Black & Decker d984, e984, k984-x8x Installation Manual
Models E984,0984 and
K984-X8X Controllers
System Planning and
Installation Guide
GM-0984-EDK
Rev. R
I Modicon I Square D 8 Telemecanique
Modicon
System Planning and
Installation Guide for
984-X8X Controllers
Models E, D, and K
GM-0984-EDK Rev. B
August, 1995
MODICON, Inc.
One High Street
North Andover, Massachusetts 01845
Preface
This guide describes the ten different yet similar 984 slot mount Programmable
Logic Controllers and their available options, together with procedures for system
planning and installation.
The major differences are identified up front for easy reference in Chapter 1.
Throughout the manual a number of sections apply to all models, while others apply only to certain models as so noted.
The information in this document is subject to change without notice and should
not be construed as a commitment by Modicon, Inc., who assumes no responsibility for any errors that may appear in this document.
No part of this document may
be reproduced in any form or by any means, electronic or mechanical, including
photocopying, without the express written permission of the publisher, Modicon,
Inc. All rights reserved.
0 Copyright 1995 Modicon, Inc.
The following are trademarks of Modicon, Inc.:
ModiconB
P190
984A
984-380
984-38 1
E984-381
984-385
E984-385
Micro 984
984
984B
984480
E984-480
984-485
E984-485
984-680
ModbusB
984X
984-685
E984485
984-780
984-785
984-785L
E984-785
984-l 20
984-l 30
984-l 45
984-351
984-455
Modsoft@
D984-385 K984-485 D984-785
K984-785 Modbus Plus
IBM8 is a registered trademark of International Business Machines, Inc.; IBM PC
is a trademark of International Business Machines, Inc.
Preface iii
Objectives
This manual will help you plan, configure, mount, wire, connect, check out, and
troubleshoot your 984 slot-mount controller system, including 984/800 Series
Remote I/O. After reading this book:
o A Control Engineer will be able to identify and physically plan the location and
mounting of system components.
o A Plant Electrician/Installer will be able to install, power-up, and check out the
system.
o A Maintenance Technician will be able to recognize, locate, identify, and re-
solve or report system failures.
How To Use This Manual
Chapter 1 describes the various controllers and their functions.
Chapter 2 offers information for planning your installation.
Chapter 3 is an installation procedure for your controller with local I/O and
Remote I/O.
Appendix A gives system specifications.
Appendix B gives troubleshooting assistance.
iv Preface
Related Documents
The Documents listed go beyond the installation and orientation contained herein
and are required for new users in programming environments:
GM-MSF--001
840 USE 101
890 USE 101
890 USE 100
Modsoft Programmer User Guide
Modicon Ladder Logic Block Library
Remote I/O Cable System Planning Guide
Modbus Plus Network Planning and
installation Guide
Minimum Revision Levels
The minimum prom revision levels for the 685/785E (only) slot-mount controller
options are:
Option
S908
s911
5985
Exec Part Number
Rev. Level Min. Prom Number
AS-E9081 31
H
1007
AS-S91 l-801
Exec (AS-9490-022)
G 1006
AM-S985800
D
1004
The minimum revision levels for programming software diskettes are:
PC
Disks
Part Number
Version
Description
SW-MS(X)D-9SA 2.0
Modsoft 2.0 (all models)
CR
Note
In Hot Standby configuration both controllers and systems must
be at the same hardware and firmware revisions. (Refer to the Redundancy 6851785 section located in Chapter One.)
Preface v
Incoming Inspection Guidelines
Guidelines for Inspection
o Before you do anything, verify your shipment is complete and undamaged. If
the shipment is incomplete or damaged, notify the carrier and your distributor.
o Remove everything from its packing and check for physical defects or damage.
If the equipment is physically defective or damaged, notify your Modicon representative.
ID=
Note
Save shipping materials until installation is complete.
Sending Something Back?
o Whenever possible, use the original packing materials supplied by Modicon.
o All equipment should be firmly packed so that it cannot move around in its ship-
ping container.
o All equipment should be protected against impact during shipment.
IJ All equipment should be clearly marked with its Return Authorization Number
@A#).
vi Preface
Table of Contents
Chapter 1 Introducing your Controller
. . . a
Programmable Logic Controllers (PLC) .
System Capacity . . . . . . . . . . . . .
. .
Optimize Mode (685E/785E ONLY) . . .
How Optimize Works . . . . . . . .
. .
Local
I/O
. . . . . . . . . . . . . . . . . . . . . . .
. .
Remote I/O . . . . . . . . . . . . . . . .
Executive NV FLASH Memory and RAM
. . .
Executive Functionality . . . . . . . .
. . .
Redundancy685785 . . . . . . . . . . . . .
Housings . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
Remote I/O Enclosures
. . . . . . .
. . .
Status Indicators . . . . . . . . . . .
. . . .
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
1
2
6
7
8
9
9
11
11
12
13
14
15
Chapter 2 System Planning
. . . . . . . . . . . . L , _ . . . . . . . .
17
Planning . . . . . . . . . . . . . .
Overview . . . . . . . . . . .
Space Requirements . . . . . . .
Primary Power Lines . . . . . . . . .
Environmental Requirements . . . .
Mounting Hardware Requirements .
Housing Installation Options . . . . .
Panel or Bulkhead Mounting . .
Rack Mounting . . . . . . . . . . .
Grounding Your Installation . . . . . . . .
Power Supply Function (AC and DC) .
Primary Power Cable (AC/DC) . .
AC Power Cable . . . . . .
DC Power Cable . . . . . . . . . . .
Communications Processing Function .
381 E/385E/385D/480E/485E/485K
......
...... 18
......
......
18
......
......
18
......
...... 18
......
...... 19
......
...... 19
......
...... 20
......
...... 20
......
...... 22
......
...... 26
......
...... 26
......
...... 29
......
...... 29
......
...... 30
......
...... 30
......
...... 31
Comm Switch Configuration for MODBUS, Ports
........
31
Modbus Port Software Configuration
.................
31
Modbus Plus Node Address Setting (385/485 ONLY)
.... 33
Modbus Plus Bridge Mode (385/485 ONLY)
............
34
Table of Contents vii
GM-0984-EDK
Using MSTR Block To Change Modbus Plus Address . . . 35
Modbus Plus Node Address Software Change (385/485 ) 35
MSTR Format . . . . . . . . . . . . . . . . . . . . . 35
Port Delay Timer . . . . . . . . . . . . 37
685El785El785DI785K . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Comm Switch Configuration for MODBUS, Ports . 37
Modbus Port Software Configuration . . . . . . . . . . . . . . . .
38
Modbus Plus Node Address Setting (685i785 ONLY) . . .
41
Chapter 3 System Installation
.....................
43
Panel/Bulkhead Mounting ..............................
44
RackMounting ....................................
50
Procedure Rack Mounting Installation ..................
52
Procedure Connecting Your Field Wiring ................
55
I/O Module insertion
...................................
58
Procedure I/O Module Installation .....................
58
PowerSupply ........................................
60
Power Supply Installation and Wiring ...................
61
Verify Your Local I/O ...............................
64
Controller to IBM PC Programming Panel Software
..... 64
Getting PLC into RUN Mode .......................
64
I/OQuickCheck
................................. 65
RI/O Head/Receiver
...................................
68
RI/O Head Installation (685E/785E/785Di785K ONLY)
..... 68
Procedure Setup & Install. of S908 RI/OP in Prim. Housing 68
RI/O Receiver Install (480E/485E/485K & 685E/785E,D & K) 69
Procedure Set Drop Address/ASCII Ports for J89X & Install 70
Verify Your RIO Installation ..........................
74
. . .
VIII
Table of Contents
Appendix A Specifications
. . . . . . . . . . . . . . . . . . . . . . .
75
Controller Specifications . . . .
Built-in Power Supply . . .
Output to I/O Service . . . .
External Power Requirements
Physical Characteristics . . .
Electrical Characteristics . . .
Circuit Characteristics . . . .
Environmental Characteristics
End User Part Numbers . . .
. . .
......
76
. . ......
76
. . .
......
77
. . . . .
......
77
. . . .
......
78
. . . .
......
78
. . .
......
78
. . . .
......
79
. . . .
......
80
Appendix B Troubleshooting
. . . . . . . . . . . . . . . . . . . . . .
83
Stopped Error Codes
. . . . . . . . . . . . .
........
. a4
Installation Verification Troubleshooting . .
........
. a7
Master Function Error Codes . . . . . . . . . . .
........
a9
Customer Service & Technical Assistance . .
........
. 90
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
GM-O984-EDK
Table of Contents ix
Figures
Figure 1 381 EI385El385D Perspective Drawing ............. 3
Figure 2 480E/485E Perspective Drawing .................. 4
Figure 3 685E/785E Perspective Drawing .................. 5
Figure 4 RI/O Head (S908) Module (S908-110) ............. 10
Figure 5 Controller Location in Primary Housing AS-H81 9-209 . 14
Figure 6 H819 Housing Panel or Bulkhead Mounting Dimensions 21
Figure 7 H827 Housing Panel or Bulkhead Mounting Dimensions 22
Figure 8 H819 Housing Rack Mount Dimensions ............ 24
Figure 9 381 E/385E/480E/485E/485K Primary Power Input Conn. 27
Figure 10 685E/785E/785K Primary Power Input Connections . . 28
Figure 11 MEM/DEFAULT/MODEM DIP Switch .............. 32
Figure 12 Communication Port Selection Screen ............ 33
Figure 13 DIP Switch for Modbus Plus Node (385/485 ONLY) . 34
Figure 14 MSTR Block on Modsoft screen With I/O Labels ..... 36
Figure
15
MEM/DIP DIP Switch
.......................... 39
Figure 16 Comm. Port Selection Screen (485E Example) ...... 40
Figure 17 DIP Switch for Modbus Plus Node (685/785 ONLY) . . 41
Figure 18 Remote I/O H819 Panel/Bulkhead Mounting Dim. .... 45
Figure 19 H827 RI/O Housing Panel/Bulkhead Mounting Dim. .. 46
Figure 20 Attach Housing to Mounting Surface .............. 47
Figure 21 Connecting Cables within Each Drop
.............. 49
Figure 22 H819 Housing Rack Mount Dimensions ........... 51
Figure 23 Attaching Rack Mounting Flange to Housing ........ 52
Figure 24 Rack Mounting Your Housing .................... 54
Figure 25 Field Wiring to Terminal Strip (20 Pin Shown) ....... 56
Figure 26 800 Series RI/O Module Installation
............... 59
Figure 27 P810 Power Supply Insertion .................... 61
Figure 28 P810 Power Supply Terminal Strip ................ 62
Figure 29 P800 Power Supply Terminal Strip ................ 63
Figure 30 P884 Power Supply Terminal Strip ................ 63
Figure 31 A Configuration Overview Screen Initial Screen ..... 65
Figure 32 I/O Map Data ................................ 66
Figure 33 J89O/J892 Dip Switch Locations (Rear of Modules) 70
Figure 34 Drop Address Switch Characteristics .............. 71
Figure 35 ASCII Drop Port Assignment Switches ............ 73
Figure 36 Modbus Cable Pinouts ......................... 85
Figure 37 Modbus Cable Pinouts Cont. .................... 86
Figure 38 Modbus Cable Pinouts Cont. .................... 86
X
Table of Contents
GMa984-EDK
Figure 39 Controller Installation Troubleshooting Chart . . . . . . 87
Figure 40 Controller Installation Troubleshooting Chart (Sheet 2)
88
Tables
Table 1 Memory Per Configuration
...........
Table 2 Memory Per Configuration Cont.
......
Table 3 Communication Options per PLC
......
Table 4 Port 1 Configuration
................
Table 5 Port 1 Configuration
................
Table 6 Partial Modbus Plus Address Examples
Table 7 J89O/J892 Drop Address Switch Settings
Table 8 J892 ASCII Port Address Settings
.....
Table 9 End User Part Numbers
.............
Table 10 Stopped Error Codes
...............
Table
11
MSTR Error Code Definitions
.........
. . .
. . . .
. . .
. . .
. .
. . .
. .
. 6
. 7
. 30
. 31
38
. 42
72
. 73
. 80
. 84
. 89
GM-0984-EDK
Table of Contents xi
Chapter
1
Introducing your Controller
~3 Programmable Logic Controllers (PLC)
0 System Capacity
o Executive NV FLASH Memory and RAM
o Housings
o Status Indicators
GM-0984-EDK
Introducing your Controller
1
Programmable Logic Controllers (PLC)
The Modicon 984-381 ~t3a5~t385Dt480~~4a5~t485bu685~~785~~785~~785u
Controllers are mid-range Programmable Logic Controllers in a modular, expandable, architecture. They employ Modicon 800 series housings, interfaces and I/O
modules. These PLC’s are supported by the same instruction set as the other 984
models, and are programmed by Modsoft panel software. All of these units have a
built-in power supply. All of these units are fully compatible with the Modicon 984
PC instruction set, and solve user logic at a rate of from 1 ms to 2.5 ms per thousand nodes of user logic. The 785El785Dl785K are 24-bit CPU’s and the rest are
16-bit CPU’s.
These units have two, or three built-in Modbus ports for data transfer and remote
programming. Through these ports, communication processing on the CPU board
links the controller to multiple supervisory and programming devices such as a
host computer or Modicon’s programming panel. The two Modbus ports allow you
to connect more than one Modbus device to the controller. Some models have
both a single Modbus port and a second port for the Modbus Plus high speed Local Area Network. While others have two Modbus ports and one Modbus Plus
port. The DIP switch for setting the Modbus Plus port address can be accessed
through the bottom of the module’s case.
User memory is backed up by a lithium battery which has a conservatively rated
service life of one year. Once energized, the BATTERY LOW indicator will come
ON when the battery has 14 days left before it will be effectively drawn down. The
battery has a five-year shelf life.
w
Note
The 485K and 785K are the same has the 485E and 785E ex-
cept the K’s have a memory protect Key Switch on the front of the unit.
w
Note
The 385D and 785D are the same has the 385E and 785E ex-
cept the D’s operate on 125VDC rather than 115/23OVAC.
Figure 1 is a perspective view of the 381 E/385E/385D controllers. Certain physical features are noted.
2
Introducing your Controller
GWO984-EDK
Figure 2 is a perspective view of the 480E/485E. The 485K looks the same, except the 485K has a memory protect Key Switch. Certain physical features are
noted.
Figure 3 is a perspective view of the 685E. The 785E/785D/785K looks the same,
except the 785K has a memory protect Key Switch.
Certain physical features are
noted.
AC & DC POWER
INPUT CONNEC-
381 E 385E
TORS (HIDDEN)
TOGGLE SWITCH
I’
(HIDDEN)
BATTERY COVER
I
MODBUS
PLUS
Figure 1 381E/385E/385D Perspective Drawing
MODBUS
PLUS
GM-0984-EDK
Introducing your Controller
3
AC 8, DC POWER
INPUT
CONNECTORS\
AC
POWER
ON/OFF
PORT 1
,“,LI.l_l . I
PROTECT-
TOGGI F .S\
Connects
MEM/DIP ENABLE ;
I
TOGGLE SWITCH ‘.
--
MODBUS
PLUS
(HIDDEN)
I
BATTERY COVER
Figure 2 4800485E Perspective Drawing
4 Introducing your Controller
GMXCF34-EDK
AC P’%
OFF
POWER OK
READY
RUN
BAT LOW
COMM
1
COMM 2
Figure 3 685En85E Perspective Drawing
GM-0984-EDK
Introducing your Controller
5
System Capacity
The system capacity for the various “E” controllers are described below.
Table 1 Memory Per Configuration
PLC
Total
State RI/O Total I/O Pts. Max.
Max. Comm
Model User
RAM Drops per System
Register Discrete Ports
Memory
(Discrete)
Capacity Capacity Total
381 16K 2K 0 512
2K 2048 2 Modbus
385 16K 2K 0 512
2K 2048 1 Modbus &
1 Modbus +
480 16K 2K 6 2048
2K 2048 2 Modbus
485 16K 2K 6 2048
2K 2048 1 Modbus &
1 Modbus +
685 16K 12.5K 16/31 16K
9999 16384 2 Modbus &
1 Modbus +
785* 32K 64K 16/31 16K”
57766 65520 2 Modbus &
1 Modbus +
785* 48K 32K 16131 16K**
28640 65520 2 Modbus &
1 Modbus +
* Size defined during configuration procedures.
‘* Only the first 16383 (16K) of each type may be used for I/O through the Traffic Cop, and
as control of the segment scheduler.
Buffer for .EXE loadables is 10X user logic size.
6
Introducing your Controller
Note You
should note that the physical State RAM size limits the
maximums allowed for discretes and registers that will only be seen if
the other maximums are set at a minimum. In a real configuration, the
available references will be determined by the other references selected at configuration time.
GM-O984-EDK
Table 2 Memory Per Configuration Cont.
PLC Extended
Model Memory
Local Drop Other Drop Points
l/o Pts. up to Defined
Max. l/O Pts.
381 None
512
N/A
385
None
512 N/A
480
None 512 512
485 None 512 512
685 None 1024 512 or 1024”
785* 96K
1024 512 or 1024”
785* 24K 1024 512 or 7024*’
* Size defined during configuration procedures.
** Defined by S908 executive in use.
Optimize Mode (685E/785E ONLY)
The 685EI785E Controllers support an Optimize mode in addition to the Normal
mode of solving ladder logic. As the controller scans in Optimize mode, it compiles an executable program that it stores in an execution buffer. The compiler
uses the buffer space to produce executable code that can scan logic as efficiently
as possible, reserving enough buffer space at start-up time to allow you to edit 2k
of logic while the program is running in Optimize mode.
w
Note
Because the execution buffer is of finite size, the compiler’s
ability to store the most efficient code is affected by both the size of
your logic program and by the efficiency with which you use the program elements in the logic networks.
GMa984-EDK
Introducing your Controller
7
How Optimize Works
When you run the controller in Optimize mode, the compiler constructs inline code
in the execution buffer that executes more efficiently than Normal-mode operations. The controller uses an algorithm to automatically calculate a higher level of
optimization that does not exceed the execution buffer’s capacity and that always
reserves buffer space for 2k of logic editing while the controller is running in Optimize mode. Optimization is fully managed by the controller and is transparent to
you during scanning.
The compiler places related contacts and coils in each network into node groups
and then solves each group as an entity.
Each node group consists of a set of
connected contacts-with or without a coil-related to a common logic path that can
be solved simultaneously. The compiler:
1. Searches each network
2. Locates connected nodes and paths in each network and solves them as a
group
3. Skips the evaluation of nodes and paths that are known to be irrelevant
within each group. That is, if input power for a series of contacts is not on,
the executive will skip the logic solving of these contacts in a network.
By considering each node group as an entity, the compiler is able to reduce the
scan time in ladder logic programs.
When you start to run the controller in Optimize mode, the compiler automatically
reserves enough space in the execution buffer to support 2k of edits while the program is running. If your edits use up all the reserved buffer space, you may either
continue to run the program in Optimize mode with no further editing permitted or
stop and restart the controller with newly generated buffer space for another 2k
edits.
03
Note System performance may be slowed when the compiler adjusts
the buffer for on-line edits and creates the new buffer space for further
edits.
8
Introducing your Controller
GM0984-EDK
Local I/O
All of the Controllers support one local I/O drop in the form of Modicon 800 series
module housings. Local I/O processing is always Drop #I Total Local I/O pro-
vides for Discrete points configured in any mix and registers, refer to Table 1 for
memory configuration for each individual Controller.
Remote I/O
The 480E/485E/485K Controllers have up to 6 drops (one local and five remote)
for a total I/O support capacity of 1024 discrete I/O points (any mix). The
480E/485E/485K also support up to 5 RI/O drops (using the built-in S908 Remote
I/O Processor and optional J89O/P890 RI/O Adapters) with a maximum of 512
more discrete I/O points on one drop or spread over them all. Also, the
480E/485E/485K support a maximum of 2 ASCII ports per drop, up to a total maximum of 12 using optional J892YP892 RI/O ASCII Adapters. Please refer to
GM-0984RIO Modicon Remote l/O Cable System Planning Guide for more details.
The 685El785El785DI785K require a separate RI/O Head module with a plug-in
executive cartridge capable of supporting either 16/31 RI/O drops. The 16 RI/O
drops (using the Executive Cartridge AS-Ego&01 6 on the S908) have
1 Kin/l Kout (I/O bits). It can also support 31 RI/O drops (using the Executive Car-
tridge AS-E908-131 on the S908) with each drop having a maximum of
512in/512out (I/O bits). While the total I/O capacity is 65536 bits, only the first 16K
can be I/O mapped regardless of which S908 executive cartridge is used, (local Ii
0 bits maximum is 1 Kin/l Kout). The S908 Remote I/O Processor comes in two
versions: a single cable (AS-S908-ll O), or dual cable (AS-S908-120). Please
refer to GM-0984RIO Modicon Remote I/O Cable System Planning Guide.
These controllers also support a maximum of 2 ASCII ports per drop up to a total
maximum of 32 using optional J892/P892 RI/O ASCII Adapters. Please refer to
GM-0984-RIO Modicon Remote I/O Cable System Planning Guide for more details. Figure 4 is a perspective view of the RIOP module.
The RI/O interface will drive RI/O up to 5000 feet away (this distance can be increased depending upon the cable selection and certain other customer application considerations). Since the 5000 foot distance allows wide latitudes in system
layout and installation, substantial economies can be realized from carefully
planned layouts. Another planning requirement is to keep attenuation losses within
the system’s 35 dB dynamic range.
GM-0984-EDK
introducing your Controller 9
EXEC CARTRIDGE -
ACCESS PORT
10
Introducing your Controller
COAX
CONNECTOR
Figure 4 RI/O Head (S908) Module (S908-110)
GM-O984-EDK
Executive NV FLASH Memory and RAM
The PLC’s feature executive firmware as two levels of memory which are referred
to in this manual as executive and user memory. The executive is contained in
Non-Volatile flash memory that can be upreved in the field if required, and the
user memory is stored in battery backed RAM. (Refer to the Customer Service &
Technical Assistance section located in Appendix B regarding upgrading NV
FLASH Memory in the field.)
A controller bootable memory software is downloaded to a protected area of flash
memory during the manufacturing process which is not accessible to the user.
Executive Functionality
381
Executive ID of 813 (Hex), CPU Clock speed 12 Mhz.
24 DX functions:
MOVE (8), MATRIX (8), JSR, RET, LAB, PID2, EMTH, TBLK, BLKT, and
CKSM.
Two standard Modbus ports, Time-of-Day clock, Local l/O only.
385
Executive ID of 81 E (Hex), CPU Clock speed 12 Mhz.
24 DX functions:
MOVE (8), MATRIX (8), JSR, RET, LAB, PID2, EMTH, TBLK, BLKT and
MSTR.
(MSTR is the user interface to Modbus Plus. It replaces the CKSM function
and uses its opcode.
One Modbus port, One Modbus Plus Port, Time-of-Day clock, Peer Cop,
Local I/O only.
480
Executive ID of 822 (Hex), CPU Clock speed 12 Mhz.
26 DX functions:
MOVE (8), MATRIX (8), JSR, RET, LAB, PID2, EMTH, TBLK, BLKT, READ,
WRIT and CKSM.
Two standard Modbus ports, Time-of-Day clock, Remote I/O.
GM-0984-EDK
Introducing your Controller
11
o 485
Executive ID of 82E (Hex), CPU Clock speed 12 Mhz.
26 DX functions:
MOVE (8) MATRIX (8) JSR, RET, LAB, PID2, EMTH, TBLK, BLKT READ,
WRIT and MSTR.
(MSTR is the user interface to Modbus Plus. It replaces the CKSM function
and uses the CKSM opcode.
One Modbus port, One Modbus Plus Port, Time-of-Day clock, Peer Cop,
Remote I/O.
IJ 685
Executive ID of 80C (Hex), CPU Clock speed 16 Mhz.
39 DX functions:
MOVE (8) MATRIX (8) JSR, RET, LAB, PID2, EMTH, TBLK, BLKT,
CKSM, 16 BIT MATH (7), PCFL (18), and MSTR.
Two standard Modbus ports, One Modbus Pius Port, Time-of-Day clock,
Peer Cop, Remote I/O (via S908 module).
o 785
Executive ID of 852 (Hex), CPU Clock speed 16 Mhz.
39 DX functions:
MOVE (8), MATRIX (8) JSR, RET, LAB, PID2, EMTH, TBLK, BLKT,
CKSM, 16 BIT MATH (7), PCFL (18) and MSTR.
Two standard Modbus ports, One Modbus Plus Port, Time-of-Day clock,
Peer Cop, Remote I/O (via S908 module).
UT
Note
Both the MSTR and CKSM may coexist in the
685E/785E.
Redundancy 685/785
o At minimum these items are needed to support redundancy:
HSBY Loadable Software, Q 2 Rev 2.0
Hot Standby Adapter, S91 I-801
Remote I/O Adapter, S908 8 1 Rev 1007
12
Introducing your Controller
GM+984-EDK
IB
Note
For the 685E/785E only, the first 10K of registers, and the first
8192 inputs and 8192 coils, are transfered on a switchover.
Housings
The PLC’s systems use Modicon 800 series housings for its controller and l/O
modules; specifically, a 19” primary housing which holds seven modules or a 27”
primary housing which holds eleven modules.
Primary Enclosure - With the single-width controllers mounted in your primary enclosure, the 19’ and 27” primary enclosures will hold up to 6 or 10 I/O modules respectively.
Secondary Enclosure-The remaining secondary housing will accommodate a
one and one-half wide P810, P800 or P884 auxiliary power supply if a power supply expander is required. That is, the standard 19” or 27” secondary housings will
accommodate five or nine I/O modules along with a one and one-half wide (twoslot) auxiliary power supply and a full seven or eleven I/O modules without the
power supply.
The 19-inch primary housing with controller is shown in Figure 5. For simplicity’s
sake, the 27” housing is not shown in this manual except as required in the
illustrations for panel mounting dimensions.
GM-O984-EDK
Introducing your Controller
13
SYSTEM BUS CONNECTOR HOUSING
CAPTIVE SCREWS
UNDER HANDLE
\
I
984-PLC’s IN FIRST SLOT ON LEFT
OURBUS CONNECTOR
Figure 5 Controller Location in Primary Housing AS-H819-209
Remote I/O Enclosures
The remote I/O enclosures are the standard 800 series I/O enclosures; i.e., 19”
and 27” enclosures accommodating seven and eleven modules respectively, as
stated in Chapter 4, Remote I/O Installation.
Each RI/O drop would utilize one auxiliary power supply and a remote I/O adapter
module in its primary housing. Up to four additional secondary housings can be
configured.
14
Introducing
your Controller
GWO984-EDK
Status Indicators
Status indicators on the Controller units are:
POWER OK
READY
RUN
BATTERY LOW
MODBUS PORT 1
MODBUS PORT 2
Green LED When ON, indicates input power OK and
voltage outputs OK.
Amber LED When ON and your I/O power is OK, indicates Controller passed power-up diagnostics. Remains
ON in Stopped and Run modes as long as health status is
OK. Indicator is OFF when an error condition is detected
by diagnostics.
Green LED When ON, indicates Controller is in the RUN
mode and solving logic. If memory checksum fails this light
will blink 3 times for .5 seconds followed by a rest period of
2.5 seconds then the pattern repeats. The controller has
detected a STOP ERROR CODE (refer to Table IO in Appendix B) and may require either restarting, reloading of the
user logic, or reloading of the executive firmware.
Red LED When ON, indicates battery needs to be re-
placed (14 day holdup from initial indication).
Green LED When ON, indicates communication processor has unit address and communications are in progress.
Green LED When ON, indicates communication processor has unit address and communications are in progress.
Additionally, if you have a 3851485 the second port, or a 6851785, the
third port will be:
MODBUS PLUS Green LED This LED displays a flashing repetitive pat-
tern to indicate the node status:
NORMAL flashes every 160 msec.
MONITOR NETWORK flashes at one
second intervals. Is in offline state receive only.
GM-0984-EDK
Introducing your Controller 15
NOT RECEIVING TOKEN flashes two times then is off for
two seconds.
SOLE STATION flashes three times then is off for 1.7 seconds.
DUPLICATE NODE ADDRESS flashes four times then is
off for 1.4 seconds.
With a 480/485 you have two additional indicators:
COMM ACTIVE Green LED
When ON, indicates Remote I/O communica-
tion is in progress.
COMM ERROR
Red LED When ON, indicates a Remote I/O comm error
detected (example: CRC framing or missing physical drop)
16
Introducing your Controller
GM-O984-EDK
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