Mode Selected or User Program Logic Error

2. If in program/test modes attempt Run mode entry.

3. If in suspend mode, check user program logic for

suspend instructions. Refer to either the Hand-Held Terminal User Manual (Catalog Number 1747-NP002) or your programming software user manual.

1. Check proper 120/240V power supply jumper

Line Power Out of Operating Range

selection and incoming power connections.

2. Monitor for proper line voltage at the incoming power connections. See page 6–8 for power supply installation.

1. Remove power and inspect the power supply Improper Seating of Power Supply, and/or Processor in the Chassis

chassis connections and the processor chassis connections.

2. Re-install the devices and re-apply power.

Important: The processor only operates in slot 0 of

chassis #1.

1. Attempt Run mode selection of Processor in

existing chassis.

2. Place processor in another chassis not in the Defective Processor, Power Supply or Chassis

existing system. Apply power, reconfigure and attempt Run mode selection. If unsuccessful, replace processor.

3. Try existing power supply in test chassis. If

unsuccessful, replace power supply. If entry into the Run mode is allowed, replace the existing chassis.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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10–6

ault

Troubleshooting

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

The Following

Error Exists

System Inoperable, No Major CPU F

sDetected

The Following

Error Exists

Probable Cause Recommended Action

1. Monitor logic in Run mode and verify desired I/O

status. User Program Logic Error

2. Check for minor CPU faults.

Refer to either the Hand-Held Terminal User Manual

(Catalog Number 1747-NP002) or your programming

software user manual Defective I/O

Devices or I/O Wiring

Test inputs and outputs according to I/O troubleshooting

procedures starting on page 10–26.

Probable Cause Recommended Action

CPU Memory Error

Cycle power.

1. Remove power and then remove the memory module

from the processor.

2. Re-install the processor and re-apply power to the

Faulty Memory Module

power supply

If steady CPU FAULT LED changes to flashing, replace the

existing memory module with a replacement module.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

CPUF

Faulty CPU/Power Supply

Processor Firmware Installed Incorrectly

Refer to chapter 6 for removing and installing memory

modules.

1. Place the processor in another chassis not in the

existing system and cycle power.

If steady CPU FAULT LED reappears, replace the

processor.

2. If CPU FAULT LED clears, monitor the line power

going to the power supply in existing system.

3. Replace existing system power supply if line power checks OK.

If upgrading the processor to a different firmware level, verify firmware chip orientation matches the upgrade kit directions.

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Troubleshooting

10–7

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

The Following

Error Exists

CPU Major Fault

The Following

Error Exists

System does not operate per ladder logic.

Probable Cause Recommended Action

Initial CPU Factory Power-up Condition

1. Refer to chapter 8 and follow the start-up procedures.

2. Clear processor memory to get rid of the flashing CPU

FAULT LED.

1. Monitor Status File Word S:6 for major error code. Hardware/Software Major Fault Detected

2. Refer to either the Hand-Held Terminal User Manual

(Catalog Number 1747-NP002) or the Instruction Set Reference Manual for error codes and additional

troubleshooting information. Erratic repetitive power cycling can cause a processor major hardware fault.

3. Remove hardware/software condition causing fault.

4. Clear Status File S:1/13 major error bits, if set.

5. Clear Status File S:5 minor error bits, if set.

6. Clear Status File S:6 major error code (optional).

7. Attempt a processor Run mode entry.

If unsuccessful, repeat recommended action steps above.

Probable Cause Recommended Action

1. Monitor program file online and identify forced I/O.

User Forced I/O Disabling Operation

2. Disable appropriate forces and test system conditions again. Refer to either the Hand-Held Terminal User Manual (Catalog Number 1747-NP002) or your programming software user manual.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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10–8

Troubleshooting

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

If the LEDs indicate:

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

➀

COMM

The Following

Error Exists

System does not operate per programmed forces.

The Following

Error Exists

CPU Major Error with Low or No Battery Back-up

Probable Cause Recommended Action

1. Monitor program file online and identify programmed

forces.

User Programmed Forces are Not Enabled

2. Enable appropriate forces and test system conditions again. Once forces are enabled, the FORCED I/O LED goes on steady. Refer to either the Hand-Held Terminal User Manual (Catalog Number 1747-NP002) or your programming software user manual.

Probable Cause Recommended Action

1. Verify battery is connected. See pages 6–1 and 9–4.

2. Replace the battery if you want RAM battery backup.

See page 9–4. If you want to back up RAM with the

Loss of RAM during Power Down Period

capacitor in a SLC 5/01 (1747-L511), add or replace the BATTERY LOW LED jumper.

3. Refer to processor major fault recommended action steps. Refer to either the Hand-Held Terminal User Manual (Catalog Number 1747-NP002) or your programming software user manual.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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Troubleshooting

ceivingdata.

ata.

Identifying SLC 5/02 Processor Communication Errors

10–9

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

COMM

The SLC 5/02 processor is not receivingd

re No communication to the programmer.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON.

Probable Cause Recommended Action

1. Check communication parameters of programmer.

Programmer and processor baud rate must match.

DH-485 communication parameters are improperly set up.

Programmer and processor node addresses must be different.

2. Try different combinations of: a. baud rate (Processor default is 19200.) b. node address (Processor default is 1.)

3. Try to increase the maximum node address. (Default is 31.)

1. Check cable continuity. Bad Connection of Communication Device

2. Check cable connections between programmer and

processor.

3. Check communication device (for example, the

1747-PIC). Replace if necessary.

1. Verify proper power supply selection and backplane Low or No Power to Communication Device

loading. (1747-PIC and 1747-AIC draw power off the backplane.)

2. Verify proper 120/240V power supply jumper selection.

See page 6–8.

Indicates the LED is FLASHING. Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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10–10

Troubleshooting

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

COMM

The SLC 5/02 processor is receiving data, but is not communicating with the programmer.

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN CPU FAULT

FORCED I/O BATTERY LOW

COMM

A fatal error has occurred.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON.

Probable Cause Recommended Action

1. Check communication parameters of programmer.

Programmer and processor baud rate must match.

DH-485 communication parameters are improperly set up.

Programmer and processor node addresses must be different.

2. Try different combinations of: a. baud rate (Processor default is 19200.) b. node address (Processor default is 1.)

3. Try to increase the maximum node address. (Default is 31.)

Probable Cause Recommended Action

1. Cycle power to obtain flashing CPU FAULT LED and

default program. Excessive noise or a faulty SLC 5/02 processor.

2. Examine the error code following the power cycle.

Take appropriate action.

3. Reload your program.

4. Contact your local Allen-Bradley representative if the

error persists.

Indicates the LED is FLASHING. Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The RUN LED on the SLC 5/01 processor is actually labeled “PC RUN.” Also, the SLC 5/01 processor does not have a COMM LED.

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10–1

1Troubleshooting

Troubleshooting the SLC 5/03, SLC 5/04, and SLC 5/05 Processors

Between the time you apply power to an SLC 5/03, SLC 5/04, or SLC 5/05 processor and the communications are established via a connected programming device, the only form of communication between you and the processor is through the LED display.

When power is applied, all of the LEDs flash on and then off while the processor conducts hardware tests. This is part of the normal powerup sequence. Following the selftest by the processor, all the LEDs again flash on momentarily. If a user program is in a running state, the RUN LED will be on. If a fault exists within the processor, the FLT LED is on.

To receive the maximum benefit of this troubleshooting section, we recommend you follow these steps:

1. Identify the status of your processor LEDs. See chapter 5 for

description of LEDs and their different states.

2. Using the tables on the following pages, match your processor

and power supply LEDs with the status LEDs located in the first column.

3. Once the status LEDs are matched to the appropriate table,

simply move across the table identifying error description and probable causes.

4. Then follow the recommended action steps for each probable

cause until the cause is identified.

5. If recommended actions do not identify the trouble cause, contact

your local Allen-Bradley sales office or distributor.

Clearing SLC 5/03, SLC 5/04, and SLC 5/05 Processor Faults Using the Keyswitch

Toggle the keyswitch from RUN to PROG and then back to RUN; this clears the fault. If the keyswitch is left in the RUN position, the processor mode cannot be changed from a programmer/operator interface device. If you return the keyswitch to the REM position, you can then use a programmer/operator interface device to change the processor mode.

ATTENTION: If you clear a processor fault using the keyswitch, the processor immediately enters the Run

mode.

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10–12

Troubleshooting

Identifying SLC 5/03, SLC 5/04, and SLC 5/05 Processor Errors

The following LEDs and tables provide you with information regarding error messages, possible cause(s) for the error, and recommended action to take to resolve the error.

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

The Following

Error Exists

Inadequate System Power

Probable Cause Recommended Action

1. Verify proper line voltage and connections on the

No Line Power

power terminals.

2. Verify proper 120/240V power supply jumper selection. See page 6–8.

1. Check the incoming power fuse, check for proper Power Supply Fuse Blown

incoming power connections. Replace fuse.

2. If fuse blows again, replace the power supply. See

page 9–8 on fuse replacement.

1. Remove line power to power supply. Remove

several output modules from the chassis. Wait five minutes. Reapply power.

Power Supply Overloaded

2. If condition reoccurs, re-calculate module

configuration power required and verify proper power supply selection. See page 2–11. This problem can occur intermittently if power supply is overloaded when output loading and temperature varies.

1. Recheck other probable causes.

Defective Power Supply

2. Monitor the line power to chassis power supply for

possible transient or shorting.

3. Replace the power supply.

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

Inadequate System Power

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

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The Following

Error Exists

Probable Cause Recommended Action

Improper Line Power Voltage Selection

Verify proper 120/240V power supply jumper selection. See page 6–8.

Troubleshooting

10–13

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

The Following

Error Exists

Processor Not in Run Mode

Probable Cause Recommended Action

1. Verify selected processor mode.

2. If the processor is in the Program/Test modes,

attempt Run mode entry:

Either Improper Mode Selected or User Program Logic

• If keyswitch is in the REM position and there is no key, use the programmer.

• If keyswitch is in REM or PROG position,

and you have the key,

toggle to the RUN

position.

3. If in the suspend mode, check user program logic

for suspend instructions. Refer to your programming software user manual.

1. Check proper 120/240V power supply jumper

Line Power Out of Operating Range

selection and incoming power connections.

2. Monitor for proper line voltage at the incoming

power connections. See page 6–8 for power supply installation.

1. Remove power and inspect the power supply

Improper Seating of Power Supply, and/or Processor in the Chassis

chassis connections and the processor chassis connections.

2. Re-install the devices and re-apply power.

Important: The processor only operates in slot 0 of

chassis #1.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Defective Processor, Power Supply, or Chassis

1. Attempt Run mode selection of Processor in

existing chassis:

• If keyswitch is in the REM position and there is no key, use the programmer.

• If keyswitch is in REM or PROG position, and you

have the key, toggle to the RUN position.

2. Place processor in another chassis not in the

existing system. Apply power, reconfigure and attempt Run mode selection. If unsuccessful, replace processor.

3. Try existing power supply in test chassis. If

unsuccessful, replace power supply. If entry into the Run mode is allowed, replace the existing chassis.

Publication

1747-6.2

10–14

NoMajorCPU

ault

Troubleshooting

If the LEDs indicate:

POWER

RUN

FLT

BATT

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

➀

FORCE DH485

RS232

The Following

Error Exists

System Inoperable,

Faults Detected

The Following

Error Exists

CPU Fault

CPUF

Probable Cause Recommended Action

1. Monitor logic in Run mode and verify desired I/O

User Program Logic Error

status.

2. Check for minor CPU faults. Refer to your programming software user manual.

Defective I/O Devices or I/O Wiring

Test inputs and outputs according to I/O troubleshooting procedures starting on page 10–26.

Probable Cause Recommended Action

CPU Memory Error

Cycle power.

1. Remove power and then remove the memory module from the processor.

2. Re-install the processor and re-apply power to the

Faulty Memory Module

power supply. If steady FLT LED changes to flashing, replace the existing memory module with a replacement module.

Refer to chapter 6 for removing and installing memory modules.

1. Place the processor in another chassis not in the existing system and cycle power. If steady FLT LED

Faulty CPU/Power Supply

reappears, replace the processor.

2. If FLT LED clears, monitor the line power going to the power supply in existing system.

3. Replace existing system power supply if line power checks OK.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Publication

1747-6.2

Processor Firmware Installed Incorrectly

If upgrading the processor to a different firmware level, verify firmware chip orientation matches the upgrade kit directions.

Troubleshooting

10–15

If the LEDs indicate:

POWER

RUN

FLT

BATT

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

➀

FORCE DH485

RS232

The Following

Error Exists

CPU Major Fault

The Following

Error Exists

System does not operate per ladder logic.

Probable Cause Recommended Action

Initial CPU Factory Power-up Condition in Effect

1. Refer to chapter 8 and follow the start-up procedures.

2. Clear processor memory to get rid of the flashing FLT

LED.

1. Use programmer to monitor and clear the fault (or if keyswitch in REM):

a. Monitor Status File Word S:6 for major error code. Hardware/ Software Major Fault Detected

b. Refer to your programming software user manual for

error codes and additional troubleshooting information.

c. Remove hardware/software condition causing fault.

d. Clear Status File S:1/13 major error bits, if set. Erratic repetitive power cycling can cause a CPU major hardware fault.

e. Clear Status File S:5 minor error bits, if set.

f. Clear Status File S:6 major error code (optional).

g. Attempt a processor Run mode entry.

If unsuccessful, repeat recommended action steps above.

2. Use the keyswitch to clear the fault. Toggle the

keyswitch to PROG and back to RUN. (See page 10–11.)

If FAULT occurs again, use programmer to get error code

and determine the source of problem.

Probable Cause Recommended Action

User Forced I/O Disabling Operation

1. Monitor program file online and identify forced I/O.

2. Disable appropriate forces and test system conditions

again.

Refer to your programming software user manual.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Publication

1747-6.2

10–16

Troubleshooting

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN

FLT

BATT

FORCE DH485

RS232

System does not operate per programmed forces.

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN

FLT

BATT

FORCE DH485

RS232

CPU Major Error with Low or No Battery Back-up

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON.

Probable Cause Recommended Action

1. Monitor program file online and identify programmed

User programmed forces are not enabled.

forces.

2. Enable appropriate forces and test system conditions again. Once forces are enabled, the FORCE LED goes on steady. Refer to your programming software user manual.

Probable Cause Recommended Action

1. Verify battery is connected. See pages 6–1 and 9–5.

Loss of RAM during Power Down Period

2. Replace the battery if you want RAM battery backup. See page 9–5.

3. Refer to processor major fault recommended action steps. Refer to your programming software user manual.

Indicates the LED is FLASHING. Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Publication

1747-6.2

Troubleshooting

Identifying SLC 5/03, SLC 5/04, and SLC 5/05 Processor Communication Errors

10–17

If the LEDs indicate:

➀

The Following

Error Exists

POWER

RUN

FLT

BATT

FORCE DH485

RS232

Fatal Error and No Communication

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Probable Cause Recommended Action

1. Check line power.

Inadequate System Power

2. Check 120/240V power supply jumper selection. See

page 6–8. Also, see the recommended actions for

inadequate system power on page 10–12.

Communication channel is “shut down.”

Check communication channel configuration with your

programming software. Also, see “Returning the SLC 5/03,

SLC 5/04, and SLC 5/05 Processors to ‘Initial Factory

Conditions’” on page 10–25. Communication

channel is

Replace processor. damaged.

Publication

1747-6.2

10–18

4.)

Troubleshooting

If the LEDs indicate:

POWER

RUN

FLT

BATT

➀

FORCE DH485

RS232

The Following

Error Exists

The SLC 5/03 and SLC 5/04 processors are trying to establish communication, but cannot find other active nodes. (The LED is flashing green on the SLC 5/03 and SLC 5/0

SLC

5/0

Probable Cause Recommended Action

1. Check communication parameters of programmer.

Programmer and processor baud rate must match. Programmer and processor node addresses must be

different. DH-485 or DH+ communication parameters are improperly set up.

2. Try different combinations of:

a. baud rate (Processor default is 19.2K for DH-485 on

the SLC 5/03, and 57.6K for DH+ on the SLC 5/04.)

b. node address (Processor default is 1.)

3. Try to increase the maximum node address. (Default

is 31 for the SLC 5/03 processor only.)

See your programming software user manual for channel

configuration information.

1. Check cable continuity. Bad Connection of Communication Device

2. Check cable connections between programmer and

processor.

3. Check communication device (for example, the

1747-PIC). Replace if necessary.

1. Verify proper power supply selection and backplane Low or No Power to Communication Device

loading. (The 1747-PIC and 1747-AIC draw power off the backplane.)

2. Verify proper 120/240V power supply jumper selection.

See page 6–8.

Duplicate drop is detected. (The LED is flashing red on the SLC 5/04.)

An ENET fault is being reported via a code. (The LED is flashing red on the SLC 5/05.)

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Another DH+ device is already on the DH+ network at the node address of this same device.

A hardware or software fault has occured.

1. Remove this device from the DH+ network.

2. Cycle power.

3. Reset the node address to an unused node before

reconnecting device to the DH+ network. (Can perform reset if on-line via channel 0 RS-232 port without disconnecting from DH+.)

Contact Allen-Bradley Global Technical Services for assistance.

Publication

1747-6.2

Troubleshooting

unication

10–19

If the RS232 Channel is in DH485 Mode and the LEDs

➀

indicate:

POWER

RUN

FLT

BATT

If the RS232 Channel is in DH485 Mode and the LEDs

➀

indicate:

POWER

RUN

FLT

BATT

FORCE DH485

RS232

FORCE DH485

RS232

The Following

Error Exists

Fatal Error and No Comm

The Following

Error Exists

The SLC 5/03, SLC 5/04, or SLC 5/05 processor is trying to establish communication, but cannot find other active

des

Probable Cause Recommended Action

1. Check line power.

Inadequate System Power

2. Check 120/240V power supply jumper selection. See page 6–8. Also, see the recommended action for Inadequate System Power on page 10–12.

Communication channel is “shut down.”

Check communication channel configuration with your programming software. Also, see “Returning the SLC 5/03, SLC 5/04, and SLC 5/05 Processors to ‘Initial Factory Conditions’” on page 10–25.

Communication channel is

Replace processor.

damaged. Channel

configured for DF1.

See your programming software user manual for channel configuration information.

Probable Cause Recommended Action

1. Check communication parameters of programmer.

Programmer and processor baud rate must match. Programmer and processor node addresses must be

DH-485 communication parameters are improperly set up.

different.

2. Try different combinations of: a. baud rate (Processor default is 19200.) b. node address (Processor default is 1.)

3. Try to increase the maximum node address. (Default is 31.) See your programming software user manual for channel configuration information.

1. Check cable continuity.

Bad Connection

2. Check cable connections between programmer and processor.

1. Verify proper power supply selection and backplane Low or No Power to Communication Device

loading. (The 1747-PIC and 1747-AIC draw power off the backplane.)

2. Verify proper 120/240V power supply jumper selection.

See page 6–8.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Publication

1747-6.2

10–20

aramet

ckin

Troubleshooting

If the RS232 Channel is in DH485 Mode and the LEDs

➀

indicate:

POWER

RUN

FLT

BATT

If the LEDs indicate:

POWER

RUN

FLT

BATT

FORCE DH485

RS232

➀

FORCE DH485

RS232

The Following

Error Exists

Probable Cause Recommended Action

Channel is configured for DH485 mode.

The SLC 5/03, SLC 5/04, or RS232/DF1 SLC 5/05 processor is not

ers

improperly set up.

transmitting.

Hardware Problem

The Following

Error Exists

Probable Cause Recommended Action

Excessive noise or

A fatal error has occurred.

a faulty SLC 5/03, SLC 5/04, or SLC 5/05 processor.

Check communication parameters of channel configuration. Also, see your programming software user manual.

Check communication parameters of programmer and channel configuration: a. baud rate b. DF1 node addresses (Processor default is 1 for DF1 half-duplex, and 9 for DF1 full-duplex.)

error che

g d. number of data bits Programmer and processor baud rate must match. Programmer and processor addresses must be different.

See your programming software user manual.

1. Check cable connections.

2. Check cable pinouts. Also, see appendix B for

RS-232 pinouts.

1. Cycle power to obtain flashing FLT LED and default program.

2. Examine the error code following the power cycle. Take appropriate action.

3. Reload your program.

4. Contact your local Allen-Bradley representative if the

error persists.

Refer to the following key to determine the status of the LED indicators:

Indicates the LED is OFF. Indicates the LED is ON. Indicates the LED is FLASHING.

Indicates the LED is FLASHING or OFF. Status of LED does not matter.

➀

The DH485 LED on the SLC 5/03 processor is labeled DH+ on the SLC 5/04 processor, and ENET on the SLC 5/05 processor.

Publication

1747-6.2

Allen-Bradley 747-L532, 1747-L524, 1747-L541, 1747-L542, 1747-L543 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual