Allen-Bradley 1785-L40B, 1785-L11B, 1785-L40L, 1785-L60B, 1785-L60L User Manual

...

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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. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manua l , in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injur y or death, property damage, or economic loss.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:

• identify a hazard

• avoid a hazard

• recognize the consequence

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfa ces may be dangerous temperatures.

Summary of Changes

Changes to this Manual

Find the New Information

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.

This New and Updated Information Is on Page

Domain Name Service 11-15 User Provided Web Pages 11-16 Multihop Messaging over Ethernet 11-29 TCP/IP Communications 11-32 Additional Ethernet Diagnostics 11-35 Memory Card Diagnostics B-12 Troubleshooting and Diagnostics F-2

Additional Ethernet PLC-5 Controller Enhan ce ment

Ethernet PLC-5 controllers support use of the 1785-RC Relay Cartridge. The relay cartridge serves as an interface from the controller to a user-supplied external device such as an Allen-Bradley 700P relay. When the controller is in run mode, it monitors online ladder program edits and I/O forcing activity. When either of these is detected, the controller opens the relay on the relay cartridge for one second.

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Summary of Changes 2

Notes

Publication 1785-UM012D-EN-P - July 2005

Table of Contents

Preface

Understanding Your Programmable Controller

Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Related PLC-5 Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Terms Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Manual Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Chapter 1

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Lay Out the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Identifying Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PLC-5/11, -5/20, and -5/26 Controller Front Panels. . . . . . . . . 1-3

PLC-5/40, -5/46, -5/60, -5/80, and -5/86

Controller Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

PLC-5/20E Controller Front Panel . . . . . . . . . . . . . . . . . . . . . . 1-6

PLC-5/40E and -5/80E Controller Front Panels . . . . . . . . . . . 1-7

PLC-5/40L and -5/60L Controller Front Panels . . . . . . . . . . . 1-8

Programming Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Using a Controller Channel as a Remote I/O Scanner . . . . . . . . . . 1-11

Using a Controller Channel as a Remote I/O Adapter . . . . . . . . . . 1-12

Using a PLC-5/40L, -5/60L Programmable Controller as an

Extended-Local I/O Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Selecting and Placing I/ O

Placing Syste m Hardware

Chapter 2

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Selecting I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Guidelines for Selecting I/O Modules . . . . . . . . . . . . . . . . . . . . 2-2

Selecting I/O Module Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Placing I/O Modules in a Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Chapter 3

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Determining the Proper Environment . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Protecting Your Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Preventing Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Laying Out Your Cable Raceway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Categorize Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Route Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Laying Out Your Backpanel Spacing . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Chassis Dimensions (Series B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

I/O Chassis and External Power Supply Dimensions . . . . . . . 3-6

Grounding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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T able of Contents 2

Addressing I/ O and Controller Memory

Chapter 4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Assigning Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Understanding PLC-5 Controller Memory. . . . . . . . . . . . . . . . . . . . 4-10

Understanding Data Storage (Data-Table Files) . . . . . . . . . . . . 4-11

Addressing File Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Understanding Program-File Storage . . . . . . . . . . . . . . . . . . . . . 4-15

Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Specifying I/O Image Addresses . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Specifying Logical Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Specifying Indirect Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Specifying Indexed Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Specifying Symbolic Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Optimizing Instruction Execution Time

and Controller Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Effectively Using I/O Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Communicating with Controller-Resident I/O

Communicating with Remote I/O

Chapter 5

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Introduction to PLC-5 Controller Scanning. . . . . . . . . . . . . . . . . . . . 5-1

Program Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Transferring Data to Controller-Resident I/O. . . . . . . . . . . . . . . . . . 5-3

Transferring Discrete Data to Controller-Resident I/O . . . . . . . 5-3

Transferring Immediate I/O Requests. . . . . . . . . . . . . . . . . . . . . 5-3

Transferring Block-Transfer Data to Controller-Resident I/O . 5-4

Configuring the System for Controller-Resident I/O . . . . . . . . . . . . 5-4

Chapter 6

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 6-2

Introduction to Remote I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Designing a Remote I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Configuring a Controller Channel as a Scanner . . . . . . . . . . . . . . . . . 6-6

Define an I/O Status File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Specify Channel Configuration Information . . . . . . . . . . . . . . . . 6-7

Specify the Scan List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Communicating to a Remote I/O Node Adapter . . . . . . . . . . . . . . 6-11

Troubleshooting Remote I/O Communication Difficulties. . . 6-12

Transferring Block Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Block-Transfers of Remote I/O Data . . . . . . . . . . . . . . . . . . . . . . . 6-15

Block-Transfer Sequence with Status Bits . . . . . . . . . . . . . . . . . . . . 6-17

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Communicating with a PLC-5 Adapter Channel

Table of Contents 3

Block-Transfer Programming Considerations . . . . . . . . . . . . . . . . . 6-19

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

For Controller-Resident Local Racks . . . . . . . . . . . . . . . . . . . . . 6-20

Monitoring Remote I/O Scanner Channels. . . . . . . . . . . . . . . . . . . 6-21

Monitoring transmission retries . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Addressing the I/O Status File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Chapter 7

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Configuring Communication to a PLC-5 Adapter Channel . . . . . . . 7-2

Specify an Adapter Channel’s Communication Rate,

Address, and Rack Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Specify the Discrete Transfer Configuration Files. . . . . . . . . . . . 7-5

Programming Discrete Transfers in Adapter Mode. . . . . . . . . . . . . 7-10

Programming Block-Transfers of Data to an Adapter Channel . . . 7-10

Configure Block-Transfer Requests . . . . . . . . . . . . . . . . . . . . . . 7-11

Examples of Block-Transfer Ladder Logic

Effects of Programming Block-Transfers to an Adapter-Mode

Controller Channel on Discrete Data Transfer . . . . . . . . . . . . . 7-15

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

Communicating with Extended-Local I/O

Communicating with Devices on a DH+ Link

Chapter 8

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 8-1

Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Addressing and Placing I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Transferring Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Discrete Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Transferring Block Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Calculating Block-Transfer Completion Time . . . . . . . . . . . . . . . 8-7

Considerations for Extended-local Racks. . . . . . . . . . . . . . . . . . . 8-8

Configuring the Controller as an Extended-Local I/O Scanner. . . . 8-9

Monitoring Extended-Local I/O Status. . . . . . . . . . . . . . . . . . . . . . 8-12

Chapter 9

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 9-1

Link Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Configuring the Channel for DH+ Communication . . . . . . . . . . . . . 9-3

Using the Global Status Flag File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Monitoring DH+ Communication Channels. . . . . . . . . . . . . . . . . . . 9-7

Monitoring Data Sent with Acknowledgment . . . . . . . . . . . . . . . 9-8

Monitoring Data Sent without Acknowledgment . . . . . . . . . . . 9-10

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T able of Contents 4

Communicating with Devices on a Serial Link

Monitoring General Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Estimating DH+ Link Performance. . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Size and Number of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Message Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Internal Processing Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

Average DH+ Link Response Time Test Results . . . . . . . . . . . 9-16

Application Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Chapter 10

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Choosing Between RS-232C, RS-422A, and RS-423 . . . . . . . . . . . . 10-1

Configuring the Controller

Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Using Channel 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

System Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Master Station to Remote Station Communication Methods . . 10-4

Polling Inactive Priority Stations. . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Changing Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Configuring Channel 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Configure Channel 0 for DF1 Point-to-Point . . . . . . . . . . . . . . 10-6

Configure Channel 0 as a Slave Station . . . . . . . . . . . . . . . . . . . 10-9

Configure Channel 0 as a Master Station . . . . . . . . . . . . . . . . . 10-12

Configure Channel 0 for User Mode (ASCII Protocol). . . . . . 10-18

Configure Channel 0 for a Communication Mode Change. . . 10-21

Monitoring Channel 0 Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

Using the System Mode Status Display . . . . . . . . . . . . . . . . . . 10-22

Using the User Mode (ASCII) Status Display . . . . . . . . . . . . . 10-24

Communicating with Devices on an Ethernet Networ k

Publication 1785-UM012D-EN-P - July 2005

Chapter 11

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Media and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Assigning Your IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Network Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Configuring Channel 2 for Ethernet Communication. . . . . . . . . . . 11-2

Manually Configuring Channel 2 . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Using BOOTP to Enter Configuration Information. . . . . . . . . 11-5

Editing the BOOTPTAB Configuration File. . . . . . . . . . . . . . . 11-7

Using Advanced Ethernet Functions . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Using Broadcast Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Using Subnet Masks and Gateways . . . . . . . . . . . . . . . . . . . . . 11-11

Manually Configuring Channel 2 for Controllers on Subnets. 11-12

Table of Contents 5

Using BOOTP to Configure Channel 2

for Controllers on Subnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

Using Domain Name Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

Using the Embedded Web Server. . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

Generating User Provided Web Pages . . . . . . . . . . . . . . . . . . . 11-22

Importing User Page Files to the PLC-5 Controller . . . . . . . . 11-26

Using Multihop Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29

Multihop Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30

Comparing Multihop and Non-Multihop Messages

Over Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32

Communicating with ControlLogix Devices . . . . . . . . . . . . . . . . . 11-32

TCP/IP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32

Interpreting Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33

Interpreting Ethernet Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . 11-34

Monitoring general Ethernet status . . . . . . . . . . . . . . . . . . . . . 11-35

Monitoring Ethernet commands. . . . . . . . . . . . . . . . . . . . . . . . 11-36

Monitoring Ethernet replies . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36

Ethernet PLC-5 Performance Considerations . . . . . . . . . . . . . . . . 11-37

Performance: Host to Ethernet PLC-5 Controller. . . . . . . . . . 11-37

Performance: Ethernet PLC-5 Controller to Ethernet

PLC-5 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38

Protecti ng Your Programs

Programming Considerations

Chapter 12

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

About 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

Chapter 13

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Forcing Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Forcing SFC Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Extended Forcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Increased Program Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

I/O Force Privileges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

Using Protected Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

Using Selectable Timed Interrupts (STIs)

and Controller Input Interrupts (PIIs) . . . . . . . . . . . . . . . . . . . . 13-5

Setting Up and Using Extended Forcing . . . . . . . . . . . . . . . . . . . . . 13-5

Step 1 - Select Which Group of Data You Want to Force . . . . 13-6

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T able of Contents 6

Preparing Power-U p Routi nes

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. . . . . 13-8

Using Special Programming Routines. . . . . . . . . . . . . . . . . . . . . . . 13-10

Priority Scheduling for Interrupts and MCPs. . . . . . . . . . . . . . . . . 13-11

Program Execution States. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12

Influencing Priority Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Defining and Programming Interrupt Routines. . . . . . . . . . . . . . . 13-15

Chapter 14

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Setting Power-Up Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Allowing or Inhibiting Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Defining a Controller Power-Up Procedure. . . . . . . . . . . . . . . . . . . 14-2

Preparing Fault Routi nes

Chapter 15

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Understanding the Fault Routine Concept. . . . . . . . . . . . . . . . . . . . 15-1

Responses to a Major Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Understanding Controller-Detected Major Faults . . . . . . . . . . . . . . 15-2

Fault in a Controller-Resident or Extended-Local I/O Rack . . 15-3

Fault in a Remote I/O Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Defining a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Defining a Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Avoiding Multiple Watchdog Faults. . . . . . . . . . . . . . . . . . . . . . 15-6

Programming a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Setting an Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Clearing a Major Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Changing the Fault Routine from Ladder Logic . . . . . . . . . . . . 15-9

Using Ladder Logic to Recover from a Fault. . . . . . . . . . . . . . 15-10

Block-Transfers in Fault Routines . . . . . . . . . . . . . . . . . . . . . . 15-11

Testing a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Monitoring Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Monitoring Major/Minor Faults and Fault Codes. . . . . . . . . . 15-12

Interpreting Major Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Interpreting Minor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Monitoring Status Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

Publication 1785-UM012D-EN-P - July 2005

Using Main Control Programs

Using Selectable Timed Interrupts

Using Processor Input Interrupts

Table of Contents 7

Chapter 16

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Selecting Main Control Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Understanding How the

Controller Interprets MCPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2

Configuring MCPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3

Monitoring MCPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5

Chapter 17

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Using a Selectable Timed Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Writing STI Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

STI Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2

Block-Transfers in Selectable Timed Interrupts (STIs) . . . . . . . 17-2

Defining a Selectable Timed Interrupt . . . . . . . . . . . . . . . . . . . . . . . 17-3

Monitoring Selectable Timed Interrupts. . . . . . . . . . . . . . . . . . . . . . 17-4

Chapter 18

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

Using a Processor Input Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

Writing PII Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2

PII Application Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2

Block-Transfers in Processor Input Interrupts (PIIs) . . . . . . . . 18-3

Design Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4

Defining a Controller Input Interrupt. . . . . . . . . . . . . . . . . . . . . . . . 18-5

Monitoring Controller Input Interrupts . . . . . . . . . . . . . . . . . . . . . . 18-6

System Specifications

Processor Status File

Appendix A

Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Memory and Channel Specifications. . . . . . . . . . . . . . . . . . . . . . A-2

Memory Backup Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

EEPROM Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Appendix B

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

S:0 - S:2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

S:3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

S:11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

S:12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

S:13-S:24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

S:26-S:35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

S:36-S:78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

S:79-S:127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

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T able of Contents 8

Maximizing System Performance

Appendix C

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 . . . . . . . . C-3

Effects of Using Interrupts on Logic Scan Time. . . . . . . . . . . . . C-3

Effects of Housekeeping Time. . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Editing While in Remote Run Mode . . . . . . . . . . . . . . . . . . . . . . C-4

Putting Block-Transfer Modules in Controller-Resident Chassis C-5

Using Global Status Flag Files . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Calculating Throughput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Input and Output Modules Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

I/O Backplane Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Remote I/O Scan Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6

Communication Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Number of Rack Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

Block-Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Calculating Worst-Case Remote I/O Scan Time. . . . . . . . . . . . . C-9

Optimizing Remote I/O Scan Time. . . . . . . . . . . . . . . . . . . . . . . C-9

Controller Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11

Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12

Performance Effects of Online Operations . . . . . . . . . . . . . . . . . . . C-12

Effect of Inserting Ladder Rungs at the 56K-word Limit. . . . . . . . C-13

Using Program Control Instructions. . . . . . . . . . . . . . . . . . . . . . . . . C-14

Using JMP/LBL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Using FOR/NXT Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . C-14

Instruction Set Quick Reference

Publication 1785-UM012D-EN-P - July 2005

Appendix D

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

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, Message Instructions. . . . . . . . . . . . . . . . . . . D-25

Block Transfer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25

Switch Setting Reference

Table of Contents 9

ASCII Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-27

Bit and Word Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30

File, Program Control, and ASCII Instructions. . . . . . . . . . . . D-32

Appendix E

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Controller Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

I/O Chassis Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

PLC-5 Controller in the I/O Chassis . . . . . . . . . . . . . . . . . . . . . . E-4

1771-ASB Remote I/O Adapter or 1771-ALX

Extended-Local I/O Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

I/O Chassis Configuration Plug. . . . . . . . . . . . . . . . . . . . . . . . . . E-6

Remote I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

(1771-ASB Series C and D) without Complementary I/O . . . . . E-7

(1771-ASB Series C and D) I/O Rack Number -

without Complementary I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

Extended-Local I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . E-9

(1771-ALX) Switch SW1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

(1771-ALX) Configuration Plug . . . . . . . . . . . . . . . . . . . . . . . . . E-10

Troubleshooting

Appendix F

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

PLC-5 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Controller Communication Channel Troubleshooting . . . . . . . . F-4

Extended-Local I/O Troubleshooting. . . . . . . . . . . . . . . . . . . . . F-5

Ethernet Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Ethernet Transmit LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

Remote I/O System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

Troubleshooting Guide for the 1771-ASB Series C and D

Adapter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

Troubleshooting Guide for the 1771-ASB Series C and D

Adapter Module (continued). . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8

Extended-Local I/O System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9

Troubleshooting Guide for the 1771-ALX Adapter Module . . . F-9

Unexpected Operation when Entering Run Mode. . . . . . . . . . . . . . . F-9

Instructions with Unique Prescan Operations. . . . . . . . . . . . . . F-10

Suggested Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

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T able of Contents 10

Cable Reference

Index

Appendix G

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

Channel 0 Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

Serial Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Connecting Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

Programming Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . G-5

Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9

Publication 1785-UM012D-EN-P - July 2005

Using This Manual

Preface

Purpose of This Manual

Related PLC-5 Documentation

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

The following docume nts contain additional i nformation rela ted to the procedures described in this document..

Publication Title Publication Number

Industrial Automation Wiring and Grounding Guidelines 1770-4.1 PLC-5 Programmable Controller Instruction Set Reference 1785-6.1 Configuring Complementary I/O for PLC-5 Controllers 1785-6.8.3 Data Highway Cable Installation Manual 1770-6.2.2 SCADA System Selection Guide, AG-SG001 PLC-5 Protected Controllers Product Data 1785-2.28 PLC-5 Protected Controller Supplement 1785-6.5.13

1 Publication 1785-UM012D - EN-P - July 2005

1771 Remote I/O Adapter Module User Manual 1771-UM001 ControlNet PLC-5 Programmable Controllers User Manual 1785-UM022

To get this documentation, you can either:

• view or download an electronic version from the internet at

www.rockwellautomation.com/literature

• contact y our local di stri but or or Rockwell Auto mation representative to

place an order

Preface 2

Terms Used in This Manual

Term Definition

Block-transfer data data transferred, in blocks of data up to 64 words, to/from a block-

Discrete-transfer data data (words) transferred to/from a discrete I/O module Enhanced PLC-5 controllers references PLC-5/11, -5/20, -5/26, -5/30, -5/40, -5/46, -5/40L,

Ethernet a local area network with a baseband communication rate of 10M

Ethernet PLC-5 controllers references PLC-5/20E, -5/40E, and -5/80E controllers

Become familiar with the following terms and definitions which are used throughout this manual.

transfer I/O module (for example, an analog module)

-5/46L, -5/60, -5/60L, -5/80, and -5/86 controllers PLC-5/26, -5/46, and -5/86 controllers are protected

controllers. See the PLC-5 Protected Controllers Supplement, publication 1785-6.5.13

This term also refers to the PLC-5/V30B, -5/V40B, -5/V40L, and

-5/V80B controllers when applicable. See the PLC-5/VME VMEbus Programmable Controllers User Manual, publication 1785-6.5.9, for more information

bps designed for the high-speed exchange of information between computers and related devices

Extended-local I/O I/O connected to a controller across a parallel link to achieve

higher throughput, thus limiting its distance from the controller

Extended local I/O link a parallel link for carrying I/O data between a PLC-5/40L or -5/60L

controller and extended-local I/O adapters

PLC-5 controller used to generically reference Enhanced PLC-5 and Ethernet PLC-5

controllers in this manual only

Controller-resident local I/O chassis

Remote I/O link a serial communication link between a PLC-5 controller port in

Remote I/O chassis the hardware enclosure that contains an adapter and I/O modules

the I/O chassis in which the PLC-5 controller is installed

scanner mode and an adapter as well as I/O modules that are located remotely from the PLC-5 controller

that are located remotely on a serial communication link to a PLC-5 controller in scanner mode

Publication 1785-UM012D-EN-P - July 2005

Preface 3

Manual Overview

This manual has three main sections:

• Design

• Operate

• Maintain

Section: For information about: See Title:

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

Operate Configuring the controller for controller-resident I/O, transferring data, and

monitoring status Configuring a system for remote I/O communication, designing a remote

I/O link, transferring data, and monitoring status Configuring a PLC-5 adapter channel, transferring data, and

monitoring status For PLC-5/40L, -5/46L, and -5/60L Controllers only: Configuring an

extended-local I/O system, transferring data, and monitoring status Configuring a system for Data Highway Plus™ and monitoring

channel status Configuring a system for serial communications and monitoring

channel status

Chapter 4 Addressing I/O and Controller Memory

Chapter 5 Communicating with Controller-Resident I/O

Chapter 6 Communicating with Remote I/O

Chapter 7 Communicating with a PLC-5

Adapter Channel

Chapter 8 Communicating with Extended-Local I/O

Chapter 9 Communicating with Devices on a DH+ Link

Chapter 10 Communicating with Devices on a

Serial Link

For PLC-5/20E, -5/40E, and -5/80E Controllers only:

Configuring a system for Ethernet communications and monitoring channel status

Assigning passwords and privileges Chapter 12 Protecting Your Programs PLC-5 programming feature overview Chapter 13 Programming Considerations Defining power-up procedure Chapter 14 Preparing Power-Up Routines Defining, programming, and monitoring fault routines Chapter 15 Preparing Fault Routines Configuring and monitoring main control programs Chapter 16 Using Main Control Programs Using, defining, and monitoring selectable timed interrupts Chapter 17 Using Selectable Timed Interrupts Using, defining, and monitoring Controller input interrupts Chapter 18 Using Controller Input Interrupts

Maintain System specifications Appendix A System Specifications

Listing of the controller status file words and meaning Appendix B Controller Status File General and specific performance considerations Appendix C Maximizing System Performance Guide to ladder instructions and execution times Appendix D Instruction Set Quick Reference How to set system switches Appendix E Switch Setting Reference Potential problems and recommended solutions Appendix F Troubleshooting Guidelines for choosing and making cables Appendix G Cable Reference

Chapter 11 Communicating with Devices on an

Ethernet Network

Publication 1785-UM012D - EN-P - July 2005

Preface 4

Notes

Publication 1785-UM012D-EN-P - July 2005

Using This Chapter

Chapter

Understanding Your Programmable Controller

For Information About Go to Page

Lay Out the System 1-1 Identifying controller components 1-2 Programming features 1-10 Using a controller channel as a remote I/O scanner 1-11 Using a controller channel as a remote I/O adapter 1-12 Using a PLC-5/40L, -5/60L programmable controller as an

extended-local I/O scanner

1-14

Lay Out the System

Lay out the system by determining the network configuration and the placement of components in each location. Decide at this time whether each location will have its own controller.

Place each controller’s I/O on an isolated network to maximize the performance and to more ea sily accommodate future network or system configuration changes. If you plan to share I/O, make sure the I/O is on a network that each controller can access.

Assume that Network A and Netw or k B both re quir e a c ontr oller and its I/O. Both controllers interact with time critical information.

RSView

Network C

Panel C

Network B

Panel B chassis 1

Panel B chassis 2

Panel A chassis 1

Network A

Panel A chassis 2

Panel A chassis 3

1 Publication 1785-UM012D - EN-P - July 2005

Panel View

1-2 Understanding Your Programmable Controller

For a PLC-5 controller to control I/O modules, both the contro ller and the I/O modules must be directly attached to the same network.

Identifying Controller Components

I/O Location Controller in

Panel A, 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

Controller in Panel B, chassis 1

Evaluate what communications need to occur between controllers. If there is sporadic information that is not time-critical, use a message-based network such as an EtherNet/IP (the information portion) or Data Highway Plus

To become familiar with the controller’s front panels, use these figures:

For the Front Panels Of Page

PLC-5/11, -5/20 and -5/26 controllers 1-3 PLC-5/30 controllers 1-4 PLC-5/40, -5/46, -5/60, -5/80 and -5/86 controllers 1-5 PLC-5/20E controllers 1-6 PLC-5/40E and -5/80E controllers 1-7 PLC-5/40L and -5/60L controllers 1-8

Publication 1785-UM012D-EN-P - July 2005

Understanding Your Programmable Controller 1-3

PLC-5/11, -5/20, and -5/26 Controll er Front Panels

keyswitch; selects controller mode

channel 0-25-pin D-shell serial port; supports standard EIA RS-232C and RS-423 and is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports controller programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

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)

force indicator (amber when I/O forces are enabled)

channel 0 communication status indicator (green when the channel is communicating)

Install memory module here.

Install battery here

channel 1A status indicator (lights green and red)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; for the PLC-5/11 controller, the default configuration is DH+

channel 1A communication port; this 3-pin port is a dedicated DH+ port

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A

equipment as long as:

termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner remote I/O adapter, DH+ communication unused

channel 1B status indicator (lights green and red)

channel 1B communication port; its default configuration is remote I/O scanner

PLC-5 family member designation

Publication 1785-UM012D - EN-P - July 2005

1-4 Understanding Your Programmable Controller

keyswitch; selects controler mode

channel 1A status indicator (lights green and red)

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)

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

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports processor programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; its default configuration is DH+

channel 1B communication port; its default configuration is remote I/O scanner

Install battery here

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422

equipment as long as:

termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner, remote I/O adapter, DH+ communication unused

channel 1B status indicator (lights green and red)

Install memory module here

Use these labels to write information about the channel: communication mode, station addresses, etc.

PLC-5 family member designation

Publication 1785-UM012D-EN-P - July 2005

keyswitch; selects controller mode

channel 2A status indicator (lights green and red)

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)

force indicator (amber when I/O forces are enabled)

channel 0 communication status indicator (green when the channel is communicating)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 2A when channel 2A is configured for DH+ communications

channel 2A communication port; its default configuration is unused

channel 2B communication port; its default configuration is unused

channel 1A status indicator (lights green and red)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; its default configuration is DH+ at 57.6 kbps

channel 1B communication port; its default configuration is remote I/O scanner

channel 2B status indicator (lights green and red)

channel 0-25-pin D-shell serial port; supports standard EIA RS-232C and RS-423 and is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports processor programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

channel 1B status indicator (lights green and red)

Use these labels to write information about the channel: communication mode, station addresses etc.

Install memory module here

Install battery here

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A equipment as long as:

termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner, remote I/O adapter, DH+ communication unused

PLC-5 family member designation

Publication 1785-UM012D - EN-P - July 2005

1-6 Understanding Your Programmable Controller

external transceiver fuse

keyswitch; selects controller mode

channel 2 Ethernet status indicator (green when functioning normally; red when not functioning)

channel 2 communication port; a 15-pin Ethernet port

channel 0*25-pin D-shell serial port; supports standard EIA RS-232C and RS-423 and is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports controller programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

PLC-5/20E Controller Front Pa ne l

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)

channel 2, Ethernet transmit indicator (green when the channel is communicating)

Install memory module here

Install battery here

channel 1A status indicator (lights green and red)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; its default

configuration is DH+ communication

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A

equipment as long as:

termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner remote I/O adapter DH+ communication unused

Configure this 3-pin port for:

remote I/O adapter DH+ communication

PLC-5/20E

Programmable

Controller

channel 1B status indicator (lights green and red)

channel 1B communication port; its default configuration is remote I/O scanner

PLC-5 family member designation

Publication 1785-UM012D-EN-P - July 2005

external transceiver fuse

keyswitch; selects controller mode

channel 2 Ethernet status indicator (green when functioning normally; red when not functioning)

PLC-5/40E and -5/80E Con troller Front Panels

Understanding Your Programmable Controller 1-7

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)

channel 2, Ethernet transmit indicator (green when the channel is communicating)

channel 2 communication port; a 15-pin Ethernet port

channel 1A status indicator (lights green and red)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; its default configuration is DH+ communication

channel 1B communication port; its default configuration is remote I/O scanner

Install battery here

PLC-5/40E

Programmable

Controller

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A

equipment as long as:

termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner remote I/O adapter DH+ communication unused

channel 0-25-pin D-shell serial port; supports standard EIA RS-232C and RS-423 and is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports controller programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

channel 1B status indicator (lights green and red)

Install memory module here

Use these labels to write information about the channel: communication mode, station addresses etc.

PLC-5 family member designation

Publication 1785-UM012D - EN-P - July 2005

1-8 Understanding Your Programmable Controller

PLC-5/40L and -5/6 0L 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)

keyswitch; selects controller mode

channel 2 extended-local I/O status indicator (green when functioning normally; red when not functioning)

channel 2 communication port; a 50-pin, dedicated extended-local I/O port

channel 1A status indicator (lights green and red)

8-pin mini-DIN, DH+ programming terminal connection parallel to channel 1A

channel 1A communication port; its default

configuration is DH+ communication channel 1B communication port; its default

configuration is remote I/O scanner

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

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports controler programming:

DF1 point-to-point 2400 bps no parity

one stop-bit BCC error check no handshaking

channel 1B status indicator (lights green and red)

Install memory module here

Use these labels to write information about the channel: communication mode, station addresses etc.

Install battery here

Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A

equipment as long as: termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements

Configure these 3-pin ports for:

remote I/O scanner, remote I/O adapter, DH+ communication unused

Publication 1785-UM012D-EN-P - July 2005

PLC-5 family member designation

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 addressed in the ladder program begins operation.)

• Force I/O.

• Save your programs to a disk drive (during operation).

• Enable outputs.

• Edit data table values.

Notes:

• You cannot create or delete a program file, create or delete data files, edit online, or change the modes of operation through the programming software while in run mode.

• You can prevent forcing and data table changes by usingRSLogix5 programming software to set user control bit S:26/6.

• Disable outputs (outputs are turned off).

• Create, modify, and delete ladder files, SFC files, or data

files.

• Download to/from a memory module.

• Save/restore programs.

Notes:

• The controller does not scan the program.

• You cannot change the mode of operation through the

programming software while in program mode.

Change between remote program, remote test, and remote run modes through the programming software.

RUN

PROG

R E M

RUN

PROG (program)

PROG

R E M

RUN

REM (remote)

Remote run

• Enable outputs.

• Save/restore programs.

• Edit while operating.

Remote program

See the program-mode description above.

Remote test

• Execute ladder programs with outputs disabled.

• Cannot create or delete ladder programs or data files.

• Save/restore programs.

• Edit while operating.

PROG

R E M

RUN

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1-10 Understanding Your Programmable Controller

Programming Features

This Capability Lets You

Ladder logic program using a language that is representative of relay logic.

Subroutines store recurring sections of program logic that can be accessed from multiple program

Sequential Function Charts (SFCs)

This table highlights the programming features of a PLC-5 programmable controller.

Choose this language

• 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.

• performing diagnostics

• programming discrete control

files. A subroutine saves memory because you program repetitive logic only once. The JSR

instruction directs the controller to go to a separate subroutine file within the logic controller , scan that subroutine file once, and return to the point of departure.

use sequence-control language to control and display the state of a sequential process. Instead of using one long ladder program for your application, divide the logic into steps

and transitions. A step corresponds to a control task; a transition corresponds to a condition that must occur before the programmable controller can perform the next control task. The display of these steps and transitions lets you see what state the machine process is in at a given time via a flowchart form.

SFCs offer constructs that enable execution of multiple paths of logic, or a single selected path of logic, as well as the ability to jump forwards and backwards.

Troubleshooting can be reduced to a small routine of logic instead of an entire ladder file.

SFCs are best for defining the order of events in a sequential process.

Structured text program using a language similar to BASIC.

Choose structured text if you are:

• more familiar with programming languages such as BASIC than with ladder logic

• using complex mathematical algorithms

• using program constructs that repeat or “loop”

• creating custom data-table monitoring screens

Main Control Programs (MCPs)

separate sequential logic from ladder logic and structured text as a way of modularized your process and making troubleshooting easier.

Use several main control programs (MCPs) to define one main control program for each particular machine or function of your process. MCPs accommodate independent or non-sequential activities.

A main control program can be an SFC file numbered 1-999 or a ladder-logic file or structured-text program numbered 2-999.

One data table is used by all MCPs (i.e., you do not have a separate data table for each MCP).

Publication 1785-UM012D-EN-P - July 2005

Understanding Your Programmable Controll er 1-11

Using a Controller Channel

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

as a Remote I/O Scanner

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. The scanner-mode PLC-5 controller can:

gather data from node adapter devices in remote I/O racks process I/O data from 8-, 16-, or 32-point I/O modules address I/O in 2-, 1-, or 1/2-slot I/O groups support a complementary I/O configuration support block-transfer in any I/O chassis

controller.

PLC-5/40

1771-ASB

Remote I/O Link Cable: Belden 9463

PLC-5/20

The scanner-mode PLC-5 controller:

transfers discrete data and block-transfer data to/from modules in remote I/O racks as well as to/from controllers in adapter mode. scans remote I/O buffers asynchronously to the program scan. updates the input/output image data table from the remote I/O buffer(s) synchronously to the program scan

PLC-5 data table

is updated synchronously to program scan (at housekeeping).

Remote I/O buffers are updated asynchronously to the program scan.

PLC-5 Data Table

Output

Remote I/O Buffer

Output Input

Input

Remote I/O

Link

Controller

-resident I/O

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1-12 Understanding Your Programmable Controller

A controller transfers I/O data and status data using:

Using a Controller Channel as a Remote I/O Adapter

In this example, a PLC-5/40 controller channel is the supervisory (scanner-mode) controller of the 1771-ASB module and the PLC-5/20 controller.

• discrete

data transfers of 8 words per rack

transfers

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

Configure a controller channel for adapter mode when you need predictable, real-time exchange of data between a distributed control adapter-mode controller channel and a supervisory controller. The remote I/O adapter channel exchanges data with a supervisory controller.

PLC-5/40

Connect the controllers via the remote I/O link.

You can monitor status between the supervisory controller and the adapter-mode PLC-5 controller channel at a consistent rate (i.e., the transmission rate of the remote I/O link is unaffected by programming terminals and other non-control-related communications).

The adapter-mode PLC-5 controller can monitor and control its controller-resident local I/O while communicating with the supervisory controller via a remote I/O link.

1771-ASB

Remote I/O Link Cable: Belden 9463

PLC-5/20

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Understanding Your Programmable Controll er 1-13

For Enhanced and Ethernet programmable controller channels in adapter mode, you do n ot ne ed ladder logic i n the a dapter c ontroll er for block- tran sfer instructions. You define the block-transfers via an adapter configuration screen and by defining block-transfer files.

Supervisory Controller

The following programmable controllers can operate as supervisory controllers:

PLC-2/20 and PLC-2/30 controllers PLC-3 and PLC-3/10 controllers PLC-5/15 and PLC-5/25E controllers All Enhanced and Ethernet PLC-5 controllers; separate channels can be configured for a remote I/O scanner and an adapter PLC-5/V30, PLC-5/V40, PLC-5/V40L, and PLC-5/V80 controllers PLC-5/250 controllers

All PLC-5 family controllers, except the PLC-5/10, can operate as remote I/O adapter modules

Remote I/O Link

PLC-5 controller channel in adapter mode

1771 I/O

Remote I/O Link

PanelView

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1-14 Understanding Your Programmable Controller

Using a PLC-5/40L, -5/60L Programmable Controller as an Extended-Local I/O Scanner

A PLC-5/40L or -5/60L controller (channel 2) and an extended-local I/O adapter module (1771-ALX) form an extended-local I/O link.

The extended-local I/O link is a parallel link that enables a PLC-5/40L or -5/60L controller to scan a maximum of 16 extended-local I/O chassis.

Due to the cabling design, you can remove an adapter module from a chassis on the extended-local I/O link without disrupting communication to other chassis on the extended-local I/O link.

Important: The PLC-5/40L and -5/60L controllers cannot be used as extended-local I/O adapters.

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 lin k. 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.

PLC-5/60L

Extended-local I/O Link Cable: 1771-CXx

1771-ALX

ExtendedLocal I/O Link

Input Output

PLC-5 data table

is updated synchronously to program scan (at housekeeping).

Remote I/O buffers

are updated asynchronously to the program scan.

PLC-5 data table

OutputInput

Remote I/O Buffer

OutputInput

Remote I/O

Link

Input Output

ControllerResident Local I/O

Publication 1785-UM012D-EN-P - July 2005

Using This Chapter

Selecting and Placing I/O

For Information About Go to Page

Selecting I/O modules 2-1 Selecting I/O module density 2-2 Placing I/O modules in a chassis 2-3

Chapter

Selecting I/O Modules

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).

• How much I/O is required to control your process(es)?

• Where will you concentrate I/O points for portions of an entire process

when the entire process is distributed over a large physical area?

• What type of I/O is required to control your process(es)?

• What is the required voltage range for each I/O mod ule?

• What is the backplane current required for each I/O module?

• What are the noise and distance limitations for each I/O module?

• What isolation is required for each I/O module?

1 Publication 1785-UM012D - EN-P - July 2005

2-2 Selecting and Placing I/O

Guidelines for Selecting I/O Modules

Choose this Type of I/O Module

Discrete input module and block I/O module

Discrete output module and block I/O module

Analog input module Temperature transducers, pressure transducers, load cell

Analog output module Analog valves, actuators, chart recorders, electric motor

Specialty I/O modules Encoders, flow meters, I/O communication, ASCII, RF type

Selecting I/O Module

For these Types of Field Devices or Operati ons (examples)

Selector switches, pushbuttons, photoelectric eyes, limit switches, circuit breakers, proximity switches, level switches, motor starter contacts, relay contacts, thumbwheel switches

Alarms, control relays, fans, lights, horns, valves, motor starter , or solenoids

transducers, humidity transducers, flow transducers, and potentiometers

drives, analog meters

devices, weigh scales, bar-code readers, tag readers, display devices

The density of an I/O module is the number of controller input or output image-table bits to which it corresponds. A bidirectional module with 8 input

Density

bits and 8 output bits has a density of 8. I/O module density helps determine your I/O addressing scheme. See chapter 4 for more information about I/O addressing.

Explanation

Input modules sense on/off or opened/closed signals. Discrete signals can be either ac or dc.

Output module signals interface with on/off or opened/closed devices. Discrete signals can be either ac or dc.

Convert continuous analog signals into input values for the PLC controller.

Interpret PLC controller output to analog signals (generally through transducers) for field devices.

Are generally used for specific applications such as position control, PID, and external device communication.

Publication 1785-UM012D-EN-P - July 2005

Use these guidelines for selecting I/O module density:

Choose this I/O Density If You

8-point I/O module • currently use 8-point modules

• need integral, separately-fused outputs

• want to minimize cost per module

16-point I/O module • currently use 16-point modules

• need separately-fused outputs with a special

wiring arm

32-point I/O module • currently use 32-point modules

• want to minimize number of modules

• want to minimize the space required for I/O

chassis

• want to minimize cost per I/O point

Selecting and Placing I/ O 2-3

Placing I/O Modules in a Chassis

Module placement priority:

1. block-transfer modules (all types)

2. dc input modules

3. dc output modules

4. ac input modules

5. ac output modules

Place block-transfer modules according to these guidelines:

Place as many modules as possible for which you need fast block-transfer times in your controller-resident local I/O chassis. Place modules in which block-transfer timing is not as critical in remote I/O chassis. Ac output modules should always be the furthest I/O modules away from any block-transfer modules in the same 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:

P L C / A S B

Block Transfer

212334455

Block Transfer

dc inputdcinputdcoutputdcoutputacinputacinputacoutputacoutput

lowV highV

Place input and output modules according to these guidelines:

left to right lowest voltage to highest voltage

For optimal speed using discrete I/O, use the following module-placement priority scheme:

1. controller chassis

2. extended-local I/O chassis

3. remote I/O chassis

empty

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2-4 Selecting and Placing I/O

Notes

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Using This Chapter

Placing System Hardware

For Information About Go to Page

Determining the proper environment 3-1 Protecting your controller 3-3 Avoiding electrostatic damage 3-3 Laying out your cable raceway 3-4 Laying out your backpanel spacing 3-5 Grounding your system 3-6

Chapter

Determining the Proper Environment

Place the controller in an environment with conditions that fall within these guidelines:

Environmental Condition Acceptable Range

Operating temperature 0 to 60° C (32 to 140° F) Storage temperature -40 to 85° C (-40 to 185° F) Relative humidity 5 to 95% (without condensation)

Separate your programmable controller system from other equipment and plant walls to allow for convection cooling. Convection cooling draws a vertical column of air upward over the controller. This cooling air must not exceed 60° C (140° F) at any point immediately below the controller . If the air temperature exceeds 60° C, install fans that bring in filtered air or recirculate internal air inside the enclosure, or install air-conditioning/heat-exchanger units.

To allow for proper convection cooling in enclosures containing a controller-resident chassis and remote I/O chassis, follow these guidelines.

1 Publication 1785-UM012D - EN-P - July 2005

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.

102mm

(4")

Area reserved for disconnect, transformer, control relays, motor starters, or other user devices.

153mm

(6")

51mm

(2")

102mm

(4")

Minimum spacing requirements for a remote I/O and extended-local I/O chassis:

Mount the I/O chassis horizontally. Allow 153 mm (6 in) above and below all

chassis. When you use more than one chassis in the same area, allow 152.4 mm (6 in) between each chassis.

Allow 102 mm (4 in) on the sides of each chassis. When you use more than one chassis in the same area, allow 101.6 mm (4 in) between 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.

153mm (6")

51mm(2")

153mm

Wiring Duct

(6")

Area reserved for disconnect, transformer, control relays, motor starters, or other user devices.

102mm 153mm

(4")

(6")

51mm (2")

Wiring Duct

51mm (2")

13081

Publication 1785-UM012D-EN-P - July 2005

102mm

(4")

102mm

(4")

153mm (6")

Wiring Duct

18749

Placing System Hardware 3-3

Protecting Your Controller

Preventing Electrostatic Discharge

You pro vi d e th e en cl osu r e fo r y o ur cont ro ll er s y st em. This en clo su re pro te ct s your controller system from atmospheric contaminants such as oil, moisture, dust, corrosive vapors, or other harmful airborne substances. To help guard against electromagnetic interference (EM I) and radio fre quency in terference (RFI), we recommend a steel enclosure.

Mount the enclosure in a position where you can fully open the doors. You need easy access to controller wiring and related components so that troubleshooting is c onvenient.

When you choose the enclosure size, allow extra space for transformers, fusing, disconnect switch, master control relay, and terminal strips.

ATTENTION

Under some conditions, electrostatic discharge can degrade performance or damage the controller. Read and observe the following precautions to guard against electrostatic damage.ESD protection

• Wear an approved wrist strap grounding device when

handling the controller.

• Touch a grounded object to discharge yourself before

handling the controller.

• Do not touch the backplane connector or connector

pins.

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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. These guidelines coincide with the guidelines f or “the installation of electrical equipment to minimize electrical noise inputs to controllers from external sources” in IEEE standard 518-1982.

To plan a raceway layout, do the following:

• categorize conductor cables

• rou te conducto r ca b l e s

Categorize Conductors

Segregate all wires and cables into categories as described in the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. See the installation data for each I/O module that y ou are using for inf ormation about its classification.

Route Conductors

To guard against coupling noise from one conductor to an other, follow the general guidelines for routing cables described in the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. You should follow the safe grounding and wiring practices called out in the National Electrical Code (NEC, published b y the National Fire Protection Association, in Quincy, Massachusetts), and local electrical codes.

Publication 1785-UM012D-EN-P - July 2005

Placing System Hardware 3-5

Laying Out Your Backpanel Spacing

1771-A1B 1771-A2B 1771-A3B1 1771-A4B

Power Connector

193mm (7.60")

Side

Use 6.35 mm (0.25 inch) mounting bolts to attach the I/O chassis to the enclosure backpanel.

Chassis Dimensions (Series B)

315mm

(12.41")

591mm (23.25")

337mm (13.25")

464mm (18.25")

210mm (8.25")

16-slot 1771 12-slot 8-slot

4-slot

254mm

(10")

1771-A3B

171mm (6.75")

217mm (8.54")

Side

Total maximum depth dimension per installation will be dependent upon module wiring and connectors.

339mm (13.53")

483mm (19.01")

229mm (9.01")

465mm (18.31")

484mm (19")

Front

610mm (24.01")

356mm (14.01")

16-slot 1771-A4B 12-slot 1771-A3B1 8-slot 1771-A2B

4-slot 1771-A1B

9mm (.34")

26mm (1.02")

178mm (7")

130mm (5.10")

12450-I

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3-6 Placing System Hardware

I/O Chassis and External Power Supply Dimensions

591mm

Use .25" dia

mounting bolts

(4 places)

315mm

(12.41")

Clearance depth is 204mm (8") for 8 I/O connection points per module.

External Power Supply

91mm (3.6")

(23.25")

337mm (13.25")

483mm (19.01")

229mm

(9.01")

464mm (18.25")

210mm (8.25")

610mm

(24.01")

356mm

(14.01")

16-slot 12-slot

8-slot 4-slot

254mm

(10")

16-slot 1771-A4B

12-slot 1771-A3B1

8-slot 1771-A2B 4-slot 1771-A1B

12451-I

Grounding Your System

Publication 1785-UM012D-EN-P - July 2005

For more information on proper grounding guidelines, see the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

Placing System Hardware 3-7

Enclosure Enclosure

Recommended Grounding Configuration for Remote I/O Systems

Enclosure

Ground Bus

Grounding Electrode Conductor

To Grounding Electrode System

I/O Chassis Wall

Star Washer

Ground Lug

Nut

15561

Required Grounding Con f i guration for Extended-Local I /O Systems

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

Publication 1785-UM012D - EN-P - July 2005

3-8 Placing System Hardware

Notes

Publication 1785-UM012D-EN-P - July 2005

Using This Chapter

Chapter

Addressing I/O and Controller Memory

For Information About Go to Page

I/O addressing concept 4-1 Choosing an addressing mode 4-3 Addressing block-transfer modules 4-7 Addressing summary 4-7 Assigning racks 4-8 Understanding PLC-5 controller memory 4-10 Addressing 4-16 Effectively Using I/O Memory 4-24

I/O Addressing Concept

Classification Term Relation to Controller Memory

A specific terminal on an I/O module that occupies a space in controller memory

I/O terminals that when combined occupy 1 word in controller’s input image table and 1 word in the controller’s output image table.

Controller memory needs to be grouped so that related I/O groups can be considered a unit.

Since the main purpose of a programmable controller is to control inputs and outputs of field devices like switches, valves, and thermocouples, these inputs and outputs must occupy a location in the controller memory so that they can be addressed in your control program. Each terminal on an input or output module that can be wired to a field device occupies a bi t within controll er memory. The part of controller memory that houses I/O addresses is the input image table and the output image table.

I/O addressing helps connect the physical location of an I/O module terminal to a bit location in the controller memory. I/O addressing is just a way to segment controller memory. The segmentation is as follows:

terminal or point

I/O group 16 input bits = 1 word in controller’s input image table

I/O rack 128 input bits and 128 output bits, or8 input words and 8 output words,

The density of an I/O module, i.e., 8-point, 16-point, 32-point, directly relates to the amount of memory (bits) the module occupies in controller memory. For example, a 16-point input module occupies 16 bits in the controller’s input image table.

16 output bits = 1 word in the controller’s output image table

or 8 I/O groups

1 Publication 1785-UM012D - EN-P - July 2005

Each PLC-5 controller has a finite amount of racks it can support. For example, a PLC-5/30 can support 8 I/O racks. The controller always occupies at least one I/O rack for itself, rack 0 by default.

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.

I/O Addressing as It Relates to an I/O Terminal

rack number 01

I/O group number 4

A B C

D 00 01 02 03 04 05 06 07 10 11 12 13 14 15

16 17

Input Module

(1771-IAD)

17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00

Output Image Table

17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00

Input Image Table

17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00

I/O group number 5

word address

rack number 01

Output Module

(1771-OAD)

A B C D 00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

Notice how input and output image file addresses correspond to hardware.

Publication 1785-UM012D-EN-P - July 2005

I:014

| | ( )

O:015

I:014/12

I for input or O for output 2-digit I/O rack number I/O group number (0-7) input or output number (0-7,10-17) (bit)

I/O image table is addressed octally.

Now that you are familiar with how controller memory is segmented to address a specific I/O term inal, the next section explains available addressing modes. These modes let you define the relationship between an I/O chassis slot and an I/O group (16 input bits and 16 output bits).

Addressing I/O and Con troller Memory 4-3

Choosing an Addressing

For each I/O chassis in your syst em, you must define how man y I/O chassis slots make up an I/O group (1 word each in the input image table and output

Mode

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.

16 bits input 16 bits output

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.

Controller memory

Rack x

Output Image Table

Word #

x x x x x x x x

16 bits input and 16 bits output

1/2-slot addressing

1/2 of an I/O chassis slot = 1 I/O group = 1 input image word and 1 output image word = 16 input bits and 16 output bits.

16 bits input and 16 bits output

When you place your I/O modules in the I/O chassis slots, the module’s density determines how quickly I/O groups form. For example, let’s choose 1-slot addressing and see how 8-, 16-, and 32-point I/O modules fill controller memory.

Word #

Input Image Table

x x x x x x x x

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4-4 Addressing I/O and Controller Memory

0 1

18-and 16-point Example

2 3

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.)

Controller memory

Rack x

Input Terminals

00 01 02 03 04 05 06 07

Group 0

An 8-point I/O module occupies 8 bits in a word. See

4 5

Input Termi nals

10 11 12 13 14 15 16 17

Input Terminals

00 01 02 03 04 05 06 07

Group 2 Group 3

Two 8-point input modules occupy 8 bits of each group. See

6 7

Input Terminals

00 01 02 03 04 05 06 07

Word #

Output Image Table

0 1 2 3 4 5 6 7

0017 bits

Input Image Table

0 1 2 3 4 5 6 7

0017 bits

Input Terminals

00 01 02 03 04 05 06 07

Output Terminals

Group 4 Group 5 Group 6 Group 7

An 8-point input module in group 4 occupies the first eight bits of input word 4. The 8 point output module occupies the first 8-output bits in output word 5. See

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Input Terminals

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

Output Terminals

16-point I/O modules occupy 16 bits, an entire word, in the image table. See

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

If you were to address the device attached to this output circuit in your control program, the address would be O:xx7/17.

32-point input module

0 1

Addressing I/O and Con troller 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.)

Controller memory Rack x

32-point input module

Group 0

32-point I/O modules use the entire word of their group and borrow the entire word of the next group. See .

1 Since the module is in group 0 and the inputs for group 0 and group 1 are used, you must: install an output module in group 1 or leave the slot empty

0 1

32-point output module

Since the input image table for group 1 is unavailable because it is being used by the input module of group 0, installing a 32-point output module makes use of output image table of group 0 and 1. See . You can also install 8- or 16-point output modules. But you cannot install another input module since all the input image space for groups 0 and 1 are used by the input module of group 0.

Word #

Output Image Table

0 1 2 3 4 5 6 7

0017 bits

Input Image Table

0 1 2 3 4 5 6 7

0017 bits

Group 0 Group 1

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4-6 Addressing I/O and Controller Memory

When planning your system de sign, con sider the dens ities o f the I/O mo dules 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.)

Controller memory Rack x

Input Terminals

00 01 02

03 04 05 06

07 10 11

Output Terminals

00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17

Group 0

16-point I/O modules occupy 16 bits, an entire word, in the image table.

Installing as a pair a 16-point input module and a 16-point output module efficiently uses the image table.

Define the addressing mode for each I/O chassis by setting the chassis backplane switch assembly. For more informa tion, see Appendix E.

Word #

Output Image Table

0 1 2 3 4 5 6 7

0017 bits

Input Image Table

0 1 2 3 4 5 6 7

0017 bits

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Addressing I/O and Con troller Memory 4-7

Addressing Block-Transfer Modules

Addressing Summary

Addressing Mode Guidelines

2-slot • Two I/O module slots = 1 group

1-slot • One I/O module slot = 1 group

1/2-slot • One half of an I/O module slot = 1 group

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.

To Address Use

single slot modules assigned I/O rack and group number of the slot in which the

module resides and 0 for the module number When using 1/2-slot addressing, use the assigned rack

number and the lowest group number and 0 for the module number.

double-slot modules assigned rack number and the lowest group number and 0 for

the module number

Use this table as a quick reference for addressing.

• Each physical 2-slot I/O group corresponds to one word (16 bits) in the input image table and one word (16 bits) in the output image table

• When you use 16-point I/O modules, you must install as a pair an input module and an output module in an I/O group; if you use an input module in slot 0, you must use an output module in slot 1 (or it must be empty). This configuration gives you the maximum use of I/O.

• You cannot use a block-transfer module and a 16-point module in the same I/O group because block-transfer modules use 8 bits in both the input and output table. Therefore, 8 bits of the 16-point module would conflict with the block-transfer module.

• You cannot use 32-point I/O modules.

• Assign one I/O rack number to eight I/O groups.

• Each physical slot in the chassis corresponds to one word (16 bi ts) in the input image table and

one word (16 bits) in the output image table

• When you use 32-point I/O modules, you must install as a pair an input module and an output module in an even/odd pair of adjacent I/O group; if you use an input module in slot 0, you must use an output module in slot 1 (or it must be empty). This configuration gi ves you the maximum use of I/O.

• Use any mix of 8- and 16-point I/O modules, block-transfer or intelligent modules in a single I/O chassis. Using 8-point modules results in fewer total I/O.

• Assign one I/O rack number to eight I/O groups.

• Each physical slot in the chassis corresponds to two words (32 bits) in the input image table

and two words (32 bits) in the output image table

• Use any mix of 8-, 16-, and 32-point I/O or block-transfer and intelligent modules. Using 8-point and 16-point I/O modules results in fewer total I/O.

• 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.

• Assign one I/O rack number to eight I/O groups.

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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 1/4 rack 1/2 rack 1 rack 8-slot 1/2 rack 1 rack 2 racks 12-slot 3/4 rack 1-1/2 racks 3 racks 16-slot 1 rack 2 racks 4 racks

TIP

2-slot Addressing, Results In

1-slot Addressing, Results In

1/2-slot Addressing, Results In

When assigning rack numbers, use the following guidelines:

• One I/O rack number is eight I/O groups, regardless of

the addressing mode that you select.

• You can assign from one to four racks in your

controller-resident local chassis (128 inputs and 128 outputs) de pending on the chassis size and addressing

mode. You cannot split a controller-resident local I/O rack over two or more chassis or assign unused controller- r esident local I/O groups t o r emote I/O racks.

• The default address of the controller-resident local rack is

• You cannot split racks across remote I/O and

extended-local I/O links. For example, if an 8-slot extended-local I/O chassis is configured as I/O groups 0-3 of I/O rack 2, an 8-slot remote I/O c hass is ca nnot b e configured as I/O groups 4-7 of I/O rack 2. For more information about addressing extended-local I/O, see chapter 8.

• When using complementary I/O addressing, treat

complementary rack addresses individually when grouping racks; primary rack numbers are separate from complement rack numbers.

• If you are not using the autoconfiguration function, group

together 1/4-racks and 1/2-racks of each logical rack on the configuration screen of your programming software. Do not intersperse these with other rack numbers. For example, your programming software has a screen with the following information for defining racks:

Group together 1/4 racks and 1/2 racks

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Rack Starting Rack Range Fault Inhibit Reset Retry Address Group Size

1 0 1/4 010-011 I 0 0 1 2 1/4 012-013 0 0 0 1 4 1/4 014-015 0 0 0 2 0 1/4 020-021 0 0 0 2 2 1/4 022-023 0 0 0 2 4 1/2 024-027 0 0 0 3 0 1/4 030-031 0 0 0 17 0 FULL 170-177 0 0 0

Addressing I/O and Con troller Memory 4-9

TIP

When assigning remote I/O rack numbers, use these guidelines:

• 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. For example, if you select 1/2-slot addressing for your controller-resident local chassis and you are using a 16-slot (1771-A4B) chassis, the controller will address racks 0, 1, 2, and 3 in this chassis.

• You can assign a remote I/O rack to a fraction of a chassis, a single I/O chassis, or multiple I/O chassis as shown below.

I/O Rack No. 0 01 23 45 67 01 23 45 67 01234567

I/O Rack No. 1

One 16-slot chassis, two racks

I/O Rack No. 3

0123

One 8-slot chassis, 1/2 rack Two 4-slot chassis, 1/4 rack each

One 16-slot chassis, one rack

16466

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4-10 Addressing I/O and Controller Memor y

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. These storage areas store:

• Data received from input modules

• Data to be sent to output module s; thi s data repr ese nt s decis ions mad e by the logic

• Intermediate results made by the logic

• Preloaded data such as presets and recipes

• Control instructions

•System status

Program Files You create files for program logic, depending on the method you are using:

ladder logic, sequential function charts, and/or structured text. These files contain the instructions to examine inputs and outputs and return results.

Publication 1785-UM012D-EN-P - July 2005

Integer

Files

File 7

Integer Data Table Files

File #

Integer

File 7

File 999

Words

(Sample Data)

1020

7779

Addressing I/O and Controller Memory 4-11

Understanding Data Storage (Data-Table Files)

The controller divides data storage into:

• 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.

• You can create multiple files of a given type. Files let you group and

organize logically related data. When you need to access data, you specify the file in which the data is stored.

• Some types of files are made up of 16-bit words. Floating-point words

are 32 bits. When you need to access this data, you specify it with a formatted address.

Integer

File

276

Timer File #

Timer #

Natural binary bit pattern for 276

(decimal format)

0 0 0 0 0 0 1 0 0 0 1 0 1 0 0

structure members

.EN .TT .DN

File #

Starting addr

(Length)

Starting addr

(Length)

Starting addr

(Length)

up to 1000

words

2760

432

preset .PRE accumulated .ACC

recipe "A" data

recipe "B" data

production counts

• Each word contains multiple bits. This is the smallest division of data.

A bit contains a value of zero or one. When you need to access this data, you specify it with a formatted address.

• Som e types of files are divided into structures used to control

instruction elements. These structures are subdivided into members at the bit or word level. When you need to access this data, you specify it with a formatted address.

Y ou can also organize data within files into data blocks to group and organize logically related data. When you need to access this data, you specify only the starting address within the file (and length) instead of each individual address.

When you organize data, group data by similar kind, such as:

• results of calculations

• batch recipes

Because of the structure of block-transfer instructions, you must group data such as:

• inputs from analog modules

• outputs to analog modules

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4-12 Addressing I/O and Controller Memor y

TIP

IMPORTANT

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

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. Each unused file , how ever , uses 6 wo rds of ov erhead memory for each data/program file you skip. Use care when leaving gaps.

Follow these guidelines when organizing data files:

• Group large amounts of related data into files.

• Address the data files from 3-999 as needed.

(See on page page 13).

• Address the words needed in each data file

consecutively from 0-999 (0-1999 for some data types in series E, revision D controllers and la ter).

• Address the words of I/O image data according to how

you configured your I/O:

– 0-37 (octal) for PLC-5/11, -5/20, -5/20E – 0-77 (octal) for PLC-5/30 – 0-177 (octal) for PLC-5/40, -5/40L, -5/40E – 0-277 (octal) for PLC-5/60, -5/60L, -5/80, -5/80E

• When addressing I/O image bits, address them 00-07

or 10-17 (octal).

• When organizing bit data, address the bits in each word

0-15 (decimal) for binary or integer files.

Each data table file allocates 6 words of memory when you create the file. This is in addition to any data stored in the file.

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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.

Data T able File Types and Memory Usage for PLC-5 Controllers Se riesE/Revision D and Later

File Type File-Type

Identifier

File Number

Maximum Size of File 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 32 64 128 192 6 1/word Status S 2 128 128 128 128 6 1/word Bit (binary) B

Timer T Counter C Control R Integer N Floating-point F

2000 words 6 1/word 6000 words/2000 structures 6 3/structure 6000 words/2000 structures 6 3/structure 6000 words/2000 structures 6 3/structure 2000 words 6 1/word 4000 words/2000 structures 6 2/structure

ASCII A 3-999 2000 words 6 1/2 per character BCD D 3-999 2000words 6 1/word Block-transfer BT 3-999 12000 words/2000 structures 6 6/structure Message MG 3-999 PID PD 3-999

32760 words/585 structures 32718 words/399 structures

6 56/structure 6 82/structure

SFC status SC 3-999 6000 words/2000 structures 6 3/structure ASCII string ST 3-999

32760 words/780 structures

Unused -- 9-999 6 6 0

This is the default file number and type. For this file type, you can assign any file number from 3 through 999.

The maximum size of a data table file is 32K words. Th e maximum size of the entire data tabl e is 64K words

6 42/structure

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4-14 Addressing I/O and Controller Memor y

Data Table File Types and Memory Usage for PLC-5 Con troll ers Seri esE/Revision C and Earlier

File Type File-Type

Identifier

File Number

Maximum Size of File 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 32 64 128 192 6 1/word Status S 2 128 128 128 128 6 1/word Bit (binary) B

Timer T Counter C Control R Integer N Floating-point F

1000 words 6 1/word 3000 words/1000 structures 6 3/structure 3000 words/1000 structures 6 3/structure 3000 words/1000 structures 6 3/structure 1000 words 6 1/word 2000 words/1000 structures 6 2/structure

ASCII A 3-999 1000 words 6 1/2 per character BCD D 3-999 1000words 6 1/word Block-transfer BT 3-999 6000 words/1000 structures 6 6/structure Message MG 3-999

PID PD 3-999

32760 words/585 structures 32718 words/399 structures

6 56/structure 6 82/structure

SFC status SC 3-999 3000 words/1000 structures 6 3/structure ASCII string ST 3-999

32760 words/780 structures

6 42/structure

Unused -- 9-999 6 6 0

This is the default file number and type. For this file type, you can assign any file number from 3 through 999.

The maximum size of a data tab le file is 32K words. The maximum size of the entire data table is 64K words

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Addressing I/O and Controller Memory 4-15

Valid Data Types/Values Are:

This Data Type/Value Accepts Any

Immediate (program constant)

Integer Integer data type: integer, timer, counter, status, bit, input, output, ASCII, BCD, control (e.g., N7:0, C4:0, etc.) Float

Block Block-transfer data type (e.g., BT14:0) or integer data type (e.g., N7:0) Message Message data type (e.g., MG15:0) or integer data type (e.g., N7:0) PID PID data type (e.g., PD16:0) or integer data type (e.g., N7:0) String String data type (e.g., ST12:0) SFC status SFC status data type (e.g., SC17:0)

Value between -32768 and 32767 (Constants greater than 1024 use 2 storage words of memory; floating point constants use 3 words of memory.)

Floating point data type (valid range is + 1.175494e

-38

to +3.402823e

+38

) with 7-digit precision

Understanding Program-File Storage

Create program fi les based on the programmin g method you are using. This table lists the number of words used by each type of program file:

Program File Number of Words Us ed

Ladder 6/file + 1/word SFC 6/file Structured Text 6/file + 1/word

The more program f iles that you create, the longer the controller takes to perform certain tasks, e.g., going to run mode, performing online editing, saving a pro gram. Also, certain instructions (JMP, LBL, FOR, and NXT) ha ve longer execution times in higher program file numbers.

Series E PLC-5 controllers support 2000 program files to allow for more SFC steps in your program. SFC step/transition program files are typically shorter in length. This enhancement will effectively double your SFC step/transition size.

Each program file you create is allocated 6 words of memory. This memory is in addition to any p rogramming within the fi le. If you create the maximum program file number 1999, this allocates 12,000 words of memory to the program files, which reduces the amount of controller memory left for programming.

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4-16 Addressing I/O and Controller Memor y

Addressing

Valid formats for addressing data files are:

If You Want to Access Use this Addressing Format And See Page

Input or output bit in the I/O image table I/O image address 4-16 Bit, word, sub-member, data block, file, or I/O image bit Logical address 4-17 A component within a logical address by substituting the

Indirect address 4-18

value in another address An address offset by some number of elements Indexed address 4-20 A substitute name for an address Symbolic address 4-21

For more information about entering addresses, see the documentation for your programming softw ar e.

Specifying I/O Image Addresses

The I/O image address corresponds to the physical location of the I/O circuit in the I/O chassis:

a I/O address identifierI = input device

O = output device

bb I/O Rack numberPLC-5/11, -5/20, -5/20E00-03 (octal)

PLC-5/3000-07 (octal) PLC-5/40, -5/40L, -5/40E00-17 (octal)

PLC-5/60, -5/60L, -5/80, -5/80E00-27 (octal) c I/O Group number0-7 (octal) dd Terminal (bit) number00-17 (octal)

To Specify this

Example

Address

Input Image Bit

I for input 2-digit I/O rack Number I/O group number (0-7) Input number (0-7, 10-17)

Output Image Bit

O for output 2-digit I/O rack Number I/O group number (0-7) Output number (0-7, 10-17)

I:017/01

O:017/01

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Addressing I/O and Controller Memory 4-17

Specifying Logical Addresses

The format of a logical address co rresponds directly to the location in data storage: # X F : e . s / b

Where Is the

# File address. Omit for bit, word, and structure addresses (also indicates indexed addressing, see next

page)

X File type:B—binaryN—integerT—timerMG—message

C—counterO—outputA—ASCIIPD—PID F—floating pointR—controlD—BCDSC—SFC status I—inputS—statusBT—block-transfer ST—ASCII string

F File number:0—output

1—input 2—status

3-999—any other type : colon or semicolon delimiter separates file and structure/word numbers e Structure/word number:0-277octal for input/output files

up to:0-127decimal for the status file

0-999for all the file types except MG, PD, and ST files . Period delimiter is used only with structure-member mnemonics in counter, timer and control files s Structure/member mnemonic is used only with timer, counter, control, BT, MG, PD, SC, and ST files / Bit delimiter separates bit number b Bit number:00-07 or 10-17 for input/output files

00-15 for all other files

00-15,999 for binary files when using direct bit address

To Specify the Address of a Use these Parameters

File

File Type File Number

Word within an integer file

File Type File Number File Delimiter Word Number

Bit within an integer file

File Type File Number File Delimiter Word Number Bit Number

9N:2

9N : 2 / 5

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4-18 Addressing I/O and Controller Memor y

To Specify the Address of a Use th es e Parameter s

Bit within a binary file

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.

B3/245

Bit within a structure file

File Type File Number File Delimiter Structure Number Member Delimiter Member Mnemonic

R6:7.DN

Y ou can also use mnemonics to address members at the w ord or bit lev el. The available mnemonics depend on the type of data (timer, counter, or control) and the program instruction. For example:

Instruction Type Word Level Example Bit Level Example

Timer TON, TOF, RTO

preset .PRE accumulated.ACC

T4:1.PRE enable.EN

timing.TT

T4:0.EN

done.DN

For information about the mnemonics for a specific instruction, see chapter 22 of the PLC-5 Programming Controller Instruction Set Reference, publication 1785-6.1.

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Specifying Indirect Addresses

ATTENTION

The controller uses the value from the pointer address to form the indirect address. You can use ladder logic to change the value stored at that substitute address.

When using indirect addressing, make sure tha t th e indirect address points to a valid data file or element. During Run mode, if ladder execution encounters an invalid or out-of-range indirect address, a run-time error occurs and the controller halts.

Addressing I/O and Controller Memory 4-19

When you specify indirect addresses, follow these guidelines:

• You can indirectly address the file number, word n umber, 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 Variable Explanation

N[N7:0]:0 File number The file number is stored in integer address

N7:0.

N7:[C5:7.ACC] Structure number The word number is the accumulated value

of counter 7 in file 5. B3/[I:017] Bit number The bit number is stored in input word 17. N[N7:0]:[N9:1] File and word number The file number is stored in integer address

N7:0 and the word number in integer

address N9:1.

ATTENTION

If you indirectly address the input or output image table, the value you specify in the integer file that you use for the indirection (the pointer) is converted to octal when executed by the instruction.

For example, if y ou enter O:[N7:0] and N7:0 contains the value 10, the v alue at N7:0 is converted to octal and the resulting address is O:012, not O:010.

To monitor for invalid indirect addresses, condition the rung with the indirect address with a limit test of the indirect address to ensure that the address stays within the intended range. This is especially advisable if the PLC-5 controller has no control over the indirect address, such as the value is determined by values from an I/O module or a peer controller.

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4-20 Addressing I/O and Controller Memor y

Specifying Indexed Addresses

The controller star ts 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.

When you specify indexed addresses, follow these guidelines:

• Make sure the index value (positive or negative) does not cause the

indexed address to exceed the file-type boundary.

ATTENTION

The controller does not check indexed addresses to make sure that the addresses do not cross data-table file boundaries (e.g., N7 to F8). You could even modify the status file, which is physically the last data table file. But if the indexed address exceeds the data-table area of memory, the controller initiates a run-time error and sets a major fault.

• When an inst ruction uses more than two indexed addresses, the

controller uses the same index value for each indexed address.

• Set the offset word to the index value you want immediately before

enabling an instruction that uses an indexed address.

MVM MASKED MOVE

Source Mask Destination #N11:5

Publication 1785-UM012D-EN-P - July 2005

#N7:10

00110011

ATTENTION

Instructions with a # sign in an address manipulate the offset value stored at S:24. Make sure you monitor or load the offset value you want prior to using an indexed ad dress. Otherwise unpredictable machine operation could occur with possible damage to equipment and/or injury to personnel.

The following MVM example uses an indexed address in the source and destination addresses. If the offset value is 10 (stored in S:24), the controller manipulates the data stored at the base address plus the offset.

Value Base Address Offset Address

Source N7:10 N7:20 Destination N11:5 N11:15

Addressing I/O and Controller Memory 4-21

Specifying Symbolic Add r esses

When you specify symbolic address, follow these guidelines:

• Star t 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.

IMPORTANT

Symbols are a feature of the programming software (not the controller) and are st ored in a database on the hard disk of the personal computer you are using. If you use a terminal other than the one on which you defined the symbols, you will not have access to the symbol database.

Example Logical Address Symbolic Address

Input image (bit)

Output image (bit)

Word F10:0

I:015/00 I:015/03 I:015/06

O:013/00 O:013/02 O:013/04

F10:1

LS1 AUTO1 SW1

M1 CL1 L1

Calc_1 Calc_2

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4-22 Addressing I/O and Controller Memor y

Optimizing Instruction Execution Time and Controller Memory

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. Address element instructions between the end of the input image and physical word 2048. Addresses stored in words greater than 2048 require more words in the controller's memory for storage.

frequently used bit addresses

frequently used element addresses

PLC-5/11,

-5/20, -5/20E

Physical Word # Physical Word # Physical Word #

0-31

32-63

PLC-5/30

Physical Word #

0-63

32-127

word 256

word 2048

PLC-5/40, -5/40L

For the bes t instruction-execution performance, s tor e y our most frequently used addresses as shown below:

PLC-5/60, -5/60L

-5/40E

0-127

32-255

-5/80, -5/80E

0-191

32-383

File Type

output image

input image

binary, timer, counter, control, integer, floating point

block transfer, message, PID, SFC status, ASCII string

Default File #

3-999

according to your

application

Publication 1785-UM012D-EN-P - July 2005

status

The minimum size of the file is 32 words.

The status file is always the last physical file in the data table.

The following examples illustrate these concepts:

Bit address example

If your data table map looks like this:

O 32 I 32 B 64 T 32 C 32 R 32 N 32

256

end

This example uses the instruction timing and memory usage tables in Appendix D. Consult these tables for information about other instructions.

An address used in an OTE instruction stored here: occupies one word in the controller's memory executes at a rate 0.48µs

The same address stored here: occupies two words in the controller's memory executes at a rate 0.64µs

Addressing I/O and Controller Memory 4-23

OTE

OTE XX

Element address example

our data table map looks like this:

O 64 I 64 B 1000 T 100 C 100 N 720

This example uses the instruction timing and memory usage tables in Appendix D. Consult these tables for information about other instructions.

Addresses used in a MOV instruction stored here occupy three words in the controller's memory.

2048

The same addresses stored here occupy five words in the controller's memory.

end

MOV N7:0

N7:1

MOV N100:0

N100:1

123

MOV XX YY

12345

MOV XX XX YY YY

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4-24 Addressing I/O and Controller Memor y

Effectively Using I/O 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.

Use Application

2-slot Install 16-point I/O modules as an input module and output module pair in

an I/O group. For example, if you place an input module in slot 0, place an output module in slot 1.

1-slot Install 32-point I/O modules as an input module and an output module

pair in an I/O group. For example, if you place an input module in slot 0, place an output module in slot 1.

complementary I/O chassis You configure complementary chassis with a primary and complement

chassis pair . You complement the I/O modules I/O group for I/O group between the two chassis. The I/O modules in the complementary chassis perform the opposite function of the corresponding modules in the primary chassis.

By designating a PLC-5 scanner channel as complementary, you can complement racks 1-7. A channel configured for complementary I/O can’t scan racks greater than 7. Those PLC-5 controllers that can address rack numbers greater than 7 can address these racks on another scanner channel which has not been configured as complementary. The remote I/O link device (such as a1771-ASB adapter) must also be configured for complimentary.

For more information see the PLC-5 Reference Guide: Configuring Complementary I/O for PLC-5 Controllers, publication 1785-6.8.3.

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Using This Chapter

Chapter

Communicating with Controller-Resident I/O

For Information About Go to Page

Introduction to PLC-5 controller scanning 5-1 Program scanning 5-2 T r ans ferring data to controller-resident I/O 5-3 Configuring the system for controller-resident I/O 5-4

This chapter explains how to configure the controller to communicate with resident I/O:

1. Set the I/O chassis switch for th e addressing mode.

Introduction to PLC-5 Controller Scanning

read the status of various input devices

(such as pushbuttons and limit switches)

make decisions via a control program like ladder logic based on the status of

those devices

2. Set the rack address.

The rack address defaults to 0. If you want to change the rack address to 1, set bit S:26/2.

The basic function of a prog rammable-controller system is to:

set the status of output devices (such as lights, motors, and

heating coils)

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5-2 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

During logic scan, inputs are read from and outputs are written to the I/O image table.

During housekeeping, data exchange occurs between the I/O image table and the remote I/O buffer, extended local I/O, and controller-resident rack.

Remote I/O

Buffer

I/O Scan

Data

Exchange

Extendedlocal I/O

I/O Image

Table

Controller-

Resident

Rack

Data

Exchange

Data

Exchange

a write outputs

Update

I/O image

Housekeeping

Logic

Scan

Program Scanning

Housekeeping

Logic Scan

b read inputs

Program Scan

The program scan is the time it takes the controller to execute the logic program once, perform housekeeping tasks, and then start executing logic again.

The controller continually performs a logic program scan and housekeeping. Housekeeping activities for PLC-5 controllers include:

• performing controller internal checks

• updating the input image table with:

– controller-resident input module data – remote input module data as contained in the remote I/O buffer – extended local I/O input module data

• sending output image table data to:

– controller-resident output modules – remote I/O buffer – extended local I/O output modules

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Communicating with Controller-Resident I/O 5-3

Transferring Data to Controller- Resident I/O

The controller scans controller-resident local I/O synchronously and sequentially to the program scan.

The controller-resident rack exchanges discrete I/O information with the I/O image table during housekeeping.

A PLC-5 controller transfers discrete and block-transfer data with controller-resident I/O.

Transferring Discrete Data to Controller-Resident I/O

Immediate I/O

I/O Image

Table

Controller-

x y

Resident

Rack

Data

Exchange

a write outputs

Update

I/O image

See explanation below.

Housekeeping

Logic

Scan

IOT (x) IIN (y)

b read inputs

Program Scan

Transferring Immediate I/O Requests

The controller responds to immediate input (IIN) and immediate output (IOT) requests during the logic scan. The logic scan is suspended at the request for immediate input/output data. The logic scan resumes after obtaining the data and fulfilling the request.

IIN data transfers directly to and IOT data transfers directly from I/ O modules in controller-resident I/O and extended-local I/O chassis. With remote I/O, only the remote I/O buffer is updated. For more information, see Appendix D.

TIP

When you place I/O modules, do not place a block-transfer module next to or in the same module group as an input module that you plan to use for immediate I/O. Place the modules in non-adjacent slots. Placing input modules for immediate I/O next to block- transfer modules can result in a -5 Block-Transfer Read error.

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5-4 Communicating with Controller-Resident I/O

If your application cann ot support this configuratio n, condition t he 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.

Transferring Block-Transfer Data to Controller-Resident I/O

The controller performs block-transfers at the same time as it scans the program.

Block-transfers to controller-resident local I/O follow these procedures:

• Block-transfer requests are queued for the addressed controller-resident

local I/O rack.

• The active buffer continuously handles all block-transfer modules

whose block-transfer instructions were enabled in the program scan via the queue scan in the order the requests were queued.

• Block-transfers of I/O data can finish and the done bit can be set

anytime during the program scan.

Configuring the System for Controller-Resident I/O

The controller runs all enabled block-transfers of I/O data to controller-resident I/O continuously as each block-transfer request enters the active buffer.

Housekeeping

Interrupt from STI or Fault Routine

Program Scan

Controller-

Resident Rack 0

Multiple Block Transfers

Q = queue A = active buffer (block-transfer data buffered here)

Q A

BTR or BTW Data

To configure the system for controller-resident local I/O, you need to set the I/O chassis switch to ind icate the rack-a ddressing mode . The addressing mode determines the number of contr olle r-resident ra ck numbers use d ba se d on the number of slots in the c hassis. For more information on addressing mod es , see chapter 4. To set the I/O chassi s switch , see Appendix E.

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The controller-resident rack address defaults to rack 0. If needed, you can set it for rack 1 by setting user control bit 2 (S26:2) on the controller configuration screen in your programming software. If you select rack 1 as the controller-resident rack, rack 0 be comes unavailable fo r yo ur system.

Using This Chapter

Communicating with Remote I/O

For Information About Go to Page

Selecting devices that you can connect 6-2 Introduction to remote I/O 6-3 Designing a remote I/O link 6-4 Configuring a controller channel as a scanner 6-6 Communicating to a remote I/O node adapter 6-11 T r ans ferring block data 6-13 Block-transfers of remote I/O data 6-15 Block-transfer sequence with status bits 6-17 Block-transfer programming considerations 6-19 Monitoring remote I/O scanner channels 6-21 Addressing the I/O status file 6-24

Chapter

This chapter explains how to configure the controller to communicate with remote I/O:

1. Select which channel to configure as a scanner.

2. Define the I/O status file.

Use a unique, unused integer file. You must define an I/O status file if you want to autoconfigure your system.

3. Define a diagnostic file.

Use a unique, unused integer file.

4. Define the scan list.

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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)

T o Remote I/O SLC 500 Remote I/O Adapter

Operator Interfaces DL40 Dataliner 2706-xxxx

Drives Remote I/O Adapter for 1336 AC

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 Direct Communication Module for

SLC Controllers

Module 1791 Block I/O 1791 series Remote I/O Adapter Module 1771-ASB 1-Slot I/O Chassis with Integral

Power Supply and Adapter 2-Slot I/O Chassis with Integral

Power Supply and Adapter Direct Communication Module 1771-DCM FLEX I/O Adapter Module 1794-ASB

RediPANEL 2705-xxx PanelView Terminal 2711-xxx

Industrial Drives Remote I/O Adapter for 1395 AC

Industrial Drives

1747-DCM

1747-ASB

1771-AM1

1771-AM2

1336-RIO

1395-NA

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Communicating with Remote I/O 6-3

Introduction to Remote I/O

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.

Remote I/O link cable: Belden 9463

Remote I/O node adapters like the 1771-ASB modules or PanelView operator interfaces addressed as remote I/O racks.

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

1771-ASB

PLC-5 channel or a controller operating as a remote I/O adapter

The remote I/O scanner channel keeps a list of all of the devices connected to each remote I/O link called a scan list. An example channel scan list looks like this:

PLC-5/40E

Ch 1A Ch 1B

Rack 1

Rack 2

Rack 3

PLC-5/20

Ch 1B Scan List

Rack Addres

1 2 3

In this example, channel 1B continually scans the three racks in its scan list and places the data in the remote I/O buffer in the controller. The controller updates its own buffer and the I/O image table. During housekeeping, the two buffers are updated by exchanging the input and output data with each other.

Starting

Group

0 0 0

Rack Size

Full 1/2 Full

Range

010-017 020-023 030-037

For more information on scan lists, see page 6-9. .

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6-4 Communicating with Remote I/O

For this Step See

1.configure the remote I/O adapter devices the device’s user manual

2.layout and connect the remote I/O link cable • page 6-4 for design

3.configure the scanner channel page 6-6

Follow these steps for setting up a remote I/O system :

• 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)

Designing a Remote I/O Link

Designing a remote I/O link requires applying:

• remote I/O link design guidelines

• cable design guidelines

Link Design Guidelines

TIP

Keep these rules in mind as you design remote I/O links:

• All devices connected to a remote I/O link must

communicate using the same communication rate, either 57.6, 115.2, or 230.4 k bps. Choose a rate that all devices support.

• Two or more c hann els o f the sa me cont roller op erating

in scanner mode cannot scan the same partial or full rack address. Assign unique partial and full racks to each channel used in remote I/O scanner mode.

• You can split rack addresses between scanner channels;

however, issues arise when performing block-data transfer. See page 6-15.

• A scan list can have a maximum of 16 rack numbers or

a maximum of 32 physical devices connected to it using 82-Ω termination resistors. See page 6-9 for more information about scan lists.

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Cable Design Guidelines

Communicating with Remote I/O 6-5

Trunk line/drop line considerations:

When using a trunk line/drop line configuration, use 1770-SC station connectors and follow these cable-length guidelines:

trunk line-cable length*depends on the communication rate of the link

drop-cable length*30.4 m (100 cable-ft)

For more information about designing trunk line/drop line configurations, see the Data Highway/Data Highway Plus/Data Highway II/Data Highway-485 Cable Installation Manual, publication 1770-6.2.2.

TIP

Specify 1770-CD (Belden 9463) cable. Connect a remote I/O network using a daisy chain or trunk line/drop line configuration.

Verify that your system’s design plans specify cable lengths within allowable measurements.

IMPORTANT

The maximum cable length for remote I/O depends on the transmission rate. Configure all devices on a remote I/O link to communicate at the same transmission rate.

For daisy chain configurations, use this table to determine the total cable length you can use.

A Remote I/O Link Using this Communication Rate

57.6 kbps 3,048 m (10,000 ft)

115.2 kbps 1,524 m (5,000 ft)

230.4 kbps 762 m (2,500 ft)

Cannot Exceed this Cable Length

IMPORTANT

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 remote I/O link by using the external resistors shipped with the programmable controller. Selecting either a 150Ω or 82 Ω terminator determines how many devices you can connect on a single remote I/O link.

If Your Remote I/O Link Use this Resistor

Rating

operates at 230.4 kbps 82Ω 32 16 operates at 57.6 kbps or 115.2 kbps and no

devices listed in the following table are on the link

contains any device listed in the following

150Ω 16 16

table operates at 57.6 kbps or 115.2 kbps, and you

do not require the link to support more than 16 physical devices.

The Maximum number of Physical Devices You can Connect on the Link:

The Maximum Number of Racks You can Scan on the lLnk

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6-6 Communicating with Remote I/O

I/O Link Devices that Require 150Ω Termination Resistors

Device Type Catalog Number Series

Scanners 1771-SN

1772-SD, -SD2 1775-SR 1775-S4A, -S4B 6008-SQH1, -SQH2

Adapters 1771-AS

1771-ASB A 1771-DCM All

Miscellaneous 1771-AF

All

Configuring a Controller Channel as a Scanner

Use this table to help you determine the controller channels you can configure as a remote I/O scanner:

Channels that Supp ort

Controller

PLC-5/11 1A PLC-5/20 PLC-5/20E 1B PLC-5/30

PLC-5/40L PLC-5/60L

PLC-5/40 PLC-5/60 PLC-5/80

PLC-5/40E PLC-5/80E

Remote I/O Scanner

1A, 1B

1A, 1B, 2A, 2B

To configure a controller channel as a scanner, you:

• define an I/O status file, which stores information about the racks

connected to the controller, by using the controller configuration screen in your programming software

• specify the scanner’ s communication rate and diagnostic file and define a

scan list by using the scanner mode channel configuration screen in y our programming software

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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.

T o define an I/O status file, enter an unused integer file number (9-255) in th e 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. However, if you want to use the autoconfiguration option to create your scan list, you must define an I/O status file. Use the controller configuration screen in your programming software:

Specify Channel Configuration Information

Use the scanner mode configuration screen in your programming software to configure a channel for scanner mode.

configure the channel as a remote I/O scanner

specify the scan list

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6-8 Communicating with Remote I/O

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.

In this Field Define By Doing the Following

Diagnostic file The file containing the channel’s status

information:

• messages received

• messages sent

• messages received with error

• unable to receive

• sent with error

• rack retries

Baud rate The communication rate for the remote

I/O scanner mode link

IMPORTANT

Cursor to the field, type an integer file number (9-999)

Cursor to the field and select the desired rate.Available rates are:

57.6, 115.2, and 230.4 kbps.

Y o u m us t de f ine a dia gnos tics f ile for a c hannel configured for anything but unused (even if you are not using the channel) if you want to get status information for that channel.

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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 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 (see page 6-7).

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. If you encounter the error message “Resource not Available,” you have not defined an I/O status file. Define the I/O status file and try automatic configuration again.

Insert an entry into the scan list

Delete an entry for the scan list

Make sure the controller is in Remote Program, Program, or Remote Run mode.

1.Position the cursor at the place on the scan list where you want to insert an entry.

2.Insert an entry into the list and enter the appropriate values for the list. Important: If incorrect information is entered for an entry, the controller will

not display the new configuration when you save edits. Make sure the controller is in Remote Program, Program, or Remote Run mode.

1.Position the cursor at the place on the scan list where you want to delete an entry.

2.Delete the entry from the list. Important: If incorrect information is entered for an entry, the controller will

not display the new configuration when you save edits.

A scan list includes the following:

For this Field: A Scan List Contains

Rack address 1-3 octal (PLC-5/11, -5/20, -5/20E controllers)

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, a C appears before the complemented rack

address. Starting group 0, 2, 4, or 6 Rack size 1/2, 1/4, 3/4, or FULL Range Automatically calculated based on rack address, starting module group and chassis

size.

An asterisk (*) after a range indicates the last valid rack entry.

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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.

Keep these limitations in mind when creating/modifying a scan list:

• The automatic configuration always displays the actual

hardware configur ation, ex cept for racks t hat hav e thei r global-rack inhibit bit set. In this case, the global-rack bit overrides the automatic configuration. You must first clear the global-rack inhibit and then select autoconfigure.

• Clear global-rack inhibit bits for the channel that scans

the racks that you want to resume scanning. Use the scanner mode status sc reen in your programmin g software.

• If you change a channel configuration from adapter or

DH+ mode to scanner mode, use the clear list function of your programming software to clear the scan list. In any other instance where you need to clear entries from the scan list, use the delete-from-l ist func tion to delete the entries one at a time.

Publication 1785-UM012D-EN-P - July 2005

Communicating with Remote I/O 6-11

Communicating to a Remote I/O Node Adapter

Rack 3

Rack 2

AdapterAdapter Adapter

Rack 1

A scanner channel e xc hanges disc rete data with remote I/O n ode adapters lik e 1771-ASB modules via the remote I/O buffer.

Remote I/O Scan and Program Scan Loops.

Remote I/O Scan Loop

Data Exchange Remote I/O Buffer

x y

I/O Image Table

ControllerResident Rack

Update I/O image

Data Exchange

Housekeeping

Program Scan Loop

Immediate I/O

a write outputs

b read inputs

Logic

Scan

IOT (x) IIN (y)

The remote I/O scan is the time it takes for the controller to communicate with all of the entries in its rack scan-list once. The remote I/O scan is independent of and asynchronous to the program scan.

In remote racks, immediate I/O data transfers update the remote I/O buffer.

IMPORTANT

The remote I/O scan for each channel configured for scanner mode is independent and asynchronous to the remote I/O scan for any other channel

For the Scanner Channel to Comm unicate with the 1771-ASB Adapter Modules, Do the Following

1.Set the I/O chassis backplane switch for each chassis that

houses an adapter module.

2.Set the switches on the adapter module itself.

3.Connect the remote I/O cable. your controller installation

During housekeeping:

Data exchange between the I/O image table, the controller-resident rack, and the remote I/O buffer occurs.

The remote I/O buffer is updated.

Remember that the I/O scanner is constantly updating the remote I/O buffer asynchronously to the program scan.

For More Information, See:

Appendix E

instructions

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6-12 Communicating with Remote I/O

Tro ub lesho otin g Remo te I/O Communi cation 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. Go to the controller configuration sc reen and assign one of the previous

file numbers to be the I/O status file (see page 6-7).

4. Go to the channel configuration screen for the appr opr ia te channel and

assign the remaining file number (from above) to be the channel diagnostic file (see page 6-7).

5. Perform an autoconfigure and confirm that all the racks were found and

listed in the I/O scan list.

6. Check all I/O rack retry counters in channel status to make sure there

are no communications problems.

If you follow the above steps and there are still remote I/O communications problems, it is possible that the I/O status file is corrupt. Try assigning a brand new I/O status file and repeat the steps above. Also, confirm that the I/O image tables exist for the racks you are having difficulty communicating with.

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Communicating with Remote I/O 6-13

Transferring Block Data

Remote I/O

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.

Block-Transferring Data to Controller-Resident Local, Extende d-Local, and

ExtendedLocal I/O Scan

Local Rack 4

Local Racks 2 and 3

Local Rack 1

Adapter

One transfer per I/O scan

Q = Queue A = Active

Buffer

BT Requests

BTR or BTW Data

BT Requests

BTR or BTW Data

BT Requests

BTR or BTW Data

Logic

Scan

Remote I/O Scan

Rack 7

Rack 6

Rack 5

Remote I/O

Adapter

Interrupt from STI or Fault Routine

The adapter used in the remote I/O scan is the 1771-ASB.

The adapter used in the extended-local I/O scan is the 1771-ALX.

ControllerResident

Rack 0

Multiple Block Transfers per I/O Scan

I/O Scan

Requests

BTR or BTW Data

Program

Scan

15299

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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 23 PLC-5/40, -5/40L, -5/40E 31 PLC-5/30 39 PLC-5/20, -5/20E 43 PLC-5/11 43

Placing the controller in program mode, cancels block-tra nsfe rs in the active buffers and in the waiting queues.

Storage Area Description

active buffers store initialized block-transfer requests for a channel

The adjacent table lists the maximum active buffers for each enhanced and Ethernet PLC-5 controller. The controller places a block-transfer request directly into the active buffer only if: a buffer is available and no block-transfers to the slot is in the queue.

waiting queues store block-transfer requests that cannot be placed into the active

buffer because: all of the channel’s active buffers are being used the slot addressed by the block-transfer is currently processing a block-transfer

Once a block-transfer to a slot completes, the controller checks the queue to see if a block-transfer addressed to the slot is waiting. If one exists, the controller moves it to the active buffer.

Since a controller can request a block-transfer from ever y slot in a chassis concurrently, the adapter device chooses the order in which the block- transfers execute on the chassis. Block-transfer requests are processed differently in fault routines, selectable timed interrupt routines (STI), and controller input interrupt routines (PII); see chapters 16, 18, and 19 respectively for more information.

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Communicating with Remote I/O 6-15

Block-Transfer Minor Fault Bits

Minor Fault Description

S:17/0Block-transfer queue full to remote I/O 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 m inor fault bit S:17/0 and skips that block-transfer instruction. This condition is self-correcting, but bit S:17/0 remains set until you reset it. You can avoid this minor fault be separating block-transfer instruction rungs with other rungs.

S:17/1 through S:17/4Queue full - channel xx The PLC-5 controller can process a maximum of 64 remote block-transfers per

channel pair (1A/1B or 2A/2B). This maximum includes: block-transfers that are currently in the active buffer initialized block-transfers that are waiting for execution in the holding queue Once the 64 block-transfer maximum is reached, the following minor fault bits are set, depending on which channel pair is involved:

Channel pair:Minor fault bits set:

1A/1BS:17/1 and S:17/2 2A/2BS17:3 and S:17/4

The PLC-5 controller won’t initialize any remote block-transfer instruction which exceeds the 64 maximum. The .EW, .DN, and .ER bits are reset on any block-transfer which exceeds the 64 maximum. This condition is self-correcting, but the bits remain set until you reset them.

S:10/7No more command blocks exist This minor fault bit is normally associated with an application programming

problem, but this bit can also be set when using block-transfers if the maximum number of command blocks available in the PLC-5 controller is exceeded. The command blocks are used by both the local and remote block-transfers.

Block-Transfers of Remote I/O Data

PLC-5 type:Maximum number of command blocks:

PLC-5/11, -5/20, -5/30128 PLC-5/40256 PLC-5/60, -5/80384

This condition generally occurs when a program attempts to repeatedly initialize block-transfers which have not yet completed with a .DN or .ER bit. This condition is self-correcting, but bit S:10/7 remains set until you reset it.

Block-transfers of I/O data to remote I/O follow these guidelines:

• Block-transfer data exchange and the program scan run independen tly

and concurrently. Once block-transfers are initiated, the controller performs them asynchronously to the program scan.

• During every remote I/O scan, the Controller performs a maximum of

one block-transfer per entry in the scan list.

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6-16 Communicating with Remote I/O

IMPORTANT

The figure below shows the remote I/O block-transfer sequence.

Scanner within PLC processorLadder Logic

][ ()

][

Processor executes a block-transfer instruction.

BlockTransfer Requests

If you split remote rack addresses between scanner channels , block-transfe rs to lower priority scanner cha nnels do not function properly. Scanner channels have priority according to the following order: 1A, 1B, 2A, then 2B.

For example: if you configure channels 1B and 2A as remote scanners and split rack #2 between them, block-transfers to channel1B (the higher priority channel) will be completed, but block-transfers to the second half of rack #2 (2A, the lower priority channel) will not be completed.

Although splitting remote I/O racks across scanner channels does not affect discrete transfers, I/O status bits such as Fault and Present may not indicate the correct status.

Remote I/O

Adapter

AdapterAdapter

Discrete I/O

3 8

Processor sends the block-transfer request to its I/O scanner.

Scanner places module control byte (MCB) into the discrete output image table.

Scanner sends MCB as part of the discrete I/O update to the adapter.

The adapter module sends the block-transfer request to the block-transfer module.

The block-transfer module returns a module status byte (MSB) to the adapter.

MSB returned to the scanner in addition to the discrete I/O by the adapter.

The scanner forms a block-transfer packet.

Publication 1785-UM012D-EN-P - July 2005

The scanner sends the block-transfer packet to

the adapter for the block-transfer module (the packet includes data if it is a block-transfer write).

The adapter passes the block-transfer packet to

the block-transfer module.

The block-transfer module sends status to the

adapter (will also send data if it is a blocktransfer read).

The adapter passes status to the I/O scanner;

if the request is a block-transfer read, adapter sends data.

Communicating with Remote I/O 6-17

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.

The following figure describes the different states of the block-transfer status bits.

Executes block-transfer asynchronously to the program scan

I/O scanner

Does this slot address have a BT in process?

Is an active buffer available?

yes

Is the request a BTW?

yes

The scanner accesses the BTW file in the data table and copies the data to the active buffer.

yes

The scanner place the request in the waiting queue.

Transfers the block-transfer request to/from the I/O chassis.

The scanner sets the .ST status

bit and starts the watchdog timer.

Does the module respond?

yes

see page 6-18

see page 6-19

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6-18 Communicating with Remote I/O

Did the block-transfer complete without errors?

yes

Sets the done .DN bit (13).

Was the block-transfer a BTR?

yes

Copies data from the active buffer to the block-transfer file in the data table.

Sets the error .ER bit (12).

Is the block-transfer continuous? (the .CO bit is set.)

Frees up the active buffer for the next request

go to

Start

see page

6-17

yes

Re-initializes the block-transfer.

go to

see page

6-17

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Communicating with Remote I/O 6-19

Is the block-transfer for a local I/O module?

yes

Sets the no response .NR bit (09).

Is the timeout .TO bit (08) set?

yes

Block-transfer is for a module in a remote rack.

Is the timeout .TO bit (08) set?

Continues to request the block-transfer for 0-1 s before setting the .ER bit (12).

Re-initializes the request until the watchdog timer expires (4 s).

Continues to request the block-transfer until the watchdog timer expires (4 s).

yes

Retries request once more before setting the .ER bit (12)

Block-Transfer Programming Considerations

For a list of block-transfer error codes, see the PLC-5 Programming Software Instruction Set Reference, publication 1785-6.1.

Read this section for information about general programming considerations and considerations for controller-resident local racks.

General Considerations

The following are general programm ing considerations when you are block-transferring I/O data.

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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., if a block-transfer module is installed in rack 2, group 4, clear output word O:024 to 0; do not use the word for storing data).

• If you use remote block-transfer instructions and have the timeout bit

(.TO) set to 1, then the controller disables the 4-second timer and continues to request the block-transfer for 0-1 seconds before setting the error (.ER) bit.

• A PLC-5 controller with at least one channel configured as an adapter

could incur a non-recoverable fault when you switch it from run to program mode.

To avoid this possibility, program the scanner to request only two or three block-transfers from the PLC-5 adapter at one time by conditioning the block-transfer instructions with the done/error bits.

For Controller-Resident Local Racks

The following are programming considerations when you are block-transferring data in a controller-resident local rack.

• Within the controller-resident local rack, limit the number of

continuous-read block- tra n sfers to 16 transfers of 4 words each or 8 transfers of 64 words each. If you attempt to exceed this block-transfer limit, a checksum error (error code -5) occurs.

• Block-transfer instructions to any of the following modules residing in

the controller-resident local rack result in frequent checksum errors.

– 1771-OFE1, -OFE2, and -OFE3 modules; all versions prior to series

B, revision B

– 2803-VIM module, all versions prior to series B, revision A – IMC-120, all versions

• To eliminate the checksum errors, replace your modules with the current

series and revision. If replacement is not possible:

1. Go to the controller configuration screen in your programming

software.

Publication 1785-UM012D-EN-P - July 2005

2. With the controll er in program mode , se t user cont rol bit 4 (S:26/4) to 1

(the local block-transfer compatibility bit).

3. Change the controller mode from program to run.

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. This screen displays the data in the diagnostic file you defined on the scanner mode configuration screen (page 6-7).

Monitoring transmission retries

Status Field Location Description

Retries Tab Retry word 5

etc. word 69

Displays the number of retries for the corresponding rack entry. Entry 1

etc. Entry 64

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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 identified with a C to the left of the rack address column on the status screen. Starting Group This field indicates the first I/O module group in the rack that the controller scans. Rack Size This field displays the portion of the I/O rack addressed by each chassis. Configurations can be

1/4, 1/2, 3/4, or FULL as long as the total sum of the rack does not exceed 8 I/O groups. Range This field displays the rack address and module groups being scanned for a rack in the scan list.

An asterisk (*) after a range indicates that it is the last valid rack entry. Fault An F displayed in this field indicates that the corresponding chassis is faulted. When a fault

indicator appears, the system sets the associated fault bit in the global rack fault status on the

controller status screen in your programming software.

When the global rack fault bit is set, all configuration information starting at the faulted quarter

is lost. When a rack faults, F is displayed. If both the fault and inhibit bits are set for a rack, no

rack exists at that I/O group. Inhibit Inhibit a rack by cursoring to the Inhibit field of the rack you want to inhibit and enter 1

When a chassis is inhibited the controller stops scanning it. You can inhibit an entire rack by

setting the global rack-inhibit bit for that rack on the controller status screen. All chassis within

that rack are inhibited, and an I appears in the

Inhibit field, indicating the rack was globally

inhibited. Reset Reset a rack by cursoring to the Reset field of the rack you want to reset and type 1

When a chassis is reset, the controller turns of f the outputs of the chassis regardless of the

last-state switch setting. You can reset an entire rack by setting the global rack-reset bit on the

controller status screen. All chassis within that rack are reset, and an R appears in the

Reset

field indicating the rack was globally reset. Retry This field displays the number of times the rack was re-scanned.

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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.

Communicating with Remote I/O 6-23

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. Messages received with

word2 Displays the number of messages containing errors received by the channel (such as bad CRC).

error Messages unable to receive word 4 Displays the number of messages received with protocol-related problems (such as a bad

block-transfer status byte with both read and write bits set).

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6-24 Communicating with Remote I/O

Addressing the I/O Status Fil e

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.

Defined I/O status file

Word in integer file

N15:0 N15:1

N15:14 N15:15

N15:30 N15:31

N15:46 N15:47

rack 0

rack 3

rack 7

rack 17

rack 27

(Maximum for PLC-5/11, -5/20, and -5/20E)

(Maximum for PLC-5/30 processors)

(Maximum for PLC-5/40, -5/40L, and -5/40E processors)

(Maximum for PLC-5/60, -5/60L,

-5/80 and -5/80E processors)

The first word for a rack contains present and fault bits, the second word contains reset and in hibit bits. The following figure shows pr e sent , fa ult , r eset, and inhibit bit layouts for rack 7 in the I/O status file.

IMPORTANT

Setting inhibit bits in the I/O status file does not update inhibit bits in the controller status file.

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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

Not Used

Fault BitsPresent Bits

00010203040506070809101112131415

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 second 1/4 rack

starting I/O group 2

10 third 1/4 rack

starting I/O group 4

11 fourth1/4 rack

starting I/O group 6

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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

Not Used

Reset Bits

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

Inhibit Bits

00010203040506070809101112131415

Not Used

08 first 1/4 rack

09 second 1/4 rack

10 third 1/4 rack

11 fourth1/4 rack

ATTENTION

starting I/O group 0

starting I/O group 2

starting I/O group 4

starting I/O group 6

When you use a ladder program or the software to inhibit and reset an I/O rack, you must set or clear the reset and inhibit bits that correspond to each quarter rack in a given chassis . Failure to set all the appropriate bits could cause unpredictable operation due to scanning only part of the I/O chassis.

Publication 1785-UM012D-EN-P - July 2005

Using This Chapter

Communicating with a PLC-5 Adapter Channel

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

Chapter

Monitoring remote I/O adapter channels 7-19

This chapter explains how to configure the controller to communicate with an adapter channel:

1. Select which channel to configure as an adapter.

2. Define a diagnostic file.

3. Use a unique, unused integer file.

4. Define the rack address, starting group and rack size.

5. The default rack address is rack 3.

6. Define the discrete transfer files (enter as decimal numbers).

7. The input source is where the supervisory controller’s output discrete

bits go (default is 001:024 - the decimal representation of rack 3). The output source is where the supervisory controller’s input bits go (default is 000:024).

8. Create the necessary block-transfer control files (one BTR and one

BTW).

1 Publication 1785-UM012D - EN-P - July 2005

9. Configure the block-transfers so the supervisory controller knows

where to address block-transfers.

7-2 Communicating with a PLC-5 Adapter Channel

Configuring Communication to a PLC-5 Adapter Channel

Supervisory Processor in Scanner Mode

a write outputs

b read inputs

Update I/O image

Housekeeping

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 adapte r-mode controller channel automatically transfer discrete data and status between themselves via the supervisory controller’s remote I/O scan.

PLC-5 Processor Channel in Adapter Mode

Discrete Transfer Configuration Files

Data Exchange

Remote I/O Buffer

I/O Image

Table

Update I/O image

Housekeeping

Logic Scan

a write outputs

b read inputs

Remote I/O Buffer

I/O Image

Table

Discrete Data and Status Bit Exchange

Remote I/O Scan Program Scan

During each remote I/O scan, the supervisory processor transfers 2, 4, 6, or 8 words*depending on whether the adapter-mode processor is configured as a 1/4, 1/2, 3/4, or full rack.

Discrete data and block-transfer status bits are transferred between a remote I/O scanner’s I/O image table and an adapter channel via the adapter channel’s discrete transfer configuration files , which you define on the adapter channel configuration screen.

For the Scanner Channel to Comm unicate with a PLC-5 Contro l ler Adapter Channel, Do the Following

1.Define the communication rate, its address, and rack size (number of words to transfer). page 7-3

2.Define the discrete transfer configuration files, which are the files from which the

adapter controller channel gets the data sent by the supervisory controller and puts data into for the supervisory controller.

3.If you plan to block-transfer data to the adapter channel, define the block-transfer files and configure the block-transfers.

The adapter-mode processor transfers 2, 4, 6, or 8 words*depending on whether it is configured as a 1/4, 1/2, 3/4, or full rack.

For More Information, See

page 7-5

page 7-10

4.Connect the remote I/O cable. your controller installation

Publication 1785-UM012D-EN-P - July 2005

instructions

Allen-Bradley 1785-L40B, 1785-L11B, 1785-L40L, 1785-L60B, 1785-L60L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual