Rockwell Automation 1747-L40 User Manual

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Page 1

AllenBradley

SLC 500t Fixed Hardware Style

(Cat.

No. 1747L20, 1747L30,

and 1747L40 Processors)

product icon

Installation and Operation Manual

Page 2

Allen-Bradley

SLC 500t Fixed Hardware Style

(Cat. No. 1747-L20, 1747-L30, and 1747-L40 Processors)

Installation and Operation Manual

Page 3

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) 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 the Allen-Bradley Company 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, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment, or software described in this manual.

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

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

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

damage, or economic loss.

Attentions help you:

• identify a hazard

• avoid the hazard

• recognize the consequences

Important: Identifies information that is especially important for successful

application and understanding of the product.

PLC and PLC 5 are registered trademarks of Allen-Bradley Company, Inc. SLC, SLC 500, Dataliner, and DTAM are trademarks of Allen-Bradley Company, Inc. IBM is a registered trademark of International Business Machines, Incorporated. Tandy is a trademark of the Tandy Corporation. Gateway 2000 is a trademark of Gateway 2000, Inc. Toshiba is a trademark of Toshiba America, Inc. Compaq is a registered trademark of Compaq Computer Corporation. Deskpro is a trademark of Compaq Computer Corporation.

Page 4

Summary of Changes

The information below summarizes the changes to this manual since the last printing as 1747-NI001 in November, 1993.

To help you find new information and updated information in this release of the manual, we have included change bars as shown to the right of this paragraph.

New Information

The table below lists sections that document new features and additional information about existing features, and shows where to find this new information.

For This New Information See

Updated list of related publications Preface

High voltage warning Chapters 2, 4, and 7

Page 5

Page 6

Summary of Changes

New

Information

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Preface P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Who Should Use this Manual P-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Use this Manual P-2 Related Related Conventions Used in this Manual P-4 Allen-Bradley Support P-4

Publications Publications

Local Product Support P-4 Technical Product Assistance P-4 Your Questions or Comments on this Manual P-4

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P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Selecting Your Hardware Components 1-1. . . . . . . . . . . . . . .

What Your SLC 500 Controller Can Do for You 1-1. . . . . . . . . . . . . . .

Overview Fixed Controller Specifications 1-3

Selecting the 2-Slot Chassis 1-8 Selecting Selecting Selecting Enclosures 1-9 Selecting Operator Interfaces 1-9

EEPROM and UVPROM Memory Modules 1-11 Selecting Special Considerations 1-13

of Y

our Fixed Control System 1-2. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Memory Backup for the SLC 500 Fixed Controller 1-4 Configuration Input

Specifications Output Relay

Contact Ratings

Programming with a Hand-Held Terminal (1747-PT1) 1-9 Programming with Advanced Programming Software (APS)

on an IBM Compatible Computer Advanced Programming Software, 1747-PA2E 1-10 DH-485 Interface Converter (1747-PIC) 1-10

Monitoring

Excessive Line V Excessive Noise 1-13 Selecting Surge Suppressors 1-14 Selecting Contact Protection 1-16 Transistor

Options

Specifications

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Discrete I/O Modules Speciality I/O Modules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with a Data T

Isolation T

Output T

able Access Module (1747-DTAM-E) 1-10. .

ransformers 1-12. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage V

ariations 1-13. . . . . . . . . . . . . . . . . . . . . .

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ransient Pulses 1-17. . . . . . . . . . . . . . . . . . . . .

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1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. . . . . . . . . . . . . . . . . . . . . . . . .

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1-9. . . . . . . . . . . . . . . . . . . .

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Page 7

Table of Contentsii

Example 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Installation Recommendations 2-1. . . . . . . . . . . . . . .

Typical

Installation Spacing Your Components 2-2 Preventing Excessive Heat 2-2 Grounding Master Control Relay 2-5

Emergency-Stop Switches 2-6

Power Considerations 2-7

Common Power Source 2-7 Loss of Power Source 2-7 Input States on Power Down 2-7 Other Types of Line Conditions 2-7

Safety Considerations 2-8

High Voltages - SLC 500 Fixed Hardware Style Controller (Series C)

Disconnecting Main Power 2-8 Wiring Distributing Power 2-9 Testing the Master Control Relay Circuit 2-9

Preventive Maintenance 2-9

Guidelines

(Applies to 1747-L20A, -L30A, -L40A, -L20C, -L30C, and -L40C controllers) 2-8

Safety Circuits

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2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Your SLC 500 Control System 3-1. . . . . . . . . . . . . .

Mounting Fixed Hardware Style Units 3-1. . . . . . . . . . . . . . . . . . . . . .

I/O Fixed ControllerÀ 30 and 40 I/O Fixed ControllerÀ 3-3 2-Slot Expansion ChassisÀ 3-4 Link Coupler (AIC)À 3-5 Data Table Access Module (DTAM)À 3-5

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3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Your Hardware Components 4-1. . . . . . . . . . . . . . . .

Mounting the 2-Slot Expansion Chassis 4-1. . . . . . . . . . . . . . . . . . . .

Installing Installing Your Memory Module 4-4

Using the High-Speed Counter 4-5

I/O and Speciality Modules

. . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Your Memory Module 4-5

High-Speed Counter Operation 4-5 High-Speed Wiring Diagram of a High-Speed Counter Sinking Input Circuit 4-7 Wiring Diagram of a High-Speed Counter Sourcing Input Circuit 4-7

Counter Input Compatibility

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4-2. . . . . . . . . . . . . . . . . . . . . .

4-6. . . . . . . . . . . . . . . . .

Page 8

Table of Contents iii

Wiring Your Control System 5-1. . . . . . . . . . . . . . . . . . . . . . . .

Defining Sinking and Sourcing 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact Output Circuits  AC or DC 5-2 Solid-State Sourcing Sinking Device with Sourcing Input Module Circuit 5-3 Sinking Device with Sourcing Output Module Circuit 5-3

Sourcing Preparing Your Wiring Layout 5-4 Features Recommendations for Wiring I/O Devices 5-6 Wiring Your I/O Modules 5-7 Using Removable Terminal Blocks (RTBs) 5-8

Removing RTBs 5-8

Installing RTBs 5-9

DC I/O Circuits

Device with Sinking Input Module Circuit

Device with Sinking Output Module Circuit

. . . . . . . . . . . . . . . . . . . . . . . . . . .

of an I/O Module

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5-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. . . . . . . . . . .

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5-3. . . . . . . . .

5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Starting Up Your Control System 6-1. . . . . . . . . . . . . . . . . . . .

Procedures for Starting Up the Control System 6-1. . . . . . . . . . . . . . .

1. Inspect Y

2. Disconnect Motion-causing Devices 6-2

Initialize and T

4. Test Your Inputs 6-4

Input Troubleshooting Steps 6-5

5. Test Your Outputs 6-6

Output Troubleshooting Steps 6-7

6. Enter and Test Your Program 6-8

7. Observe Control Motion 6-10

8. Conduct a Dry Run 6-11

our Installation

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est Your Processor 6-3. . . . . . . . . . . . . . . . . . . . . .

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6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining Your Control System 7-1. . . . . . . . . . . . . . . . . . . .

Handling, Storing, and Transporting Battery

Catalog Number 1747-BA 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling 7-1 Storing 7-1 Transporting 7-2

Installing or Replacing Your SLC 500 Battery 7-4 Replacing the Power Supply Fuse 7-5 Replacing

Removing Damaged Retainer Clips 7-6 Installing New Retainer Clips 7-6

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Retainer Clips on an I/O Module

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7-6. . . . . . . . . . . . . . . . . .

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Page 9

Table of Contentsiv

Troubleshooting 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calling Allen-Bradley for Assistance 8-1. . . . . . . . . . . . . . . . . . . . . .

Tips for Troubleshooting Your Control System 8-2

Removing Power 8-2 Replacing Fuses 8-3 Program

Troubleshooting Your Fixed Controller 8-3

Identifying Fixed Controller Errors 8-4

Troubleshooting Your Input Modules 8-8

Input Circuit Operation 8-8 Corrective

Troubleshooting Your Output Modules 8-10

Output Circuit Operation 8-10 Corrective

Alteration

Action

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8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Parts 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Parts 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Terminal Blocks 9-2

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Setting Up the DH-485 Network A-1. . . . . . . . . . . . . . . . . . . . .

DH-485 Network Description A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

DH-485 Network Protocol A-1 DH-485 Token Rotation A-2 DH-485 Devices that Use the DH-485 Network A-3 1747-AIC Isolated Link Coupler for DH-485 A-4 Example System Configuration A-5 Important Planning Considerations A-6

DH-485

Network Initialization

Hardware Considerations A-6

Number of Devices and Length of Communication Cable A-6 Planning Cable Routes A-6

Software Considerations A-7

Number of Nodes A-7 Setting Node Addresses A-8 Setting Processor Baud Rate A-8 Maximum Node Address Setting A-8

Network Installation DH-485 Communication Cable and Isolated Link Coupler A-9 Installing the DH-485 Communication Cable A-10 Connecting the Communication Cable to the Isolated Link Coupler A-11

Single Cable Connection A-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Single Cable Connection A-11

Multiple Cable Connection A-11 Grounding and Terminating the DH-485 Network A-13 Powering the Link Coupler A-14

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A-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

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A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Page 10

Table of Contents v

Installing and Attaching the Link Couplers A-16. . . . . . . . . . . . . . . . .

The 1771-Remote I/O Network B-1. . . . . . . . . . . . . . . . . . . . . .

1771-Remote

I/O Network

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

RS-232 Communication Interface C-1. . . . . . . . . . . . . . . . . . .

RS-232 and SCADA Applications C-1. . . . . . . . . . . . . . . . . . . . . . . .

RS-232 Communication Interface Overview C-1 SLC 500 Devices that Support RS-232 Communication C-2

1770-KF3 Module C-2 1747-KE Module C-2 1746-BAS Module C-2

Wiring Connectors for RS-232 Communication C-3

Types of RS-232 Connectors C-3 DTE

Pinout

DCE

Pinout

Pin Assignments for Wiring Connectors C-5

IBM AT to a Modem (Hardware Handshaking Enabled) C-6 IBM AT to a 5/03 Processor, 1770-KF3, 1775-KA, 1773-KA,

5130-RM, or PLC-5 (Hardware Handshaking Disabled)

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À C-6 1747-KE to a Modem (Hardware Handshaking Enabled) C-7 1747-KE to a 5/03 Processor

1773-KA, 5130-RM, or PLC-5

(Hardware Handshaking Disabled) À C-7 1746-BAS to a Modem (Hardware Handshaking Enabled) C-8 1746-BAS to a 5/03 Processor

1773-KA, 5130-RM, or PLC-5 (Hardware Handshaking

Disabled)À C-8 1770-KF3 to a Modem (Hardware Handshaking Enabled) C-8 2760-RB to a Modem (Hardware Handshaking Enabled) C-9 2760-RB to a 5/03 Processor

1773-KA, 5130-RM, or PLC-5

(Hardware Handshaking Disabled) À C-9 1771-KGM to a Modem (Hardware Handshaking Enabled) C-10 1771-KGM to a 5/03 Processor

1775-KA, 1773-KA, 5130-RM, or PLC-5

(Hardware Handshaking Disabled) À C-10 1775-KA to a Modem (Hardware Handshaking Enabled) C-11 1775-KA to a 5/03 Processor

5130-RM, or PLC-5 (Hardware Handshaking Disabled) À C-11 PLC-5 (Channel 0) to a Modem

(Hardware Handshaking Enabled) C-12 PLC-5 (Channel 0) to a 5/03 Processor

1773-KA, 5130-RM, PLC-5, 1747-KE, or 1746-BAS

(Hardware Handshaking Disabled) À C-12 5130-RM to a Modem (Hardware Handshaking Enabled) C-13

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, IBM A

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, IBM A

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T, 1770-KF3, 1775-KA,

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. . .

T, 1770-KF3, 1775-KA,

. . .

. . . .

T, 1770-KF3, 1775-KA,

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T, 1770-KF3,

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. . . .

T, 1770-KF3, 1773-KA,

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, IBM A

T, 1770-KF3,

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C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

Page 11

Table of Contentsvi

5130-RM to a 5/03 Processor

5130-RM, PLC-5, 1747-KE, or 1746-BAS (Hardware Handshaking Disabled) À C-13

, IBM A

T, 1770-KF3, 1773-KA,

. . . . . . . . . . . . . . .

Calculating Heat Dissipation for the SLC 500

Control System D-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Definition of Key Terms D-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module

Heat Dissipation: Calculated W

Use

this T

able to Calculate the Power Supply Loading D-2. . . . . . . . . .

Example

Worksheet

Heat Dissipation Calculation

Example Worksheet for Calculating Heat Dissipation D-4

for Calculating Heat Dissipation

atts vs. Maximum W

. . . . . . . . .

atts D-1. . .

D-4. . . . . . . . . . . . . . . . . . . . .

D-5. . . . . . . . . . . . . . . . .

Wiring and Circuit Diagrams and Voltage Ranges

for Your Fixed Controller E-1. . . . . . . . . . . . . . . . . . . . . .

Wiring Symbols E-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring and Circuit Diagrams and Voltage Range Locations E-2 Catalog Number 1747-L20A (12) 120 VAC Inputs & (8)

Relay Outputs

Input Circuit Diagram E-5

On/Off

State V

Output Circuit Diagram E-5

Operating Voltage Range E-5

Catalog Number 1747-L20B (12) 120 VAC Inputs & (8)

Triac Outputs E-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-7

On/Off

State V

Output Circuit Diagram E-7

Operating Voltage Range E-7

Catalog Number 1747-L20C (12) 24 VDC Sinking Inputs, High-Speed

Counter Input & (8) Relay Outputs E-8. . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-9

On/Off

State V

On/Off

State V

Output Circuit Diagram E-10

Operating Voltage Range E-10

Catalog Number 1747-L20D (12) 24 VDC Sinking Inputs, High-Speed

Counter Input & (8) Triac Outputs E-11. . . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-12

On/Off

State V

On/Off

State V

Output Circuit Diagram E-13

Operating Voltage Range E-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-5. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-7. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-9. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-9. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-12. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-12. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 12

Table of Contents vii

Catalog Number 1747-L20E (12) 24 VDC Sinking Inputs, High-Speed

Counter Input & (8) Transistor Sourcing Outputs E-14

Input Circuit Diagram E-15

On/Off

State V

On/Off

State V

Output Circuit Diagram E-16

Operating Voltage Range E-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-15. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-15. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

Catalog Number 1747-L20F (12) 24 VDC Sinking Inputs, High-Speed

Counter Input & (8) Relay Outputs E-17. . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-18

On/Off

State V

On/Off

State V

Output Circuit Diagram E-19

Operating Voltage Range E-19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-18. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-18. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L20G (12) 24 VDC Sinking Inputs, High-Speed

Counter Input & (8) Transistor Sourcing Outputs E-20

Input Circuit Diagram E-21

On/Off

State V

On/Off

State V

Output Circuit Diagram E-22

Operating Voltage Range E-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-21. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-21. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

Catalog Number 1747-L20L (12) 24 VDC Sourcing Inputs, High-Speed

Counter Input & (8) Transistor Sinking Outputs E-23. . . . . . . . . . . .

Input Circuit Diagram E-24

On/Off

State V

On/Off

State V

Output Circuit Diagram E-25

Operating Voltage Range E-25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-24. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-24. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L20N (12) 24 VDC Sourcing Inputs, High-Speed

Counter Input & (8) Transistor Sinking Outputs E-26. . . . . . . . . . . .

Input Circuit Diagram E-27

On/Off

State V

On/Off

State V

Output Circuit Diagram E-28

Operating Voltage Range E-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-27. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-27. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L20P (12) 240 VAC Inputs & (8)

Triac Outputs E-29

Input Circuit Diagram E-30

On/Off

Output Circuit Diagram E-30

Operating Voltage Range E-30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

State V

oltage Ranges E-30. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L20R (12) 240 VAC Inputs & (8)

Relay Outputs

Input Circuit Diagram E-32

On/Off

State V

Output Circuit Diagram E-32

Operating Voltage Range E-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-32. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

E-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 13

Table of Contentsviii

Catalog Number 1747-L30A (18) 120 VAC Inputs & (12)

Relay Outputs

Input Circuit Diagram E-34

On/Off

State V

Output Circuit Diagram E-34

Operating Voltage Range E-34

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-34. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

E-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L30B (18) 120 Vac Inputs & (12)

Triac Outputs E-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-36

On/Off

State V

Output Circuit Diagram E-36

Operating Voltage Range E-36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-36. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L30C (18) 24 VDC Sinking Inputs, High-Speed

Counter Input & (12) Relay Outputs E-37. . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-38

On/Off

State V

On/Off

State V

Output Circuit Diagram E-39

Operating Voltage Range E-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-38. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-38. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L30D (18) 24 VDC Sinking Inputs, High-Speed

Counter Input & (12) Triac Outputs E-40. . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-41

On/Off

State V

On/Off

State V

Output Circuit Diagram E-42

Operating Voltage Range E-42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-41. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-41. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L30L (18) 24 VDC Sourcing Inputs, High-Speed

Counter Input & (12) Transistor Sinking Outputs E-43

Input Circuit Diagram E-44

On/Off

State V

On/Off

State V

Output Circuit Diagram E-45

Operating Voltage Range E-45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-44. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-44. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

Catalog Number 1747-L30P (18) 240 VAC Inputs & (12)

Triac Outputs E-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-47

On/Off

State V

Output Circuit Diagram E-47

Operating Voltage Range E-47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-47. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40A (24) 120 VAC Inputs & (16)

Relay Outputs

Input Circuit Diagram E-49

On/Off

State V

Output Circuit Diagram E-49

Operating Voltage Range E-49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges E-49. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

E-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 14

Table of Contents ix

Catalog Number 1747-L40B (24) 120 VAC Inputs & (16)

Triac Outputs E-50

Input Circuit Diagram E-51

On/Off

Output Circuit Diagram E-51

Operating Voltage Range E-51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

State V

oltage Ranges E-51. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40C (24) 24 VDC Sinking Inputs, High-Speed

Counter Input & (16) Relay Outputs E-52. . . . . . . . . . . . . . . . . . . .

Input Circuit Diagram E-53

On/Off

State V

On/Off

State V

Output Circuit Diagram E-54

Operating Voltage Range E-54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-53. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-53. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40E (24) 24 VDC Sinking Inputs, High-Speed

Counter Input & (16) Transistor Sourcing Outputs E-55. . . . . . . . . .

Input Circuit Diagram E-56

On/Off

State V

On/Off

State V

Output Circuit Diagram E-57

Operating Voltage Range E-57

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-56. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-56. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40F (24) 24 VDC Sinking Inputs, High-Speed

Counter Input & (16) Relay Outputs E-58 Wiring Diagram E-58 Input Circuit Diagram E-59

On/Off

State V

On/Off

State V

Output Circuit Diagram E-60

Operating Voltage Range E-60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-59. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-59. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40L (24) 24 VDC Sourcing Inputs, High-Speed

Counter Input & (16) Transistor Sinking Outputs E-61. . . . . . . . . . .

Input Circuit Diagram E-62

On/Off

State V

On/Off

State V

Output Circuit Diagram E-63

Operating Voltage Range E-63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

oltage Ranges - Input 0 (HSC) E-62. . . . . . . . . . . .

oltage Ranges - All Other Inputs E-62. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Number 1747-L40P (24) 240 VAC Inputs & (16)

Triac Outputs E-64

Input Circuit Diagram E-65

On/Off

Output Circuit Diagram E-65

Operating Voltage Range E-65

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

State V

oltage Ranges E-65. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary G-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 15

Page 16

Preface

Read this preface first. It provides an overview of the entire manual and will acquaint you with the information that is provided throughout these pages. In this preface, you will learn about:

• who should use this manual

• how to use this manual

• related publications

• conventions used in this manual

• Allen–Bradley support

Who Should Use this Manual

The tasks and procedures in this manual require you to have some knowledge of programmable controller installation and electrical wiring. We also assume that you have a “working” knowledge of SLCt products. If you do not have this knowledge base, obtain the proper training before attempting any of the tasks and/or procedures detailed in this manual.

P–1

Page 17

Preface

How to Use this Manual

As much as possible, we organized this manual to explain, in a task–by–task manner, how to install and operate (preliminary start–up operations) the SLC 500 fixed programmable controller. This manual also provides some system design information.

Before using this manual, read over the table below and familiarize yourself with the general content of the chapters and appendixes. If you already have a topic in mind that you want to find specific information about, turn to the index at the back of the manual.

If You Want See

An overview of the manual The Preface

Information on how to select certain components for your SLC 500 control system

A guide on how to prepare for the installation of your control system

Mounting dimensions of your fixed controller, DTAM

t, and/or 1747-AIC

Procedures on how to install your hardware components

Information on how to wire the components of your SLC 500 control system

A guide on how to start up your control system Chapter 6  Starting Up Your Control System

Chapter 1  Selecting Your Hardware Components

Chapter 2  System Installation Recommendations

Chapter 3  Mounting Your SLC 500 Control System

Chapter 4  Installing Your Hardware Components

Chapter 5  Wiring Your Control System

Information on how to maintain your control system

To identify error messages generated by your control system

To replace parts of your SLC 500 control system or purchase other SLC components

Information on setting up the DH-485 network Appendix A  Setting Up the DH-485 Network

Information on the 1771-Remote I/O network Appendix B  The 1771-Remote I/O Network

Information on configuring the RS-232 network Appendix C  RS-232 Communication Interface

Information on how to calculate the heat dissipation of your controller

Wiring and circuit diagrams and voltage ranges

Definitions of terms used in this manual The Glossary

Chapter 7  Maintaining Your Control System

Chapter 8  Troubleshooting

Chapter 9  Replacement Parts

Appendix D  Calculating Heat Dissipation for the SLC 500 Control System

Appendix E  Wiring and Circuit Diagrams and Voltage Ranges for Your Fixed Controller

P–2

Page 18

Preface

Related PublicationsRelated Publications

The table below provides a listing of publications that contain important information about Allen–Bradley Small Logic Controllers and their installation and application. You may want to reference them while you are installing the SLC 500 controller. (To obtain a copy of one of these publications, contact your local Allen–Bradley office or distributor.)

For Read this Document

An overview of the SLC 500 family of products SLC 500 System Overview 1747-2.30

A description on how to install and use your Modular SLC 500 programmable controller

A procedural manual for technical personnel who use APS to develop control applications

A reference manual that contains status file data, instruction set, and troubleshooting information about APS

An introduction to APS for first-time users, containing basic concepts but focusing on simple tasks and exercises, and allowing the reader to begin programming in the shortest time possible

A procedural and reference manual for technical personnel who use the APS import/export utility to convert APS files to ASCII and conversely ASCII to APS files

A procedural and reference manual for technical personnel who use an HHT to develop control applications

An introduction to HHT for first-time users, containing basic concepts but focusing on simple tasks and exercises, and allowing the reader to begin programming in the shortest time possible

Installation & Operation Manual for Modular Hardware Style Programmable Controllers

Advanced Programming Software (APS) User Manual 9399-APSUM

SLC 500t and MicroLogixt 1000 Instruction Set Reference Manual

APS Quick Start for New Users 9399-APSQS

APS Import/Export User Manual 9399-APSIE

Allen-Bradley Hand-Held Terminal User Manual 1747-NP002

Getting Started Guide for HHT 1747-NM009

Document Number

1747-6.2

1747-6.15

In-depth information on grounding and wiring Allen-Bradley programmable controllers

A description on how to install a PLC-5r system

A description of important differences between solid-state programmable controller products and hard-wired electromechanical devices

An article on wire sizes and types for grounding electrical equipment National Electrical Code

A complete listing of current Automation Group documentation, including ordering instructions. Also indicates whether the documents are available on CD-ROM or in multi-languages.

A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1

Allen-Bradley Programmable Controller Grounding and Wiring Guidelines

PLC-5 Family Programmable Controllers Hardware Installation Manual

Application Considerations for Solid-State Controls SGI-1.1

Allen-Bradley Publication Index SD499

1770-4.1

1785-6.6.1

Published by the National Fire Protection Association of Boston, MA.

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Page 19

Preface

Conventions Used in this Manual

Allen-Bradley Support

The following conventions are used throughout this manual:

• Bulleted lists such as this one provide information, not procedural steps.

• Numbered lists provide sequential steps or hierarchical information.

• Italic type is used for emphasis.

• Dimensions are in millimeters. (Dimensions in parentheses are in

inches.)

• Text in this

Allen–Bradley offers support services worldwide, with over 75 Sales/Support offices, 512 authorized Distributors and 260 authorized Systems Integrators located throughout the United States alone, plus Allen–Bradley representatives in every major country in the world.

font

indicates words or phrases you should type.

Local Product Support

Contact your local Allen–Bradley representative for:

• sales and order support

• product technical training

• warranty support

• support service agreements

P–4

Technical Product Assistance

If you need to contact Allen–Bradley for technical assistance, please review the information in the Troubleshooting chapter first. Then call your local Allen–Bradley representative.

Your Questions or Comments on this Manual

If you find a problem with this manual, please notify us of it on the enclosed Publication Problem Report.

If you have any suggestions for how this manual could be made more useful to you, please contact us at the address below:

Allen–Bradley Company, Inc. Automation Group Technical Communication, Dept. 602V, T122 P.O. Box 2086 Milwaukee, WI 53201–2086

Page 20

Chapter

Selecting Your Hardware Components

This chapter provides general information on what your SLC 500 controller can do for you and an overview of the fixed control system. It also explains how to select:

• 2–slot chassis

• discrete I/O modules

• specialty I/O modules

• enclosures

• operator interfaces

• memory modules

• isolation transformers

• suppressors

• output contact protection

What Your SLC 500 Controller Can Do for You

There is also a section on special considerations for controller installations. This chapter does not provide you with all the information that you need to

select a complete SLC 500 control system. To do this, we recommend that you use the latest version of the system overview, SLC 500 Family of Small Programmable Controllers, Publication Number 1747–2.30.

The SLC 500 programmable controller has features that previously could only be found in large programmable controllers. It has the flexibility and power of a large controller with the size and simplicity of a small controller. The SLC 500 controller offers you more control options than any other programmable controller in its class.

These programmable controllers make up a technologically advanced control system having inherent flexibility and advantages characteristic of other programmable controllers, but with one important difference — simplicity!

1–1

Page 21

Chapter 1

Selecting Your Hardware Components

Overview of Your Fixed Control System

Fixed Hardware Components

Fixed Hardware Controller

The basic fixed controller consists of a processor with 1,024 (1K) instruction capacity, a power supply, and a fixed number of I/O contained in a single package. The figure below shows typical hardware components for a fixed controller.

Input Module

Output Module

Fixed

Controller with 2-slot Expansion Chassis

Operator Interface

2-Slot Expansion Chassis

for I/O Modules

1–2

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Fixed Controller Specifications

This section provides the specifications for the SLC 500 Fixed Controller.

Description Specification

Memory Type Capacitor-backed RAM memory. Battery back-up optional.

Memory Backup Options EEPROM or UVPROM

Program Memory 1K Instruction Capacity

Capacitor Memory Back-up Time Refer to curve on page 1-4.

Battery Life 5 years

Typical Scan Time

➀

Bit Execution (XIC) 4 microseconds

Program Scan Hold-up Time after Loss of Power

Power Supply Operating Voltage

Power Supply Fuse Protection

Power Supply Inrush Rating 30 Amperes maximum

Maximum Power Requirement

24 VDC User Power Output Current

24 VDC User Power Output Voltage

Wire Size #14 AWG Max.

8 milliseconds/1K

20 milliseconds to 700 milliseconds (dependent on loading)

AC units: 85-265 VAC 47-63 Hz

DC units: 21.6-26.4 VDC (24 VDC ± 10%)

AC units: 120/240 VAC 1.25A DC units: 24 VDC 1.6A

➁

50 VA

➂

200mA

➂

20.4 - 27.6 VDC (24 VDC ± 15 %)

I/O Electrical-Optical Isolation 1500 VAC at 1 minute

1747-AIC Link Coupler Electrical-Optical Isolation

LED Indicators

1500 VDC

POWER, PC RUN, CPU FAULT, FORCED I/O, and BATTERY LOW

Noise Immunity NEMA Standard ICS 2-230

Ambient Temperature Rating

Operating: 0°C to +60°C (+32°F to +140°F) Storage: 40°C to +85°C (-40°F to +185°F)

Humidity 5 to 95% without condensation

Displacement: .015 inch, peak-to-peak @ 5-57 Hz

Vibration

Certification

➀

The scan times are typical for a 1K ladder logic program consisting of simple ladder logic and communication servicing. Actual scan times depend on your program size, instructions used, and the DH-485 communication.

➁

This specification does not include input and output values. (See page

➂

This applies only to fixed controllers that have AC line power and DC input circuits.

Acceleration: 2.5 Gs @ 57-2000 Hz

Duration: 1 hr per axis (x, y

, z)

UL listed/ CSA approved

1-6.)

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Time (Days)

Memory Backup for the SLC 500 Fixed Controller

The curve below illustrates the ability of the memory back–up capacitor to maintain the contents of the RAM in a fixed controller. To back up the memory for a longer period of time, a lithium battery, Catalog Number 1747–BA, is required.

Capacitor Memory Back-up Time VS Temperature

25 30 35 40 45 50 55 60

(77°) (86°) (95°) (104°)(113°) (122°) (131°) (140°)

Temperature °

C (

°F)

1–4

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Catalog

High-Speed

Selecting Your Hardware Components

Configuration Options

The following table provides configuration options for 20, 30, or 40 I/O points.

Catalog Number

1747-L20A (12) 120 Volts AC (8) AC/DC Relay No

1747-L30A (18) 120 Volts AC (12) AC/DC Relay No NA

1747-L40A (24) 120 Volts AC (16) AC/DC Relay No NA

1747-L20B (12) 120 Volts AC (8) AC Triac No NA

1747-L30B (18) 120 Volts AC (12) AC Triac No NA

1747-L40B (24) 120 Volts AC (16) AC Triac No NA

1747-L20C (12) 24 Volts DC Sink (8) AC/DC Relay Ye s 24V-200mA

1747-L30C (18) 24 Volts DC Sink (12) AC/DC Relay Ye s 24V-200mA

1747-L40C (24) 24 Volts DC Sink (16) AC/DC Relay Ye s 24V-200mA

1747-L20D (12) 24 Volts DC Sink (8) AC Triac Yes 24V-200mA

1747-L30D (18) 24 Volts DC Sink (12) AC Triac Yes 24V-200mA

1747-L20E

1747-L40E (24) 24 Volts DC Sink

1747-L20L

1747-L30L

1747-L40L

1747-L20R (12) 240 Volts AC (8) AC/DC Relay No NA

Line Power

120/240 VAC

(12) 24 Volts DC Sink

(12) 24 Volts DC Source

(18) 24 Volts DC Source

(24) 24 Volts DC Source

I/O Configuration

Input Output

(8) DC Transistor Source

(16) DC Transistor Source

(8) DC Transistor Sink

(12) DC Transistor Sink

(16) DC Transistor Sink

High-Speed

Counter

Yes 24V-200mA

User Power

1747-L20P (12) 240 Volts AC (8) AC Triac No NA

1747-L30P (18) 240 Volts AC (12) AC Triac No NA

1747-L40P (24) 240 Volts AC (16) AC Triac No NA

1747-L20F (12) 24 Volts DC Sink (8) AC/DC Relay Yes NA

1747-L40F (24) 24 Volts DC Sink (16) AC/DC Relay Yes NA

1747-L20G

1747-L20N

24 VDC±

10%

(12) 24 Volts DC Sink

(12) 24 Volts DC Source

(8) DC Transistor Source

(8) DC Transistor Sink

Yes NA

1–5

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Input Specifications

The following table details the input specifications for SLC 500 Fixed I/O units. See the glossary for a definition of specifications.

Inputs Specifications

120 VAC Inrush Current 0.8A peak

On-State Voltage 85-132 VAC

Frequency

Off-State Voltage 30 VAC (maximum)

Nominal Input Current 12mA at 120 VAC

Turn-On Time 35 milliseconds (maximum)

Turn-Off Time 45 milliseconds (maximum)

Maximum Off-State Current 2mA

On-State Voltage 170-265 VAC

47-63 Hz

Frequency 47-63 Hz

Off-State Voltage 50 VAC (maximum)

240 VAC Inrush Current 1.6A peak

Nominal Input Current 12mA at 240 VAC

Turn-On Time 35 milliseconds (maximum)

Turn-Off Time 45 milliseconds (maximum)

Maximum Off-State Current 2mA

On-State Voltage 10-30 VDC

4 VDC maximum for input 0 (HSC) 5 VDC for all others

20mA at 24 VDC (for input 0 only) 8mA at 24 VDC (all others inputs)

DC Sink & Source

Off-State Voltage

Nominal Input Current

Turn-On Time 8 milliseconds (maximum)

Turn-Off Time 8 milliseconds (maximum)

Maximum Off-State Current 1mA

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Triac

➂

Selecting Your Hardware Components

Output Specifications

The following table details the output specifications for SLC 500 Fixed I/O Units.

Outputs Specifications

Output Voltage 85-265 VAC

Triac

Transistor Sink & Source

Continuous Current (per output)

0.5 Amp at +30°C

0.25 Amp at +60°C (maximum)

Minimum Load Current 10mA

Turn-On Time

0.1 milliseconds (maximum)

Turn-Off Time 10 milliseconds (maximum)

Maximum Off-State Leakage Current 2mA

Maximum On-State Voltage Drop 1.5V @ 0.5 Amps

Maximum Surge Current

10 Amps for 25 milliseconds

Output Voltage 10-50 VDC

Continuous Current (per output)

0.5 Amp at +30°C

0.25 Amp at +60°C (maximum)

Minimum Load Current 1mA

Turn-On Time 0.1 millisecond (maximum)

Turn-Off Time

1 millisecond (maximum)

Maximum Off-State Leakage Current 1mA

Maximum On-State Voltage Drop 1.5V @ 0.5 Amps

Maximum Surge Current

3.0 Amps for 25 milliseconds

Output Voltage Range 5-265 VAC, 5-125 VDC

➀

Continuous Current (per output) 2.5 Amps (maximum)

Relay

Continuous Current (per group)

➂

Maximum Load (per chassis) 1440 VA

➁

8 Amps (maximum)

Turn-On Time 10 milliseconds (maximum)

Turn-Off Time 10 milliseconds (maximum)

Maximum Off-State Leakage Current 0mA

Minimum Load Current at 5 VDC 10mA

➀

Repeatability is once every 1 second at +30°C. Repeatability is once every 2 seconds at +60°C.

➁

Refer to the wiring diagrams for output groupings on the fixed I/O chassis.

➂

Surge suppression across the output device is recommended to protect relay contacts.

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Relay Contact Ratings

Selecting the 2-Slot Chassis

Maximum

Volts

240 VAC 120 VAC

125 VDC 0.22A 1.0A 28 VA

24 VDC 1.2A 2.0A 28 VA

7.5A 15A

Amperes

Make Break

0.75A

1.5A

Amperes

Continuous

2.5A 1800 VA 180 VA

Voltamperes

Make Break

To calculate make and break ratings for other load voltages, divide the voltampere rating by the load voltage; for example:

28 VA/48 VDC = 0.583 A

For the 20, 30, and 40 I/O fixed controllers, an optional 2–slot expansion chassis lets you add two additional I/O modules providing even more versatility. The power supply provides backplane power for the modules in the optional expansion chassis.

Refer to chapter 3 for chassis dimensions and chapter 4 for mounting directions.

Selecting Discrete I/O Modules

Selecting Speciality I/O Modules

There are three types of I/O modules: input, output, and combination I/O. They are available in a wide variety of densities including 4, 8, 16, and 32 point and can interface to AC, DC, and TTL voltage levels. Output modules are available with solid–state AC, solid–state DC, and relay contact type outputs.

For a complete, up–to–date listing of discrete I/O modules and their specifications, contact your Allen–Bradley sales office for the latest product data entitled Discrete Input and Output Modules, Publication Number 1746–2.35.

Refer to chapter 4 for installation directions.

The SLC 500 family offers specialty I/O modules that enhance your control system. These modules range in function from analog interface to motion control, from communication to high–speed counting.

For a complete, up–to–date listing of specialty I/O modules and their specifications, contact your Allen–Bradley sales office for the latest System Overview entitled SLC 500 Family of Small Programmable Controllers, Publication Number 1747–2.30, or for a related product data.

1–8

Refer to chapter 4 for installation directions.

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Selecting Enclosures

Selecting Operator Interfaces

The enclosure protects the equipment from atmospheric contamination. Standards established by the National Electrical Manufacturer’s Association (NEMA) define enclosure types, based on the degree of protection an enclosure will provide. Use a fan to circulate the air of sealed enclosures that use convection cooling to dissipate heat. Select a NEMA–rated enclosure that suits your application and environment. The enclosure should be equipped with a disconnect device. To calculate the heat dissipation of your controller, see appendix D.

Use an operator interface to program and/or monitor your SLC 500 controller. You can choose from several Allen–Bradley operator interface devices.

Programming with a Hand-Held Terminal (1747-PT1)

Use the Hand–Held Terminal (HHT) to configure the SLC 500 controller, enter/modify a user program, download/upload programs, monitor control operation, and test/troubleshoot. When equipped with a battery (1747–BA), the HHT retains a user program in memory for storage and later use.

The display area accommodates 8 lines x 40 characters. You can display five rungs of a user program. The top row of keys are the menu function keys.

Important: Using the HHT, you can program the SLC 5/01t and 5/02t

processors and the SLC 500 fixed controllers. You cannot, however, program the SLC 5/03 processor.

Refer to the Hand–Held Terminal User Manual, Catalog Number 1747–NP002, for information on programming your fixed controller with the HHT.

Programming with Advanced Programming Software (APS) on an IBM Compatible Computer

The Advanced Programming Software (APS) can be used with an Allen-Bradley T45, T47, or T50 terminal, an IBM Portable, Portable II, Deskprot 286, 386/SX, 386, a Tandyt 3000HL, Toshibat 3100E, or GATEWAY 2000t models 386DX/25, 386DX/33, 486DX/33, and 486DX2/50 personal computer. Your computer must have:

r-AT or XT, a Compaqr

• 640 Kbytes of RAM (extended or expanded memory is recommended, but

not required)

• 10 Mbyte fixed-disk drive (APS requires a minimum or 2.5 MBytes of

free disk space.)

• DOS version 3.1 or higher

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Advanced Programming Software, 1747–PA2E

APS, Catalog Number 1747–PA2E, comes on 5–1/4 and 3–1/2 inch disks. You must have DOS installed in your computer. You also must have at least 550 Kbytes of free memory to execute the APS software. Like the Hand–Held Terminal, APS lets you configure the SLC 500 controller, enter/modify a user program, restore/save programs to the SLC 500, monitor controller operation, and test/troubleshoot. You can also:

• create and print ladder diagrams, data tables, instruction cross references,

and configurations

• use cut/copy/paste editor

• store multiple programs in the memory of the computer (on the hard disk)

Refer to the Advanced Programming Software User Manual, Catalog Number 1747–NM002, and the Advanced Programming Software Reference Manual, Catalog Number 1747–NR001, for information on programming your fixed controller with APS.

DH–485 Interface Converter (1747–PIC)

For communication, use an RS–232/DH–485 Interface Converter between the computer and SLC controller. The converter includes a 279.4 mm (11.0 in.) ribbon cable, already attached to the converter, for connection to the computer serial port and a Catalog Number 1746–C10 cable for connection to the controller.

Monitoring with a Data Table Access Module (1747-DTAM-E)

The Data Table Access Module (DTAM) is a plant floor device that lets you access data file information, change operating modes, monitor and clear processor faults, and transfer the user program between RAM and an EEPROM memory module with any SLC 500 family processor. You cannot

use it to create new programs.

Important features of DTAM include:

• shorthand addressing, which provides easier access to data files

• display prompts in six, user–selectable languages: English, French,

German, Italian, Spanish, and Japanese

• UL listed, CSA Certified

• NEMA type 12 and 13 enclosures

• point–to–point interface to an SLC family processor, or as a network

device on a DH–485 network

Refer to the Data Table Access Module (DTAM) User Manual, Catalog Number 1747–ND013, for information on monitoring your fixed controller with the DTAM.

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EEPROM and UVPROM Memory Modules

These optional memory modules provide a non–volatile memory back–up in a convenient modular form. The modules plug into a socket on the controller.

You can store (save) your program in the EEPROM by inserting it into the processor and using either the Hand–Held Terminal or Advanced Programming Software.

Use of the UVPROM provides you with an extra degree of program security because the user program cannot be altered while it is installed in the controller. You can program the UVPROM with commercially available UVPROM programming and erasing equipment. You can use an EEPROM module as a master, or you can use an archived processor file as the source by using the APS PROM translator utility.

Adapter sockets are required when inserting memory modules into commercially available PROM programmer. The memory module fits into the adapter socket and then into a PROM programmer.

ATTENTION: Make sure the adapter is inserted properly or damage could result.

The following table lists the types of memory modules that are available for the fixed controller. Also listed are the manufacturer part number for determining compatibility with an external PROM burner.

Description Catalog Number Manufacturer Manufacturer's Part Number

NEC uPD28C64 - 250

1K User Words EEPROM 1747-M1

4K User Words EEPROM 1747-M2

1K User Words UVPROM 1747-M3 Fujitsu MBM27C64 - 25

4K User Words UVPROM 1747-M4 Not compatible with the fixed controller.

Adaptor Socket 1747-M5 NA NA

OKI MSM28C64ARS - 20

XICOR X28C64BP - 25

SEEQ PE28C64 - 250

X28C256DI - 25

XICOR

X28256DI - 25

SEEQ DE28C256 - 25

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Selecting Isolation Transformers

If there is high frequency conducted noise in or around your distribution equipment, we recommend that you use an isolation transformer in the AC line to the power supply. This type of transformer provides isolation from your power distribution system and is often used as a “step down” transformer to reduce line voltage. Any transformer used with the controller must have a sufficient power rating for its load. This power rating is generally expressed in voltamperes (VA).

To select an appropriate isolation transformer, you must calculate the power required by the fixed I//O chassis and any input circuits and output loads that are connected through this transformer. The power requirement of any fixed I/O unit is 50 VA.

The power requirement for the input circuits is determined by the number of inputs, the operating voltage, and the nominal input current. The power requirement for output loads is determined by the number of outputs, the load voltage, and load current.

For example, if you have a 1747–L30B fixed unit with 18 AC inputs (12mA at 120 VAC) and 12 triac outputs (0.5A at 120 VAC), the power consumed would be:

50 + (18)(120)(0.012) + (12)(120)(0.5) = 796 VA

Important: In this case, 0.5 Amp is the maximum rating of the triac output

(at +30° C). If your load draws less than 0.5 Amp, this figure may be reduced accordingly. The output portion of the VA calculation should reflect the current requirements of your loads.

In general, we recommend that the transformer is oversized to provide some margin for line voltage variations and other factors. Typically a transformer that is 25% larger than the calculated VA is sufficient.

1–12

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Special Considerations

The recommendations given previously provide favorable operating conditions for most controller installations. Your application may involve one or more of the following adverse conditions. Additional measures can be taken to minimize the effect of these conditions.

Excessive Line Voltage Variations

The best solution for excessive line voltage variation is to correct any feeder problems in your distribution system. Where this does not solve the line variation problem, or in certain critical applications, use a constant voltage transformer. If you require a constant voltage transformer, connect it to the power supply and all input devices connected to the SLC 500 controller.

Connect output devices on the same power line, but their connection along the power line is normally made before the constant voltage transformer. A constant voltage transformer must have a sufficient power rating for its load.

Excessive Noise

When you operate the SLC 500 controller in a “noise polluted” industrial environment, special consideration should be given to possible electrical interference.

The following reduces the effect of electrical interference:

• SLC 500 controller design features

• proper mounting of controller within an enclosure

• proper equipment grounding

• proper routing of wiring

• proper suppression added to noise generating devices

Potential noise generators include inductive loads, such as relays, solenoids, and motor starters when operated by “hard contacts” like push buttons or selector switches. Suppression may be necessary when such loads are connected as output devices or when connected to the same supply line that powers the controller.

Lack of surge suppression on inductive loads may attribute to processor faults and sporadic operation, RAM memory can be corrupted (lost) and I/O modules may appear to be faulty or reset themselves.

For extremely noisy environments, use a memory module and program it for auto loading on processor fault or power cycle for quick recovery.

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Selecting Surge Suppressors

Most output modules have built–in surge suppression to reduce the effects of high voltage transients. However, we recommend that you use an additional suppression device if an output module is being used to control an inductive device such as:

• relays • motor starters

• solenoids • motors

Additional suppression is especially important if your inductive device is in series with or parallel to a hard contact such as:

• pushbuttons • selector switches

By adding a suppression device directly across the coil of an inductive device, you will reduce the effects of voltage transients caused by interrupting the current to that inductive device and prolong the life of the switch contacts. The diagram below shows an output module with a suppression device.

DC or L1

VAC/VDC

Snubber

DC COM or L2

or DC

Output Module

OUT 0

OUT 1

OUT 2

OUT 3

OUT

OUT 6

OUT 7

COM

If you connect an SLC 500 controller triac output to control an inductive load, we recommend that you use varistors to suppress noise. Choose a varistor that is appropriate for the application. The surge suppression we recommend for triac outputs when switching 120 VAC inductive loads is Harris MOV, part number V220 MA2A. For a 509 motor starter, use a 599–K04 or 599–KA04 series C or later MOV with triac outputs.

1–14

Consult the varistor manufacturer’s data sheet when selecting a varistor for your application.

ATTENTION: Damage could occur to SLC 500 triac outputs if you use suppressors having RC networks. Allen–Bradley AC

surge suppressors not recommended for use with triacs include Catalog Numbers 199–FSMA1, 199–FSMA2, 1401–N10, and 700–N24.

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Allen–Bradley surge suppressors recommended for use with Allen–Bradley relays, contactors, and starters are shown in the table below.

Device Coil Voltage

Bulletin 509 Motor Starter Bulletin 509 Motor Starter

Bulletin 100 Contactor Bulletin 100 Contactor

120 VAC 240 VAC

Bulletin 709 Motor Starter 120 VAC

Suppressor Catalog

Number

➀

599-K04 599-KA04

199-FSMA1 199-F5MA2

1401-N10

➀

➁

Bulletin 700 Type R, RM Relays AC coil None Required

Bulletin 700 Type R Relay Bulletin 700 Type RM Relay

12 VDC 12 VDC

24 VDC 24 VDC

48 VDC 48 VDC

115-125 VDC 115-125 VDC

230-250 VDC 230-250 VDC

700-N22 700-N28

700-N10 700-N13

700-N16 700-N17

700-N11 700-N14

700-N12 700-N15

Bulletin 700 Type N, P, or PK Relay

Miscellaneous

150V max, AC or DC

700-N24

➁

electromagnetic devices limited to 35 sealed VA

➀

This

is an MOV without a capacitor. The 599-K04 or 599-KA04 MOV must be series C or later when used

with triac outputs. Do not use series A or B with triac outputs.

➁

Not recommended for use with triac outputs.

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Selecting Contact Protection

Inductive load devices such as motor starters and solenoids may require the use of some type of surge suppression to protect the controller output contacts. Switching inductive loads without surge suppression can significantly reduce lifetime of relay contacts. The figure below shows the use of surge suppression devices.

Surge Suppression for Inductive AC Load Devices

Output Device

Varistor

Surge Suppression for Inductive DC Load Devices

Diode (A surge suppressor can also be used.)

Contact Protection Methods for Inductive AC and DC Output Devices

Output DeviceOutput Device Output Device

RC Network



Output DeviceOutput Device

Surge Suppressor

These surge suppression circuits connect directly across the load device. This reduces arcing of the output contacts. Suitable surge suppression methods for inductive AC load devices include a varistor, an RC network, or an Allen–Bradley surge suppressor. These components must be appropriately rated to suppress the switching transient characteristic of the particular inductive device.

For inductive DC load devices, a diode is suitable. A 1N4004 diode is acceptable for most applications. A surge suppressor can also be used. See table on page 1–15.

1–16

We recommend that you locate the suppression device as close as possible to the load device.

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Transistor Output Transient Pulses

This section applies to the following SLC 500 Fixed I/O processors and SLC 500 I/O modules that have transistor outputs.

Fixed I/O Processors I/O Modules

1747-L20E 1746-OB8

1747-L20G 1746-OV8

1747-L20L 1746-OB16

1747-L20N 1746-OBP16

1747-L30L 1746-OV16

1747-L40E 1746-OB32

1747-L40L 1746-OV32

For the SLC 500 products listed above, the maximum duration of the transient pulse occurs when minimum load is connected to the output. However, for most applications the energy of the transient pulse is not sufficient to energize the load.

ATTENTION: A transient pulse occurs in transistor outputs when the external DC supply voltage is applied to the common

output terminals (e.g., via the master control relay). The sudden application of voltage creates this transient pulse. (See the following graph.) This condition is inherent in transistor outputs and is common to solid state devices. A transient pulse can occur regardless of the processor having power or not.

(On-State Load Current)

Current

Transient (I)

Duration of Transient (T)

Time

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To reduce the possibility of inadvertent operation of devices connected to transistor outputs, adhere to the following guidelines:

• Either ensure that any programmable device connected to the transistor

output is programmed to ignore all output signals until after the transient pulse has ended,

• or add an external resistor in parallel to the load to increase the on–state

load current. The duration of the transient pulse is reduced when the on–state load current is increased.

The duration of the transient pulse is proportional to the load impedance. This is illustrated in the following graph.

Time

Duration of Transient (ms)

1 100 200

400 500 600 700 800 900

300

On-State Load Current (mA)

1000

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Example

Increasing the load current by 100mA decreases the transient time from approximately 7 ms to less than 2.5 ms. To calculate the size of the resistor added in parallel to increase the current, use the following information:

24V = your applied voltage

Need 100mA of load current to reduce the transient to < 2.5 ms. (taken from graph on previous page)

V (Volts)

R (Ohms)

Resistor value (Ohms) = Applied voltage (Volts) / Desired current (Amps)

P (Watts) = I

Actual Power (Watts) = (Desired Current)2 x Resistor Value

Resistor size = 2 x Actual power (Watts)

Round resistor size to 5 Watts.

I (Amps)

= 24 / 0.1 = 240 (Ohms)

(Amps) x R (Ohms)

= (0.1)

x 240

= 2.4 (Watts)

= 2 x 2.4 = 4.8 (Watts)

You need a resistor rated for 240 Ohms at 5 Watts to increase the load current by 100mA; thus decreasing the transient time from approximately 7 ms to less than 2.5 ms.

1–19

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Chapter

System Installation Recommendations

To help you install the SLC 500 programmable controller as safely and securely as possible, we have set up a few specific recommendations for you to follow.

For general installation guidelines, also refer to article 70E of the National Fire Protection Association (NFPA). Article 70E describes electrical safety requirements for employee workplaces. This chapter covers the following:

• typical installation

• spacing your controllers

• preventing excessive heat

• grounding guidelines

• master control relay

• power considerations

• safety considerations

• preventative maintenance

Typical Installation

NEMA rated enclosure suitable for your application and

environment that shields your controller from electrical noise

and airborne contaminants.

Disconnect, to remove power from the system

Fused isolation transformer or a constant voltage transformer, as

your application requires

Master control relay/emergency stop circuit

Terminal blocks or wiring ducts

Suppression devices for limiting EMI (electromagnetic

interference) generation

The figure below consists of some components that make up a typical installation. The following symbols are used:

MCR

Disconnect Device

Isolation Transformer

SLC 500 Controller

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Chapter 2

System Installation Recommendations

Spacing Your Components

Follow the recommended minimum spacing shown below to allow for convection cooling within the enclosure. Air in the enclosure must be kept within a range of 0° to +60° C (+32° to +140° F).

Important: Be careful of metal chips when drilling mounting holes for the

controllers. Do not drill holes above a mounted SLC 500 controller. Metal chips or clippings may short circuit electronic components of the controller and cause intermittent or permanent malfunction.

Greater than 152.4 mm (6 inches)

Greater than 101.6 mm

(4 inches)

Greater than 101.6 mm

(4 inches)

Preventing Excessive Heat

Enclosure

Greater than 152.4 mm (6 inches)

For most applications, normal convection cooling will keep the controller components within the specified operating range. Proper spacing of components within the enclosure is usually sufficient for heat dissipation.

In some applications, a substantial amount of heat is produced by other equipment inside or outside the enclosure. In this case, place blower fans inside the enclosure to assist in air circulation and to reduce “hot spots” near the controller.

Additional cooling provisions might be necessary when high ambient temperatures are encountered.

Important: Do not bring in unfiltered outside air. It may introduce harmful

contaminants of dirt that could cause improper operation or damage to components. In extreme cases, you may need to use air conditioning to protect against heat build–up within the enclosure.

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Chapter 2

System Installation Recommendations

Grounding Guidelines

Size 12 Internal Star Washer

Size 10 or 12 Hardware Screw

Scrape paint off panel to insure electrical connection between chassis and grounded metal panel.

In solid–state control systems, grounding helps limit the effects of noise due to electromagnetic interference (EMI). The grounding path for the controller and its enclosure is provided by the equipment grounding conductor.

Normal Electrical Noise Conditions Severe Electrical Noise Conditions

Chassis Mounting Tab

Tapped Hole (Minimum of Three Threads)

Metal Panel (Must be connected to earth ground.)

#10 AWG to Ground Bus

Ground Lug

Size 12 Internal Star Washer

Size 10 or 12 Hardware Screw

Scrape paint off panel to insure electrical connection between chassis and grounded metal panel.

Size 12 Internal Star Washer

Chassis Mounting Tab

Metal Panel (Must be connected to earth ground.)

Tapped Hole (Minimum of Three Threads)

ATTENTION: The SLC 500 controller, other control devices, and the enclosure must be properly grounded. All applicable

codes and ordinances must be observed when wiring the controller system.

Ground connections should run from the chassis and power supply on each controller and expansion unit to the ground bus. Exact connections will differ between applications. An authoritative source on grounding requirements for most installations is the National Electrical Code. Also, refer to Allen–Bradley Programmable Controller Grounding and Wiring Guidelines, Publication Number 1770–4.1.

In addition to the grounding required for the controller and its enclosure, you must also provide proper grounding for all controlled devices in your application. Care must be taken to provide each device with an acceptable grounding path.

2–3

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Chapter 2

System Installation Recommendations

The figure below shows you how to run ground connections from the chassis to the ground bus.

SLC 500 Controller Only

#8 AWG

Wire

#10 AWG Wire

Chassis Mounting Tabs

SLC 500 Controller with 2-slot Expansion Chassis

#10 AWG Wire

Chassis Mounting Tabs

Ground Bus

Earth

Ground

#8 AWG

Wire

Ground Bus

Earth

Ground

2–4

Page 44

Chapter 2

System Installation Recommendations

Master Control Relay

A hard–wired master control relay (MCR) provides a convenient means for emergency controller shutdown. Since the master control relay allows the placement of several emergency–stop switches in different locations, its installation is important from a safety standpoint. Overtravel limit switches or mushroom head push buttons are wired in series so that when any of them opens, the master control relay is de–energized. This removes power to input and output device circuits. Refer to the figure on page 2–6.

ATTENTION: Never alter these circuits to defeat their function, since serious injury and/or machine damage could result.

Important: If you are using a DC output power supply, interrupt the output

side rather than the AC line to avoid the additional delay of power supply turn–on and turn–off. The power supply should receive its power directly from the fused secondary of the transformer. Connect the power to the DC input and output circuits through a set of master control relay contacts.

Place the main power disconnect switch where operators and maintenance personnel have quick and easy access to it. If you mount a disconnect switch inside the controller enclosure, place the switch operating handle on the outside of the enclosure, so that you can disconnect power without opening the enclosure.

Whenever any of the emergency–stop switches are opened, power to input and output devices is stopped.

When you use the master control relay to remove power from the external I/O circuits, power continues to be provided to the controller’s power supply so that diagnostic indicators on the processor can still be observed.

The master control relay is not a substitute for a disconnect to the controller. It is intended for any situation where the operator must quickly de–energize I/O devices only. When inspecting or installing terminal connections, replacing output fuses, or working on equipment within the enclosure, use the disconnect to shut off power to the rest of the system.

Important: The operator must not control the master control relay with the

SLC 500 controller. Provide the operator with the safety of a direct connection between an emergency–stop switch and the master control relay.

2–5

Page 45

Chapter 2

System Installation Recommendations

L1 L2

230 V

Emergency-Stop Switches

Adhere to the following points concerning emergency–stop switches:

• Do not program emergency–stop switches in the controller program. Any

emergency–stop switch should turn off all machine power by turning off the master control relay.

• Observe all applicable local codes concerning the placement and labeling

of emergency–stop switches.

• Install emergency–stop switches and the master control relay in your

system. Make certain that relay contacts have a sufficient rating for your application. Emergency–stop switches must be easy to reach.

The figure below shows the Master Control Relay Wired in Grounded System.

Disconnect

Isolation Transformer

15 V

ACX1X2

Fuse

of either of these contacts will remove

Operation power from the controller external I/O circuits, stopping machine motion.

Emergency-Stop Push Button

(Lo) (Hi)

Incoming Line T 1

15 V

AC terminals of Power Supply

erminals. Connect to

Overtravel Limit Switch

Stop

Fuse

Start

MCR

230 V I/O Circuits

Master Control Relay (MCR) Cat. No. 700-PK400A1

Suppressor Cat. No. 700-N24

MCR

Suppr.

MCR

1 I/O Circuits

DC Power Supply Use N.E.C. Class 2 for UL Listing.

Incoming line terminals. Connect to 24 VDC terminals of Power Supply

MCR



15 VAC

24 VDC I/O Circuits

2–6

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Chapter 2

System Installation Recommendations

Power Considerations

The following explains power considerations for the SLC 500 fixed controller.

Common Power Source

We strongly recommend that the chassis power supply has the same power source as the input and output devices. This helps:

• reduce the chance of electrical interference due to multiple sources and

grounds

• maintain system integrity if power is interrupted

Loss of Power Source

The chassis power supply is designed to withstand brief power losses without affecting the operation of the system. The time the system is operational during power loss is called “program scan hold–up time after loss of power.” The duration of the power supply hold–up time depends on the number, type and state of the I/O, but is typically between 20 ms and 700 ms. When the duration of power loss reaches a limit, the power supply signals the processor that it can no longer provide adequate DC power to the system. This is referred to as a power supply shutdown. The POWER LED is turned off.

Input States on Power Down

The power supply hold–up time as described above is generally longer than the turn–on and turn–off times of the input circuits. Because of this, the input state change from “On” to “Off” that occurs when power is removed may be recorded by the processor before the power supply shuts down the system. Understanding this concept is important. The user program should be written to take this effect into account. For example, hard wire power to one spare input. In the user program, check to be sure that one input is on; otherwise, jump to the end of the program and avoid scanning the logic. Use of a common power source as recommended in the previous section is assumed.

Other Types of Line Conditions

Occasionally the power source to the system can be temporarily interrupted. It is also possible that the voltage level drops substantially below the normal line voltage range for a period of time. Both of these conditions are considered to be a loss of power for the system.

2–7

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Chapter 2

System Installation Recommendations

Safety Considerations

Safety considerations are an important element of proper system installation. Actively thinking about the safety of yourself and others, as well as the condition of your equipment, is of primary importance. Several safety areas are discussed below.

High Voltages SLC 500 Fixed Hardware Style Controller (Series C) (Applies to 1747-L20A, -L30A, -L40A, -L20C, -L30C, and -L40C controllers)

Front

Cover

ATTENTION: The printed circuit board, located under the front cover of Series C Fixed Hardware Style Controllers, has high

voltages (120 VAC and 240 VAC) available at certain points when the controller is powered up. If the front cover is removed, exercise extreme care and consider all points on the circuit board to be electrically hazardous. Therefore, whenever possible, turn off power to the controller before removing the front cover. Do not remove the protective insulation covering the circuit board. Cutouts in the insulation are provided to allow access to the high–speed counter jumper, memory module, and battery connector. If the insulation is missing, do not touch any portion of the circuit board. Failure to heed this warning may result in personal injury or death.

2–8

Disconnecting Main Power

The main power disconnect switch should be located where operators and maintenance personnel have quick and easy access to it. Ideally, the disconnect switch is mounted on the outside of the enclosure, so that it can be accessed without opening the enclosure. In addition to disconnecting electrical power, all other sources of power (pneumatic and hydraulic) should be de–energized before working on a machine or process controlled by an SLC controller.

Page 48

Chapter 2

System Installation Recommendations

Wiring Safety Circuits

Circuits installed on the machine for safety reasons, like overtravel limit switches, stop push buttons, and interlocks, should always be hard–wired directly to the master control relay. These devices must be wired in series so that when any one device opens, the master control relay is de–energized thereby removing power to the machine. Never alter these circuits to defeat their function. Serious injury or machine damage could result.

Distributing Power

There are some points about power distribution that you should be aware of. First, the master control relay must be able to inhibit all machine motion by removing power to the machine I/O devices when the relay is de–energized.

Second, if you are using a DC power supply, interrupt the load side rather than the AC line power. This avoids the additional delay of power supply turn–on and turn–off. The DC power supply should be powered directly from the fused secondary of the transformer. Power to the DC input and output circuits is connected through a set of master control relay contacts.

Preventive Maintenance

Testing the Master Control Relay Circuit

Any part can fail, including the switches in a master control relay circuit. The failure of one of these switches would most likely cause an open circuit, which would be a safe power–off failure. However, if one of these switches shorts out, it no longer provides any safety protection. These switches should be tested periodically to assure they will stop machine motion when needed.

The printed circuit boards of the controller must be protected from dirt, oil, moisture, and other airborne contaminants. To protect these boards, the controller must be installed in an enclosure suitable for the environment. The interior of the enclosure should be kept clean and the enclosure door should be kept closed whenever possible.

Regularly inspect your terminal connections for tightness. Loose connections may cause improper functioning of the controller or damage the components of the system.

ATTENTION: To ensure personal safety and to guard against damaging equipment, inspect connections with incoming power

off.

The National Fire Protection Association (NFPA) provides recommendations for electrical equipment maintenance. Refer to article 70B of the NFPA for general requirements regarding safety related work practices.

2–9

Page 49

Page 50

Chapter

Mounting Your SLC 500 Control System

This chapter provides you with mounting dimensions for the following SLC 500 components:

• 20 I/O fixed controller

• 30 & 40 I/O fixed controller

• 2–slot expansion chassis

• link coupler (AIC)

• Data Table Access Module (DTAM)

Mounting Fixed Hardware Style Units

You can mount the fixed hardware style units directly to the back panel of your enclosure using the mounting tabs and #10 and #12 screws. The torque requirement is 3.4 N–m (30 in–lbs) maximum. Dimensions are in millimeters. (Dimensions in parentheses are in inches.)

3–1

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Chapter 3

Mounting Your SLC 500 Control System

20 I/O Fixed Controller

11 Dia. (0.433)

158

140

(6.22)

(5.51)

5.5

(0.217)

(1.18)

1.0

(0.04)

➀

105

(4.13)

105

(4.13)

165

(6.50)

Front View

5.5 Dia. (0.217)

(0.79)

(0.55)

5.5 Dia.

(0.217)

3–2

171

(6.73)

12.5

(0.49)

CAT

SERIAL NO.

145

(5.71)

Left Side View

➀

Dimensions are in millimeters. (Dimensions in parentheses are in inches.)

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Chapter 3

Mounting Your SLC 500 Control System

30 and 40 I/O Fixed Controller

11 Dia. (0.433)

158

140

(6.22)

(5.51)

55.0

6.35

(0.25)

(0.217)

➀

175

(6.89)

175

(6.89)

260

(10.24)

Front View

5.5 Dia. (0.217)

30.0

(1.18)

(0.79)

(0.55)

5.5 Dia (0.217)

1.0

(0.04)

171

(6.73)

CAT

SERIAL NO.

145

(5.71)

Left Side View

➀

Dimensions are in millimeters. (Dimensions in parentheses are in inches.)

3–3

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Chapter 3

Mounting Your SLC 500 Control System

2-Slot Expansion Chassis

(3.15)

158

(6.22)

5.5 Dia. (0.217)

(1.57)

Front View

(1.57)

➀

5.5 Dia. (0.217)

11 Dia. (0.433)

(0.55)

140

(5.51)

4.83

CAT

SERIAL NO.

145

(5.71)

(0.190)

(0.55)

Right Side View

➀

Dimensions are in millimeters. (Dimensions in parentheses are in inches.)

1.0

(0.04)

171

(6.73)

18.5

(0.728)

3–4

Page 54

Chapter 3

Mounting Your SLC 500 Control System

Link Coupler (AIC)

R 2.74

(0.11)

159

(6.24)

7.1

(0.28)

(1.50)

Front View

➀

(0.22)

137

(5.41)

(0.55)

5.5

5.5 Dia. (0.216)

146

(5.75)

Right Side View

4.3

(0.17)

172

(6.75)

Data Table Access Module (DTAM)

➀

Comm

152

(6.0)

140

(5.5)

Front View

➀

Dimensions are in millimeters. (Dimensions in parentheses are in inches.)

(2.76)

(2.5)

Right Side View

127

(5.0)

3–5

Page 55

Page 56

Chapter

Installing Your Hardware Components

This chapter shows you how to install and remove the following hardware components:

• 2–slot expansion chassis

• I/O and speciality modules

• memory module

• high–speed counter

Mounting the 2-Slot Expansion Chassis

The expansion chassis mounts on the right side of the fixed controller. The chassis has mounting tabs that are inserted into slots in the fixed controller and slid forward. No tools are required.

1. Insert the mounting tabs of the expansion chassis into the mounting slots

of the controller.

Mounting

Slots

Right Side of the

Fixed Controller

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Chapter 4

Installing Your Hardware Components

2. Slide the expansion chassis forward until the back of the expansion

chassis is flush with the fixed controller and the connector on the expansion circuit board is mated with the connector in the controller.

Installing I/O and Speciality Modules

19528

With the 2–slot expansion chassis on the fixed style unit, additional I/O and specialty modules can be supported.

ATTENTION: Never install, remove, or wire modules with power applied to the chassis.

1. Align circuit board of the module with card guide in chassis.

Retainer Clip

Side View

4–2

Retainer Clip

Page 58

Chapter 4

Installing Your Hardware Components

2. Gently slide the module in until both top and bottom retainer clips are

secured.

19530

3. To remove the module, press the retaining clips at the top and bottom of

the module and slide the module out.

4–3

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Chapter 4

Installing Your Hardware Components

Installing Your Memory Module

Always turn off power to the controller before inserting or removing the memory module. This guards against possible damage to the module and also undesired processor faults. Memory modules are mounted in carriers and have connectors that are “keyed” to guard against improper installation.

ATTENTION: To avoid potential damage to the memory modules, handle them by the ends of the carrier or edges of the

plastic housing. Skin oil and dirt can corrode metallic surfaces, inhibiting electrical contact. Also, do not expose memory modules to surfaces or areas that may hold an electrostatic charge. Electrostatic charges can alter or destroy memory.

1. Always turn off power to the controller before inserting or removing the

memory module. This guards against possible damage to the module and also undesired processor faults.

ATTENTION: When power is applied to the controller hazardous electrical potentials exist under the front cover. See

page 2–8 for more information.

2. Remove the processor compartment cover.

3. Locate the socket on the PC board.

Socket

4. Position the module correctly over the socket and press it firmly in place.

(The memory module is keyed.)

1747-M1,

-M2, -M3

4–4

5. Replace the cover on the SLC controller and restore power.

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Chapter 4

Installing Your Hardware Components

Removing Your Memory Module

To remove a memory module use the following procedure:

1. Remove the power from the fixed I/O unit.

2. Remove the processor compartment cover.

3. Grasp the carrier tabs with the thumb and index fingers, then gently but

firmly lift upwards on either end of the memory module carrier.

4. When the end is partially raised, begin lifting the other end in the same

manner. Repeat this until the memory module has been completely removed from the socket.

5. Replace processor cover.

Using the High-Speed Counter

The fixed I/O units that have 24 VDC input circuits are also equipped with a high–speed counter. The counter is capable of counting at a rate of up to 8 kHz.

You have the option of using input 0 as a normal input or as a high–speed counter. To accommodate this dual function the input is equipped with a jumper selectable filter. You must cut the jumper for high–speed counter use. A shielded cable is recommended to reduce noise to the input.

High-Speed Counter Operation

For high–speed counter operation do the following:

1. Turn off power to the fixed controller.

ATTENTION: When power is applied to the controller

hazardous electrical potentials exist under the front cover. See

page 2–8 for more information.

2. Remove the SLC 500 cover.

3. Locate and cut jumper wire J2. The jumper is either beneath or to the

right of the battery connector, as shown below. Do not remove completely but make certain that the ends of the cut jumper wire are not touching each other.

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Chapter 4

Installing Your Hardware Components

The High-Speed Counter jumper is located either

beneath

the battery connector OR to the right of the battery connector

4. Replace the cover.

High-Speed Counter Input Compatibility

The high–speed counter input circuit has the following characteristics:

• nominal input impedance of ≈ 1200 Ω

• on–state voltage of 10–30 VDC

• nominal input current draw of 20mA

• minimum pulse width of 62.5 µsec.

Your input device or encoder must be single–ended and be compatible with the specifications of the high–speed counter input. See the table below for more information.

4–6

For an Input Device or Encoder that Is Use an HSC Input Circuit that Is

Sourcing Sinking

Open Collector/ Sinking Sourcing

Open Collector with Pull-up Resistor Sinking

Page 62

Chapter 4

Installing Your Hardware Components

Wiring Diagram of a High-Speed Counter Sinking Input Circuit

IN 3

IN 5

IN 4

Shielded Twisted Pair Belden or Equivalent

CHASSIS GND

DC COM

COM

IN 0 HSC

IN 2

1030 VDC

Sourcing Input Device

Wiring Diagram of a High-Speed Counter Sourcing Input Circuit

CHASSIS GND

VDC IN

VDC

1030 VDC

IN 0 HSC

IN 2

Sinking Input Device

IN 3

IN 5

IN 4

Shielded Twisted Pair Belden or Equivalent

4–7

Page 63

Page 64

Chapter

Wiring Your Control System

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

• defining sinking and sourcing

• determining approximate transient duration

• preparing your wiring layout

• features of an I/O module

• recommendations for wiring I/O devices

• wiring your I/O modules

• using Removable Terminal Blocks (RTBs)

Defining Sinking and Sourcing

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

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

supply are sourcing field devices.

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

power supply are called sinking field devices.

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

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

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

5–1

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Chapter 5

Wiring Your Control System

Contact Output Circuits  AC or DC

Relays can be used for either AC or DC output circuits and accommodate either sinking or sourcing field devices. These capabilities are a result of the output switch being a mechanical contact closure, not sensitive to current flow direction and capable of accommodating a broad range of voltages.

This high degree of application flexibility makes contact output modules very popular and useful in control environments with a broad mix of electrical I/O circuit requirements.

Solid-State DC I/O Circuits

The design of DC field devices typically requires that they be used in a specific sinking or sourcing circuit depending on the internal circuitry of the device.

Sourcing Device with Sinking Input Module Circuit

The field device is on the positive side of the power supply between the supply and the input terminal. When the field device is activated, it sources current to the input circuit.

FIELD DEVICE

DC POWER SUPPLY

Input

DC INPUT CIRCUIT

DC Com

5–2

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Chapter 5

Wiring Your Control System

Sinking Device with Sourcing Input Module Circuit

The field device is on the negative side of the power supply between the supply and the input terminal. When the field device is activated, it sinks current from the input circuit.

FIELD DEVICE

DC POWER SUPPLY

Input

DC INPUT CIRCUIT

VDC

Sinking Device with Sourcing Output Module Circuit

The field device is on the negative side of the power supply between the supply and the output terminal. When the output is activated, it sources current to the field device.

VDC

DC POWER SUPPLY

FIELD DEVICE

Out

DC OUTPUT CIRCUIT

DC Com

Sourcing Device with Sinking Output Module Circuit

The field device is on the positive side of the power supply between the supply and the output terminal. When the output is activated, it sinks current from the field device.

VDC

Out

DC OUTPUT CIRCUIT

DC Com

5–3

DC POWER SUPPLY

FIELD DEVICE

Page 67

Chapter 5

Wiring Your Control System

Preparing Your Wiring Layout

Careful wire routing within the enclosure helps to cut down electrical noise between I/O lines. Follow these rules for routing your wires:

• Route incoming power to the controller by a separate path from wiring to

I/O devices. Where paths must cross, their intersection should be perpendicular.

Important: Do not run signal or communications wiring and power

wiring in the same conduit.

• If wiring ducts are used, allow for at least two inches between I/O wiring

ducts and the controller. If the terminal strips are used for I/O wiring, allow for at least two inches between the terminal strips and the controller.

• Segregate I/O wiring by signal type. Bundle wiring with similar electrical

characteristics together.

Wires with different signal characteristics should be routed into the enclosure by separate paths.

ATTENTION: If the controller is being installed within a potentially hazardous environment (that is, Class I, Division 2),

all wiring must comply with the requirements stated in the National Electrical Code 501–4 (b).

5–4

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Chapter 5

Wiring Your Control System

Features of an I/O Module

Input and Output Terminals Connected to Terminal Block

Terminal Block (May Be Colorcoded and Removable on Some Modules)

Terminal Block Release Screw

Below is an example of a combination I/O module.

Color Band

OUTPUT INPUT

HSCE

501 2 3

5 2 3

I/O Status Indicators

Terminal Block Release Screw

VAC–VDC

OUT

OUT 3

OUT

NOT USED

IN 1

IN 3

IN 5

NOT USED

OUT 0

OUT 2

OUT 4

NOT USED

IN 0

IN 2

IN 4

NOT USED

AC COM

Hinged Wiring Terminal Door with Label

Tie Wire

Wires Leading to Output and Input Devices

5–5

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Chapter 5

Wiring Your Control System

Recommendations for Wiring I/O Devices

The following are general recommendations for wiring I/O devices.

ATTENTION: Before you install and wire I/O devices, disconnect power from the controller and any other source to the

I/O devices.

Use acceptable wire gauge — The I/O wiring terminals are designed to accept #14 or smaller AWG stranded wires, and two wires per terminal (maximum). Maximum torque 0.9 N–m (8 in–lb).

Label wires — Label wiring to I/O devices, power sources, and ground. Use tape, shrink–tubing, or other dependable means for labeling purposes. In addition to labeling, use colored insulation to identify wiring based on signal characteristics. For example, you may use blue for DC I/O wiring and red for AC I/O wiring.

Bundle wires — Bundle wiring for each similar I/O device together. If you use ducts, allow at least 5 cm (2 in.) between the ducts and the controller so there is sufficient room to wire the devices.

Identify terminals — Terminal cover plates have a write–on area for each terminal. Use this area to identify your I/O devices. Label the Removable Terminal Block (RTB) with appropriate slot, rack (chassis) and module identification if you have not already. Refer to page 5–8 for more information.

ATTENTION: Calculate the maximum possible current in each power and common wire. Observe all local electrical codes

dictating the maximum current allowable for each wire size. Current above the maximum ratings may cause wiring to overheat, which can cause damage.

Capacitors on input modules have a stored charge that can cause a non–lethal shock. Avoid mounting the controller in a position where installation or service personnel would be in danger from startle reaction.

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Chapter 5

Wiring Your Control System

Wiring Your I/O Modules

Terminals on the modules have self–lifting pressure plates that accept two #14 AWG wires. Series B 12–point and 16–point and analog modules are equipped with removeable terminal blocks (RTBs) for ease of wiring. For more information on using RTBs, see the next section.

LED indicators on the front of each module display the status of each I/O point. The LED indicators turn on when the proper signal to an input terminal is applied or when the processor commands an output to be energized.

To locate the I/O module wiring diagrams, contact your Allen–Bradley sales office for the latest product data entitled Discrete Input and Output Modules, Publication Number 1746–2.35. Or, locate the installation instruction sheet that was sent with your I/O module; it also includes I/O wiring diagrams.

1. Install a wire tie to secure your wiring and keep it neat. (If you feed the

tie into one hole, it will be routed back out through the other.)

OUTPUT INPUT

501

Tie Wire

Wires Leading to Output and Input Devices

2. Cover any unused slots with card slot fillers, Catalog Number 1746–N2,

to keep the chassis free from debris and dust.

5–7

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Chapter 5

Wiring Your Control System

Using Removable Terminal Blocks (RTBs)

Removable Terminal Blocks (RTBs) are provided on all 12–point and 16–point discrete I/O modules and analog modules. RTBs can only be used with these modules in the 2–slot expansion chassis. RTBs allow for faster and more convenient wiring of the I/O modules. The modules and RTBs are color–coded as follows:

Color Type of I/O Removable Terminal Block

Red AC inputs/outputs

Blue DC inputs/outputs

Orange relay outputs

Green specialty modules

Replacement terminal blocks are available if they are lost or damaged. See the replacement part list in chapter 9.

Removing RTBs

Below are guidelines for removing the I/O RTBs.

ATTENTION: Never install or remove I/O modules or terminal blocks while the SLC is powered.

erminal Block Release Screw

Dot

indicates terminal number 0

(or top of I/O wiring).

1. If the I/O module is already installed in the chassis, remove power to the

SLC.

2. Unscrew the upper right and lower left terminal block release screws.

3. Grasp the RTB with your thumb and forefinger and pull straight out.

4. Label the RTB with appropriate slot, rack (chassis) and module

identification.

erminal Block Release Screw

SLOT______RACK______

• MODULE______

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Chapter 5

Wiring Your Control System

Installing RTBs

Below are guidelines for installing the I/O RTBs.

1. Label the RTB properly.

2. Match the label identification to the correct chassis, slot, and module

type.

ATTENTION: Inserting a wired RTB on an incorrect module can damage the I/O module circuitry when power is applied.

3. Be sure the color band on the I/O module matches the color of the RTB.

ATTENTION: Never install or remove I/O modules or RTBs

while the SLC 500 chassis is powered.

4. Remove power from the SLC 500 chassis.

5. Line up terminal block release screws.

6. Press the RTB firmly onto connector contacts.

7. Tighten the RTB release screws.

5–9

Page 73

Page 74

Chapter

Starting Up Your Control System

This chapter describes how to start up your control system. To accomplish this, you must go through eight procedures.

Procedures for Starting Up the Control System

Start–up involves the following procedures to be carried out in sequence:

1. Inspect your installation.

2. Disconnect motion–causing devices.

3. Initialize and test your processor.

4. Test your inputs.

5. Test your outputs.

6. Enter and test your program.

7. Observe control motion.

8. Conduct a dry run of your application.

These procedures isolate problems such as wiring mistakes, equipment malfunction, and programming errors in a systematic, controlled manner.

We urge you to go through these procedures very carefully. This will help you avoid possible personal injury and equipment damage.

Important: Do not attempt system start–up until you are thoroughly

familiar with the controller components and programming/editing techniques. You must also be thoroughly familiar with the particular application.

For general recommendation concerning installation safety requirements and safety requirements and safety related work practices, refer to NFPA 70E, Electrical Safety Requirements for Employee Workplaces.

6–1

Page 75

Chapter 6

Starting Up Your Control System

1. Inspect Your Installation

2. Disconnect Motion-causing Devices

You can often prevent serious problems in later test procedures by first making a thorough physical inspection. We recommend that you do the following:

1. Make sure that the controller and all other devices in the system are

securely mounted. Refer to chapter 3 and chapter 4 for more information.

2. Check all wiring including:

• connections from the main disconnect to the controller input

• the master control relay/emergency–stop circuit

• input device circuits

• output device circuits

Make certain that all wiring connections are correct and that there are no missing wires. Check the tightness of all terminals to make certain wires are secure. Refer to chapter 5 for more information.

3. Measure the incoming line voltage. Be certain that it corresponds to

controller requirements and that it falls within the specified voltage range. See specifications for input voltage ranges in chapter 1.

In the following test procedures, the controller will be energized. As a safety precaution, you must make certain that machine motion will not occur. The preferred way is to disconnect the motor wires at the motor starter or the motor itself. In this way, you can test the operation of the starter coil, verifying that your output circuit is wired correctly and functioning. Similarly, the preferred way to disconnect a solenoid is to disengage the valve, leaving the coil connected.

6–2

In some instances, you may not be able to disconnect a device the preferred way. In this case, it will be necessary to open the output circuit at some convenient point.

For circuit testing purposes, it is best to open the circuit at a point as close as possible to the motion–causing device. For example, your output might be a relay coil that in turn energizes a motor starter; if it is impractical to disconnect the motor wires, the next best thing to do is to open the circuit at a point between the motor starter and the relay contact.

ATTENTION: Machine motion during system checkout can be hazardous to personnel. During the checkout procedures 3, 4, 5,

and 6, you must disconnect all devices that, when energized, might cause machine motion.

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3. Initialize and Test Your

Processor

When you are certain that machine motion cannot occur with the controller energized, you may begin by initializing the processor using the following steps:

1. Energize the controller. If power is supplied to the controller and the

installation is correct, then: A. The POWER LED turns on as shown in the figure below.

POWER PC RUN CPU FAULT

FORCED I/O

BATTERY LOW

Indicates the LED is OFF.

Indicates the LED is ON.

The CPU FAULT LED also turns on during power–up, but it should go off after a few seconds. If instead this LED starts flashing, it indicates you must clear the processor memory before continuing.

B. The following processor initial factory conditions apply:

• Mode = PROGRAM MODE

(S:1/0 – S:1/4 = 0 0001)

• Watchdog values = 100ms

(S:3H = 0000 1010)

• I/O Slot enables = ALL ENABLED

(S:11/1 through S:12/14 set to 1)

• Node address = 1

(S:15L = 0000 0001)

• Baud Rate = 19.2K baud

(S:15H = 0000 0100)

• Processor Name = DEFAULT

2. Power up the programming device.

Refer to the Hand–Held Terminal User Manual, Catalog Number 1747–NP002, for information on programming your fixed controller with the HHT.

Refer to the Advanced Programming Software User Manual, Catalog Number 1747–NM002 Series C, and the Advanced Programming Software Reference Manual, Catalog Number 1747–NR001, for information on programming your fixed controller with APS.

3. Configure the controller.

4. Name the processor file.

5. Program a sample test rung not affecting machine operation.

6. Save the program and the controller configuration.

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7. Transfer the controller configuration and the sample test program to the

processor. After the new program is transferred to the processor, the processor fault status should clear. (The CPU FAULT LED stops if it was flashing.)

8. Enter the Run mode.

The processor PC RUN LED should turn on indicating the controller is in the RUN mode with no processor faults. If any other processor status exists, refer to chapter 8.

9. Monitor the sample test rung.

If the sample test rung operates successfully without processor faults, you have verified that basic processor functions are properly functioning. If any other processor status exists, refer to chapter 8.

4. Test Your Inputs

After successful processor initialization and test, you may begin testing inputs following these steps:

1. Assuming you are still online with the programming device, put the

controller into the Continuous Test mode. This allows the processor to scan the I/O and program, but not turn on any physical outputs.

2. Monitor the data in data File 1, the input data file. All configured inputs

should be displayed.

3. Make sure the first input slot, slot 0, is shown on the monitor.

4. Select the first input device connected to Input 0 of the fixed I/O chassis.

5. Manually close and open the addressed input device.

ATTENTION: Never reach into a machine to actuate a device,

unexpected machine operation could occur.

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6. Observe the associated bit status using the programming device monitor

function. Also, observe the input status LED on the fixed I/O chassis. A. When the input device is closed verify that the voltage at the input

terminal is within the specified on–state range, the input status LED is on, and the associated status bit is set to a one.

If any of these conditions are not satisfied, follow the recommended troubleshooting steps listed below.

B. When the input device is opened verify that the voltage at the input

terminal is within the specified off–state range, the input status LED is off, and the associated status bit is reset to 0.

If any of these conditions are not satisfied, follow the recommended troubleshooting steps listed below.

7. Select the next input device and repeat steps 5 and 6 until all inputs on the

fixed I/O chassis and in the 2–slot expansion rack (if used) have been tested.

Input Troubleshooting Steps

1. Make sure the processor is in the Continuous Test mode.

2. Verify that your inputs and outputs are enabled. Status file bit S:11/0

represents the inputs and outputs of the fixed controller. Status file bits S:11/1 and S:11/2 represent the inputs and outputs (slot 1 and slot 2 respectively) of the 2–slot expansion chassis. These bits must be set to one, enabling all your inputs and outputs.

3. Check your wiring and verify that all connections are tight. A. Make sure that power connections have been made to your input

device if needed.

B. Verify that the signal connection has been made from the input device

to the correct input circuit of the fixed controller.

C. Check that all common connections have been made.

4. Check your specifications. A. Make sure that the power is within the specified voltage range if your

input device requires power.

B. Verify that your power supply is not overloaded. An overloaded

supply can deliver the correct voltage when some of its loads are not energized but the voltage may fall out of range when all of its loads are energized.

C. Verify that your input device signal contact is specified to deliver

sufficient current to the input circuit and any other loads connected to it.

D. Make certain that your input device does not have a minimum load

specification that is greater than the input circuit current specification.

E. Verify that the input device is on and off longer than the specified

turn–on and turn–off times for the input circuit.

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5. Disconnect your input devices from the fixed controller input terminals.

Make a direct connection from a power supply to the fixed controller input and common terminals. The power supply voltage must be within the specified on–state voltage range of the input circuit. If you can energize and de–energize the input circuit by turning the power supply on and off, the basic operation of the input circuit is functioning correctly. The problem is likely to be with the input device or wiring. If you cannot operate the the input circuit by a direct connection, the input circuit is not functioning and should be replaced.

6. Connect a different load to your input device. Open and close the input

device and measure the voltage at the load. If your input device cannot operate other loads, the input device is not functioning properly and should be replaced.

For more information on input troubleshooting, see page 8–8.

5. Test Your Outputs

After you test all inputs, and have determined that they are functioning properly, test the outputs following these steps.

1. Refer to page 6–2 to insure that no motion will occur when any

controller output is energized.

2. Place the controller in the Program mode.

3. Create an output test rung as shown below for each output slot

configured. Enter your source and destination address:

MOV

SOURCE B3: “X” DEST O: “X”

Here “X” represents the slot number of the output currently selected. This rung moves a word of data from the bit file to the output file. The slot number is 0 for outputs of the fixed controller. If the 2–slot expansion chassis is used, numbers one and two are used for the outputs in slots 1 and 2 respectively.

4. Save the output test program and controller configuration.

5. Transfer the output test program to the processor.

6–6

6. Put the controller in the Run mode.

7. Monitor the data in bit file B3 on the programming device display.

8. Enter

B3: “X”

at the address prompt to select the output slot to be

tested.

9. Move the cursor to the bit position that corresponds to the specific output

being tested. Set the bit to 1.

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10.Observe the output status LED and the output device. The output status LED should turn on. The output device should be

energized unless you disconnected it to prevent machine motion. It may be necessary to connect a dummy load to the output to complete this test. If the LED does not turn on or if the load is not energized, follow the output troubleshooting steps listed below.

11. Reset the bit value back to zero for the selected address. Both the output status LED and the output device should de–energize. If the LED does not turn off or if the load does not de–energize, follow the output troubleshooting steps listed below.

12.Repeat steps 9 through 11 for all outputs of the selected slot.

13.Repeat steps 8 through 12 for all slots (with outputs) that are a part of the

fixed controller configuration.

Output Troubleshooting Steps

1. Make sure the processor is in the Run mode.

2. Verify that the test rung recommended in the previous section has been

entered correctly.

3. Check the status file I/O slot enable bits. Status file bit S:11/0 represents the inputs and outputs of the fixed controller. Status file bits S:11/1 and S:11/2 represent the inputs and outputs (slot 1 and slot 2 respectively) of the 2–slot expansion chassis. These bits must be set to one, enabling all your inputs and outputs.

4. Use a programming device to verify that the bit being tested in the output file tracks the on/off status of the corresponding bit in the bit file.

If the output file does not track the bit file, but your program has been entered correctly and the I/O are enabled, then your processor is not functioning properly and should be replaced.

If the output file tracks the bit file, then the processor is functioning properly and the output command is being sent to either the I/O section of the fixed controller, or to the output module in the 2–slot expansion chassis.

5. Check the electrical connections. A. If the output being tested is in the 2–slot expansion chassis, verify that

the expansion chassis connector is properly mated to the expansion connector of the fixed controller.

B. Turn off power to the I/O circuits. Verify that power and/or common

connections are made to the proper output circuit terminals.

C. Verify that the power connections are made to the output load device if

they are required.

D. Verify that the output terminal being tested is connected to the correct

termination point of the load device.

E. Check the tightness of all terminals to make certain that all wires are

secure.

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6. Check your specifications. A. Verify that all power supplies used are within the specified operating

ranges of the I/O circuits and loads.

B. Check that the specified load current is greater than the minimum load

current specified for the output circuit. (Leakage current from the output circuit may prevent you from turning off a low current load.)

C. Check that the specified load current is less than the maximum load

current of the output circuit.

D. Make sure that the sum of all the load currents is equal to or less than

the power supply capacity.

7. Restore power to the I/O circuits and test the output. If the preceding measures have not corrected the problem, turn off the I/O power and disconnect the load. Connect the load directly to the I/O power supply. You should be able to operate the load by turning the power supply on and off.

nter and Tes

t Y

our Program

If you can operate the load, and the load is within the specified operating range of the output circuit, the output circuit is not functioning properly. Replace the fixed controller or output module as necessary.

If you cannot operate the load by turning the power supply on and off, the load is not operating properly and it should be replaced.

For more information on output troubleshooting, refer to page 8–10.

After you test all inputs and outputs and they are functioning properly, we recommend the following steps to safely and successfully enter and test your specific application program. (For extra assistance, see the Hand–Held

Terminal User Manual or the Advanced Programming Software User Manual.)

1. Verify the offline program. After the program has been entered in the offline edit file mode, program

verification may begin. Remaining in the offline edit file mode you may use the cursor keys

and/or search function of your programming device to inspect every instruction and rung for errors.

2. Check your written program, rung for rung, against the program entered into the offline memory. The most common errors found in program entry are:

• incorrect addressing of instructions

• omission of an instruction

• more than one output instruction programmed using the same address

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3. Transfer the program into the processor. A. Place your programming device online.

B. Place the processor in Program mode. C. Select download function when using the Hand–Held Terminal or the

restore function when using Advanced Programming Software.

4. Verify the online program transfer. A. Select monitor file function.

B. Cursor through the program to verify that you selected the right

program.

5. Conduct a single–scan program test. A. Select the monitor file function and place the cursor on the first rung.

B. Select the Test mode. C. Select Single–Scan (SSN) test. In this test mode, the processor

executes a single operating cycle, which includes reading the inputs, executing the ladder program, and updating all data without energizing the output circuits. However, the monitor file function will identify the output status as if the outputs were enabled.

Timers are also incremented a minimum of 10 milliseconds each single scan.

D. Simulate the input conditions necessary to execute the current

monitored rung of the program. If it is not practical to manually activate the input device, use the force function to simulate the proper condition.

ATTENTION: Never reach into a machine to actuate a device, unexpected machine operation could occur.

E. Activate a single operating scan as outlined in the programming device

user manual.

F. Verify the intended effects on the output instructions for that rung and

overall program logic effects.

G. Select the next program rung and repeat test procedures as listed above

until the entire program has been tested.

6. Conduct a continuous scan program test. Once the individual single scan rung tests have been completed and

proper program operation verified, a continuous scan test might be appropriate before motion checkout.

This mode simulates the controller Run mode without energizing the external outputs.

6–9

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7. Observe Control Motion

Now that program execution has been verified, checkout of control motion can begin. All persons involved with the programming, installation, layout design, machine or process design, and maintenance should be involved in making decisions for determining the best and safest way to test the total system.

The following procedures are general in nature. Individual conditions may warrant their modification. The basic approach is to initiate testing with the least amount of machine motion. Only some outputs are allowed to generate machine motion. Then additional machine motion can be gradually added, thereby allowing any problems to be detected more easily under controlled conditions. The following procedure provides the steps for testing machine motion using one output at a time.

ATTENTION: During all phases of checkout, station a person ready to operate an emergency–stop switch if necessary. The

emergency–stop switch will de–energize the master control relay and remove power from the machine. This circuit must be hardwired only, it must not be programmed.

Use the following procedures:

1. Identify the first output device to be tested and reconnect its wiring.

ATTENTION: Contact with AC line potential may cause injury

to personnel. When reconnecting wiring, make sure that AC

power disconnect switch is opened.

2. Place the controller in the Run mode and observe the behavior of the

output device. To do this, simulate the input conditions necessary to energize the output in the program. If it is not practical to manually activate an input device, use the force function to simulate the proper input condition.

ATTENTION: Never reach into a machine to actuate a device, unexpected machine operation could occur.

3. Repeat steps 1 and 2, testing each output device, one at a time.

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8. Conduct a Dry Run

ATTENTION: During all phases of the dry run test, station a person ready to operate an emergency–stop switch if necessary.

The emergency–stop switch will de–energize the master control relay and remove power from the machine. This circuit must be hardwired only, it must not be programmed.

After thoroughly checking out the controller system and program, proceed with a dry run of the application with all of the output devices enabled. This dry run will vary with the application. For example, a machine tool dry run might test the program with all outputs enabled but without tooling an actual part.

After you check out the entire system, and your dry run has been completed satisfactorily, we recommend that you load your program into an EEPROM memory module for back–up program storage. See chapter 3 for more information. Refer to the Hand–Held Terminal User Manual, Catalog Number 1747–NP002, or the Advanced Programming Software User Manual, Catalog Number 1747–NM002, for directions on loading the EEPROM from RAM.

This step completes the start–up procedures. Your SLC Programmable Controller is now ready for operation.

6–11

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Chapter

Maintaining Your Control System

This chapter covers the following:

• handling, storing, and transporting battery, Catalog Number 1747–BA

• installing or replacing your SLC 500 battery

• replacing the power supply fuse

• replacing retainer clips on a module

Refer to chapter 2 for important information on testing the master control relay circuit and preventive maintenance.

Handling, Storing, and Transporting Battery, Catalog Number 1747-BA

Follow the procedure below to ensure proper battery operation and reduce personnel hazards.

Handling

Use only for the intended operation.

•

• Do not ship or dispose of batteries except according to recommended

procedures.

• Do not ship on passenger aircraft.

ATTENTION: Do not charge the batteries. An explosion could result or they could overheat causing burns.

Do not open, puncture, crush, or otherwise mutilate the batteries. A possibility of an explosion exists and/or toxic, corrosive, and flammable liquids would be exposed.

Do not incinerate or expose the batteries to high temperatures. Do not attempt to solder batteries. An explosion could result.

Do not short positive and negative terminals together. Excessive heat could build up and cause severe burns.

Storing

Store the lithium batteries in a cool, dry environment, typically +20° C to +25° C (+68° F to +77° F) and 40% to 60% relative humidity. Store the batteries and a copy of the battery instruction sheet in the original container, away from flammable materials.

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Transporting

One or Two Batteries – Each battery contains 0.23 grams of lithium. Therefore, up to two batteries can be shipped together within the United States without restriction. Regulations governing shipment to or within other countries may differ.

Three or More Batteries – Procedures for the transportation of three or more batteries shipped together within the United States are specified by the Department of Transportation (DOT) in the Code of Federal Regulations, CFR49, “Transportation.” An exemption to these regulations, DOT – E7052, covers the transport of certain hazardous materials classified as flammable solids. This exemption authorizes transport of lithium batteries by motor vehicle, rail freight, cargo vessel, and cargo–only aircraft, providing certain conditions are met. Transport by passenger aircraft is not permitted.

A special provision of DOT–E7052 (11th Rev., October 21, 1982, par. 8–a) provides that:

“Persons that receive cell and batteries covered by this exemption may reship them pursuant to the provisions of 49 CFR 173.22a in any of these packages authorized in this exemption including those in which they were received.”

The Code of Federal Regulations, 49 CRF 173.22a, relates to the use of packaging authorized under exemptions. In part, it requires that you must maintain a copy of the exemption at each facility where the packaging is being used in connection with shipment under the exemption.

Shipment of depleted batteries for disposal may be subject to specific regulation of the countries involved or to regulations endorsed by those countries, such as the IATA Restricted Articles Regulations of the International Air Transport Association, Geneva, Switzerland.

Important: Regulations for transportation of lithium batteries are

periodically revised.

ATTENTION: Do not incinerate lithium batteries in general trash collection. Explosion or violent rupture is possible.

Batteries should be collected for disposal in a manner to prevent against short circuiting, compacting, or destruction of case integrity and hermetic seal.

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Maintaining Your Control System

For disposal, batteries must be packaged and shipped in accordance with transportation regulations, to a proper disposal site. The U.S. Department of Transportation authorizes shipment of “Lithium batteries for disposal” by motor vehicle only in regulation 173.1015 of CRF49 (effective January 5,

1983). For additional information contact: U.S. Department of Transportation

Research and Special Programs Administration 400 Seventh Street, S.W. Washington, D.C. 20590

Although the Environmental Protection Agency at this time has no regulations specific to lithium batteries, the material contained may be considered toxic, reactive, or corrosive. The person disposing of the material is responsible for any hazard created in doing so. State and local regulations may exist regarding the disposal of these materials.

7–3

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Maintaining Your Control System

Installing or Replacing Your SLC 500 Battery

Back–up power for RAM is provided by a capacitor that will retain the contents of the RAM for a period of 5 to 30 days. For applications requiring memory back–up for a longer period of time an optional replaceable battery, Catalog Number 1747–BA, is required. The lithium battery provides back–up for approximately five years. A red BATTERY LOW LED turns on when the battery voltage has fallen below a threshold level.

For battery installation or replacement, do the following:

1. Back up your ladder program.

2. Disconnect power to the processor.

ATTENTION: When power is applied to the controller

hazardous electrical potentials exist under the front cover. See

page 2–8 for more information.

3. Remove the processor cover.

4. If you are: installing a battery in a new processor (battery never installed before),

remove the jumper from the battery socket. Store jumper in safe place for possible future use without battery.

replacing an old battery, unplug the battery connector from the socket. The figure below shows you where to install the battery in a fixed controller.

5. Insert a new or replacement battery in the holder making sure it is held in by the retaining clip.

6. Plug the battery connector into the socket. See the figure below.

Battery

Connector

Red Lead

Battery

Retaining Clips

7. Replace the cover.

White Lead

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Maintaining Your Control System

Replacing the Power Supply Fuse

Under normal power–up conditions, the POWER LED turns on. If a power supply fuse is blown, the POWER LED will not turn on. One of the following conditions could cause a blown power supply fuse:

• excessive line voltage

• internal power supply malfunction

• overloading 2–slot chassis

ATTENTION: Contact with AC line potential can cause injury to personnel. Remove system power before attempting fuse

replacement. Use only replacement fuses of the type and rating recommended

for the unit. Improper fuse selection can result in equipment damage.

After the conditions causing the malfunction have been corrected, you can replace the fuse:

1. Disconnect power to the processor.

ATTENTION: When power is applied to the controller

hazardous electrical potentials exist under the front cover. See

page 2–8 for more information.

2. Remove the cover on the processor.

3. Locate the fuse. Use a miniature fuse puller to grip the fuse and remove it

from its holder.

4. Discard the fuse and replace it with the recommended replacement fuse.

(See chapter 9 for more information.)

Fuse

5. Replace the cover on the processor.

6. Restore power to the processor. The POWER LED should now turn on.

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Maintaining Your Control System

Replacing Retainer Clips on an I/O Module

If it becomes necessary to replace the retainer clip (also called self–locking tab), order Catalog Number 1746–R15 (4 clips per package).

Retainer Clip

Holding Tabs

Removing Damaged Retainer Clips

If necessary, pry off the broken retainer clip from the bottom with a screwdriver. Do not twist it off. You can damage the module.

Retainer Clip

7–6

Installing New Retainer Clips

Insert one of the pins of the retainer clip into the hole in the I/O module and then snap the other end in place.

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Chapter

Troubleshooting

In this chapter, you will learn about:

• calling Allen–Bradley for assistance

• tips for troubleshooting your control system

• troubleshooting your fixed controller

• troubleshooting your input modules

• troubleshooting your output modules

Calling Allen-Bradley for Assistance

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

• processor type, series letter, and firmware (FRN) number (see label on

side of processor module)

• processor LED status

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

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

• revision of programming device (on the main menu of the Hand–Held

Terminal or Advanced Programming Software)

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Chapter 8

Troubleshooting

Tips for Troubleshooting Your Control System

When troubleshooting, pay careful attention to these general warnings:

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

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

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

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

If installation and start–up procedures detailed in chapters 3, 4, and 5 were followed closely, your SLC controller will give you reliable service. If a problem should occur, the first step in the troubleshooting procedure is to identify the problem and its source.

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

8–2

Removing Power

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

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

• fuse is blown

• voltage drops below the normal operating range. Refer to chapter 1 for

more information.

• power supply is defective

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Chapter 8

Troubleshooting

Replacing Fuses

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

Program Alteration

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

Troubleshooting Your Fixed Controller

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

1. Match your processor LEDs with the status LEDs located in the first

column in the tables on the following pages.

2. Once the status LEDs are matched to the appropriate table, simply move

across the table identifying error description and probable causes.

3. Follow the recommended action steps for each probable cause until the

cause is identified.

4. If recommended actions do not identify the cause, contact your local

Allen–Bradley sales office or distributor.

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Chapter 8

Power Supply

incoming power connections

Replace fuse

Troubleshooting

If the LEDs indicate:

Identifying Fixed Controller Errors

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

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

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

If the LEDs indicate:

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

The Following

Error Exists

Inadequate

ystem Power

The Following

Error Exists

Processor Not in Run Mode

Probable Cause Recommended Action

No Line Power

Power Supply Fuse Blown

Verify proper line voltage and connections on the power terminals.

1. Check the incoming power fuse, check for proper

incomin

ower connections. Re

2. If fuse blows again, replace the fixed controller.

This problem can occur intermittently if power supply is

Power Supply Overloaded

lightly overloaded when output loading and temperature varies. If you are using a 2-slot chassis, verify the compatibility of the modules to prevent overloading the backplane power.

Probable Cause Recommended Action

1. Verify selected processor mode.

2. If in program/test modes, attempt RUN mode entry.

Either Improper Mode Selected or User Program Logic Error

3. Check user program logic for suspend instructions if

in suspend mode.

Refer to either the Hand-Held Terminal User Manual, Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002.

Line Power Out of Operating Range

1. Check incoming power connections.

2. Monitor for proper line voltage at the incoming power

connections.

lace fuse.

8–4

Page 96

If the LEDs indicate:

Chapter 8

Troubleshooting

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

If the LEDs indicate:

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

The Following

Error Exists

System Inoperable, No Major CPU Faults Detected

The Following

Error Exists

CPU Fault

Probable Cause Recommended Action

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

User Program Logic Error

Refer to either the Hand-Held Terminal User Manual Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002.

Defective I/O Devices or I/O Wiring

Test inputs and outputs according to I/O troubleshooting procedures starting on page 8-8.

Probable Cause Recommended Action

CPU Memory Error

Cycle power.

1. Remove power and then remove the memory module

from the controller.

Faulty Memory Module

2. Re-energize the controller.

If steady CPU FAULT LED changes to flashing, replace the existing memory module with a replacement module.

Refer to chapter 4 for removing and installing memory modules.

Processor Firmware Installed Incorrectly

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

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

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

Indicates the LED is FLASHING.

8–5

Page 97

Chapter 8

Troubleshooting

If the LEDs indicate:

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

If the LEDs indicate:

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

The Following

Error Exists

CPU Major Fault

The Following

Error Exists

System does not operate per ladder logic.

Probable Cause Recommended Action

Initial CPU Factory Power-up Condition

1. Refer to chapter 6 and follow the start-up procedures.

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

FAULT LED.

1. Monitor Status File Word S:6 for major error code.

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

Hardware/Software Major Fault Detected

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

Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002, for error codes and additional troubleshooting information.

3. Remove hardware/software condition causing fault.

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

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

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

7. Attempt a processor Run mode entry.

If unsuccessful, repeat recommended action steps above.

Probable Cause Recommended Action

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

2. Disable appropriate forces and test system conditions

User Forced I/O Disabling Operation

again.

Refer to either the Hand-Held Terminal User Manual, Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002.

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

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

Indicates the LED is FLASHING.

8–6

Page 98

If the LEDs indicate:

Chapter 8

Troubleshooting

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

If the LEDs indicate:

POWER

PC RUN

CPU FAULT

FORCED I/O

BATTER

Y LOW

The Following

Error Exists

Probable Cause Recommended Action

1. Monitor program file online and identify programmed

forces.

System does not operate per programmed forces.

User Programmed Forces are Not Enabled

2. Enable appropriate forces and test system conditions

again. Once forces are enabled, the FORCED I/O LED goes on steady.

Refer to either the Hand-Held Terminal User Manual, Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002.

The Following

Error Exists

Probable Cause Recommended Action

1. Verify battery is connected. See page 7-4.

2. Replace the battery. See page 7-4.

➀

CPU Major Error with Low or No Battery Back-up

Loss of RAM during Power Down Period

3. Refer to processor major fault recommended action

steps.

Refer to either the Hand-Held Terminal User Manual, Catalog Number 1747-NP002, or the Advanced Programming Software User Manual, Catalog Number 1747-NM002.

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

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

Indicates the LED is FLASHING.

➀

Regardless of any other LED status indicator condi tions, always replace the battery when the BA LOW LED is on if you want RAM battery backup. If you want to back up RAM with a capacitor replace the BA

TTER

Y LOW LED jumper

TTERY

, add or

8–7

Page 99

Chapter 8

Troubleshooting

Troubleshooting Your Input Modules

The following will assist you in troubleshooting your input modules.

Input Circuit Operation

An input circuit responds to an input signal in the following manner:

1. An input filter removes false signals due to contact bounce or electrical interference.

2. Optical isolation protects the backplane circuits by isolating logic circuits from input signals.

3. Logic circuits process the signal.

4. An input LED turns on or off indicating the status of the corresponding

input device.

Input

Conditioning

Optical

Isolation

Logic Circuits Processor

LED

5. The processor receives the input status for use in processing the program logic.

8–8

Page 100

Corrective Action

Your program operates as

pg p

Chapter 8

Troubleshooting

If your Input

Circuit LED is

Off

And Your Input

Device is

On/Closed/Activated

Off/Open/Deactivated

On/Closed/Activated

Off/Open/Deactivated

And Probable Cause Recommended Action

Your input device will not turn off.

Your program operates as though it is off.

Your program operates as though it is on and/or the input circuit will not turn off.

Your program operates as though it is off and/or the input circuit will not turn on.

Your input device will not turn on.

Your program operates as though it is on.

Device is shorted or damaged.

Input is forced off in program.

Input circuit is damaged.

Input device Off-state leakage current exceeds input circuit specification.

Input device is shorted or damaged.

Input circuit is miswired or damaged.

Input circuit is incompatible.

Low voltage across the input.

Incorrect wiring or an open circuit.

Input signal turn on time too fast for input circuit.

Input circuit is damaged.

Input device is opened or damaged.

Input is forced on in program.

Input circuit is damaged.

Verify device operation. Replace device.

Check the FORCED I/O or FORCE LED on processor and remove forces.

Try other input circuit. Replace module.

Check device and input circuit specifications. Use load resistor to bleed-off current.

Verify device operation. Replace device.

Verify proper wiring. Try other input circuit. Replace module.

Check specification and sink/source compatibility (if DC input).

Check the voltage across input circuit and check source voltage.

Check wiring and COMmon connections.

Check timing specifications.

Verify proper wiring. Try other input circuit. Replace module.

Verify operation. Replace device.

Check processor FORCED I/O or FORCE LED and remove forces. Verify proper wiring. Try other input circuit.

Verify proper wiring. Try other input circuit. Replace module.

8–9

Rockwell Automation 1747-L40 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New Information

Table of Contents

Preface

Who Should Use this Manual

How to Use this Manual

Conventions Used in this Manual

Allen-Bradley Support

Local Product Support

Technical Product Assistance

Your Questions or Comments on this Manual

What Your SLC 500 Controller Can Do for You

Overview of Your Fixed Control System

Fixed Controller Specifications

Memory Backup for the SLC 500 Fixed Controller

Configuration Options

Input Specifications

Output Specifications

Relay Contact Ratings

Selecting the 2-Slot Chassis

Selecting Discrete I/O Modules

Selecting Speciality I/O Modules

Selecting Enclosures

Selecting Operator Interfaces

Programming with a Hand-Held Terminal (1747-PT1)

Programming with Advanced Programming Software (APS) on an IBM Compatible Computer

Monitoring with a Data Table Access Module (1747-DTAM-E)

EEPROM and UVPROM Memory Modules

Selecting Isolation Transformers

Special Considerations

Excessive Line Voltage Variations

Excessive Noise

Selecting Surge Suppressors

Selecting Contact Protection

Transistor Output Transient Pulses

Typical Installation

Spacing Your Components

Preventing Excessive Heat

Grounding Guidelines

Master Control Relay

Emergency-Stop Switches

Power Considerations

Common Power Source

Loss of Power Source

Input States on Power Down

Other Types of Line Conditions

Safety Considerations

Disconnecting Main Power

Wiring Safety Circuits

Distributing Power

Preventive Maintenance

Testing the Master Control Relay Circuit

Mounting Fixed Hardware Style Units

20 I/O Fixed Controller

30 and 40 I/O Fixed Controller

2-Slot Expansion Chassis

Link Coupler (AIC)

Data Table Access Module (DTAM)

Mounting the 2-Slot Expansion Chassis

Installing I/O and Speciality Modules

Installing Your Memory Module

Removing Your Memory Module

Using the High-Speed Counter

High-Speed Counter Operation

High-Speed Counter Input Compatibility

Wiring Diagram of a High-Speed Counter Sinking Input Circuit

Wiring Diagram of a High-Speed Counter Sourcing Input Circuit

Defining Sinking and Sourcing

Solid-State DC I/O Circuits

Sourcing Device with Sinking Input Module Circuit

Sinking Device with Sourcing Input Module Circuit

Sinking Device with Sourcing Output Module Circuit

Sourcing Device with Sinking Output Module Circuit

Preparing Your Wiring Layout

Features of an I/O Module