Rockwell Automation 1772-L8, 1772-LW, 1772-LWP, 1772-LX, 1772-LXP User Manual

MiniPLC2/02, 2/16, 2/17 Processor
(cat. no. 1772LZ, LZP, LX, LXP,
LW, LWP)

User Manual

Important User Information

Because of the variety of uses for this product and because of the differences
between solid state products and electromechanical products, those responsible
for applying and using this product must satisfy themselves as to the
acceptability of each application and use of this product. For more information,
refer to publication SGI-1.1 (Safety Guidelines For The Application, Installation
and Maintenance of Solid State Control).

The illustrations, charts, and layout examples shown in this manual are intended
solely to illustrate the text of this manual. Because of the many variables and
requirements associated with any particular installation, Allen-Bradley Company
cannot assume responsibility or liability for actual use based upon the illustrative
uses and applications.

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

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 make notes to alert you to possible injury to people
or damage to equipment under specific circumstances.

ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property
damage or economic loss.

Attention helps you:

- Identify a hazard

- Avoid the hazard

- recognize the consequences

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

Summary of Changes

Summary of Changes

Summary of Changes

This release of the publication contains updated information:

For this updated information: See:

revised conventions chapter 1

clarified ATTENTION statement about using
1770XZ batteries

revised illustrations showing the new chassis
(1771A1B, A2B, A3B, A3B1, and A4B)

minor corrections to the structure for
2slot addressing

added information about adding Branch Start and
Branch End instructions while programming
on line

corrected last counter address information for
counter instructions

minor corrections to Limit Test examples chapter 12

added more information about output alarms and
output limits

minor correction to FIFO ladder diagram examples chapter 15

added warning about using Jump instructions;
corrections to programming examples

corrections to programming examples chapter 18

added warning about using selectable timed
interrupt routines

minor revisions to programming examples chapter 25

clarified the Important statement about
illegal opcodes

new format all chapters and appendices

chapter 3

chapter 3
chapter 4
chapter 5
chapter 10

chapter 7
appendix E

chapter 9

chapter 11

chapter 16

appendix E

chapter 17

chapter 22

chapter 26

To help you find new information in this publication, we have included
change bars as shows to the left of this paragraph.

i

Table of Contents

Summary of Changes

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Using This Manual 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Differences 11
What's this User Manual Contains 12
Vocabulary 12
Conventions 13
Related

Objectives

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Publications

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fundamentals of a Programmable Controller 21. . . . . . . . . . .

Chapter
Traditional Controls 21
Programmable Systems 22
The Four Major Sections 22
Control Sequence 29
Scan Sequence 210

Objectives

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21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hardware Features 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

Chapter
Major Features 31
Processor Features 31
Series Changes 32
Special Features 33
Processors 33
Optional

Objectives

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Equipment

31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Your Programmable Controller 41. . . . . . . . . . . . . .

Chapter
Related Hardware 41
Planning Your Processor System 42
How
Step 1 - Mounting the Backpanel 414
Step 2 - Mounting and Grounding Components on the Backpanel 415
Step
Step 4 - Installing Keying Bands and Field Wiring Arms 424
Step
Step 6 - Backup Battery 428
Step
Step 8 - Installing the Processor 431
Step 9 - Installing the Power Supply 431

Objectives

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to Install Y

3 - Setting the Switches within the Switch Group Assembly

5 - Installing I/O Modules

7 - Installing the EEPROM Memory Module

our Processor 413. . . . . . . . . . . . . . . . . . . . . . . . . . .

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41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

422. .

426. . . . . . . . . . . . . . . . . . . . . . . . . .

429. . . . . . . . . . . . .

Table of Contentsii

Step 10 - Connecting to the Field Wiring Arms 432. . . . . . . . . . . . . . .

Step 11 - Connecting Power to the Processor or Power Supply 437
Step 12 - Connecting the Industrial Terminal 442
Master Control Relay 443

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. . .

Starting Your Processor 51. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Verify Your System's Addresses 51
Status Indicators for I/O Modules 53
Addressing Your Hardware 54
Before You Supply AC Power 518
Testing Output Devices 518
Testing Input Devices 520

Objectives

51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Maintaining and Troubleshooting Your Processor 61. . . . . . .

Chapter
General 61
Preventive Maintenance 61

Objectives

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61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Memory Organization 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Introduction 71
Memory Areas 72
Adjusting the Data Table 77
Expanding the Data Table Between 48 and 128 Words 77
Expanding the Data Table Between 130 and 256 Words 79
User Program 711
Message Storage 711

Objectives

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71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Scan Theory 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Scan Function 81
Average Scan Time 83

Objectives

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81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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RelayLike Instructions 91. . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Programming Logic 91
Bit
Examine On and Examine Off 94
Bit
Output Energize 95
Output
Branching Instructions 98

Objectives

Examining

Controlling

Latch/Unlatch

91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contents iii

Branch

Start/End

Nesting 911

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99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Control Instructions 101. . . . . . . . . . . . . . . . . . . . . .

Chapter
Introduction 101
Output Override Instructions 101
Immediate

Objectives

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I/O Update Instructions

101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105. . . . . . . . . . . . . . . . . . . . . . . .

Timers and Counters 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Introduction 111
Timer Instructions 112
Timer On Delay 112
Timer
Retentive Timer On 114
Retentive Timer Reset 115
Counter Instructions 117
Up Counter 117
Down Counter 118
Counter Reset 119

Objectives

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Of

f Delay

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111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data Manipulation and Comparison Instructions 121. . . . . . . .

Chapter
Get 121
Put 122
Compare Instructions 123
Equal To 123
Less Than 124
Limit Test 125
Operations Involving Transfer and Comparison Instructions 128
Equal To or Less Than 128
Greater Than 129
Equal To or Greater Than 1210
Get Byte 1211
Get

Objectives

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Byte/Put

121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ThreeDigit Math Instructions 131. . . . . . . . . . . . . . . . . . . . . .

Chapter
ThreeDigit
Entering a ThreeDigit Math Instruction 133

Objectives

Math

131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Table of Contentsiv

EAF Math Instructions 141. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Two Operand EAFs 141
Addition and Subtraction 146
Multiplication and Division 148
Y
One Operand EAFs 1410
Exponential and Square Root 1414
10
Reciprocal 1418
BCD to Binary 1419
Binary

EAF

Chapter
One Operand EAFs 151
Log to Base 10 or Log to Base e 155
Sine and Cosine 156
FIFO Load and FIFO Unload 157

Objectives

to the X

to the X

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to BCD

Logarithmic, T

Objectives

141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1417. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1420. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rigonometric, and FIFO Instructions 151. . .

151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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EAF Process Control Instructions 161. . . . . . . . . . . . . . . . . . .

Chapter
PID Control 161
Loop Considerations 165
Programming 165
Entry and Display of a Selectable Timed Interrupt

Software
Cascading Loops 1621
DeScaling
Averaging and Standard Deviation Functions 1634
Difference Between ThreeDigit and SixDigit Functions 1634
Wall Clock/Calendar 1645

Objectives

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(STI) Controlled PID Function 1614

Manual Control Station

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Inputs

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161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1620. . . . . . . . . . . . . . . . . . . . . . . . .

1623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump Instructions and Subroutine Programming 171. . . . . . . .

Chapter
Jump 171
Jump to Subroutine 172
Label 172
Return 173
Entering Jump Instructions 173
Subroutine Area Instruction 173

Objectives

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171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v

Block Transfer 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Basic Operation 181
Block Transfer Format 184
Block Transfer Read 188
Block Transfer Write 1811
BiDirectional Block Transfer 1812
Multiple
Buffering
Two
Support Rungs 1823

Objectives

Reads of Dif

Data

Get Method

181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ferent Block Lengths 1816. . . . . . . . . . . . . . . . . . .

1817. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1820. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Data Transfer File Instructions 191. . . . . . . . . . . . . . . . . . . . . .

Chapter
FiletoFile Move Instruction 192
WordtoFile Move Instruction 1913
FiletoWord Move Instruction 1914
Data Monitor Display 1916
Adjusting the Data Table Size 1918

Objectives

191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Bit Shift Registers 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Bit
Bit
Examine
Examine
Set
Reset

Objectives
Shift Left
Shift Right

Of
On Bit Shift

Bit Shift

Bit Shift

f Bit Shift

201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequencers 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Comparison
Mask 212
Programming
Sequencer Instructions 213
Sequencer
Sequencer
Sequencer Load 2120

Objectives

with File Instructions

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

Limitations

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

Input
Output

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

211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211. . . . . . . . . . . . . . . . . . . . . . . .

213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsvi

Selectable Timed Interrupt 221. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Introduction 221
Selectable Timed Interrupt 223
Operational Overview 224

Objectives

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

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

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

221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Report Generation 231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Report Generation Commands 232
Entering a Message 238
Graphic Programming 2316

Program

Chapter
Editing a Program 241
Online Data Change 246
Search Functions 247
Clearing Memory 2411
Special Programming Aids 2413
Online Programming 2415
Data

Objectives

Editing

Objectives

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

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

Initialization Key

231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

2416. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Techniques 251. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
OneShot Programming 251
Restart 253
Cascading Timers 254
Temperature Conversions 255
Program Control 259

Objectives

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

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

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

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

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

251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Troubleshooting 261. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Run Time Errors 261
Bit
Contact Histogram 263
Force Functions 265
Temporary End Instruction 267
Testing Your Program 269
ERR Message for an Illegal Opcode 2610

Objective

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

Monitor/Manipulation

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

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

261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Table of Contents vii

Specifications A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Processor Comparison Chart B1. . . . . . . . . . . . . . . . . . . . . .

Number Systems C1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Objectives C1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Decimal Numbering System C1
Octal Numbering System C2
Binary Numbering System C3
Hexadecimal Numbering System C5

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

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

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

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

Glossary D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction D1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Reference E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of References E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Data Table E2
Block Transfer Instructions E4
Clearing Memory E6
Counter Instructions E7
Data Monitor Functions E8
Data Transfer File Instructions E9
EAF Function Numbers E10
Editing Functions E11
Execution Times and Words Per Instruction E12
FIFO Load and FIFO Unload E16
Graphic Programming E17
Help E19

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

Memory Layout E20
Memory Structure E21
PID Control Block E24
PROC Indicator E28
Report Generation E29
Search E30
Sequencer Instructions E31
Switch Group Assembly Settings E32
Timer Instructions E34
Diagnostic Word 027 E35

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Using This Manual

Chapter

1

Chapter Objectives

Differences

Read this chapter before you use your processor.
Important: This manual is for the series D Mini-PLC-2/02,

Mini-PLC-2/16 and Mini-PLC-2/17 processors. See the Series Changes on
page 3-2 for the differences with other processor series.

This manual describes the Mini-PLC-2/02, Mini-PLC-2/16 and
Mini-PLC-2/17 processors. Unless stated otherwise, assume the features
or instructions are common to all the processors.

Feature MiniPLC2/02 MiniPLC2/16 MiniPLC2/17

Size of memory (words) 2K 4K 7.75K

Size of EEPROM backup (words) 4K 4K 8K

Data table expansion (words) 1920 3968 7808

EAF instructions (up to 12 digits) Add

Subtract
Multiply
Divide

EAF instructions Square Root

BCD to Binary
Binary to BCD
FIFO Load
FIFO Unload
Log

10

Sin X
Cos X

x

10

Add
Subtract
Multiply
Divide

Square Root
BCD to Binary
Binary to BCD
FIFO Load
FIFO Unload
Log

10

Sin X
Cos X

x

10

Add
Subtract
Multiply
Divide

Square Root
BCD to Binary
Binary to BCD
FIFO Load
FIFO Unload
Log

10

Sin X
Cos X

x

10

Additional EAF instructions none none Log

y+/
e+/
Reciprocal of x
Averaging
Standard
Deviation
PID
Wall Clock/Calendar

e

x
x

1-1

Chapter 1

Using This Manual

What's this User
Manual Contains

This manual is divided into eight sections (Table 1.A):

Table 1.A
Sections of the MiniPLC2/02, MiniPLC2/16, and MiniPLC2/17
Processor User Manual

Information Sections What's Covered In Chapters

Overview how to use this manual; fundamentals of

Hardware the processor's hardware features; how to assemble,

Basic instruction set how to use basic instructions common to all PLC2

Advanced instruction set how to use advanced instructions unique to some

Programming procedures and
troubleshooting

Specifications, comparison chart,
number systems, and glossary

12

programmable controllers

3

install, start, maintain, and troubleshoot the processor

413

family processors

1422

the processors

how to use special programming techniques and follow
a troubleshooting guide so you can minimize production
down time

specifications; PLC2 family comparison chart;
explanation of number systems; and list of processor
terms used in this manual

2326

Appendices AD

Vocabulary

Quick reference selected tables in this manual Appendix E

This manual is procedure oriented. It tells you how to program and
operate your Mini-PLC-2/02, Mini-PLC-2/16, and Mini-PLC-2/17
processor. If you need to learn more about these processors, contact your
local Allen-Bradley representative or distributor.

To make this manual easier to read and understand, we refer to the:

We Refer to the: As the:

MiniPLC2/02, MiniPLC2/16, and
MiniPLC2/17 Processors

Electrically Erasable Programmable
Read Only Memory

Programmable Read Only Memory PROM

Execute Auxiliary Function EAF

Complementary Metal Oxide
Semiconductor Random Access Memory

Industrial Terminal (cat. no. 1770T3) 1770T3 terminal

processors

EEPROM

CMOS RAM

1-2

A glossary at the back of this manual clarifies technical terms.

Chapter 1

Using This Manual

Conventions

A word equals 16 bits; a byte equals 8 bits (1/2 of a word).

Words in [ ] denote a key name or symbol. Words in < > denote
information that you must provide - for example, an address value.

All word addresses are displayed in the octal numbering system.
Therefore, references to base 8 are not displayed.

Word values are displayed in:

decimal (0-9) for timers, counters, and mathematics

010

00

Decimal

hexadecimal values (0-9, A-F) for Get and Put instructions

010

010

011 012

GG

00

00

030

CTU

PR 555
AC 123

030

00FFF 123

Hexadecimal

Important: Numbers 0-9 are displayed the same in decimal and
hexadecimal.

octal byte values for examine on and output energize instructions

0101 030

B

237

Octal

Keystroke directions are divided into two columns:

tells you what key or keys to press

tells you the processor’s action

00

1-3

Chapter 1

Using This Manual

Figure 1.1 shows the keystrokes to produce a display.

DISPLAY

0

Figure 1.1
Illustration

Showing Keystroke Conventions

Start by positioning your cursor on the words SEQUENCER INPUT.
Use the arrow keys to move the cursor.

The word display appears in the lower left hand corner of the screen.

BINARY DATA MONITOR
SEQUENCER OUTPUT

COUNTER ADDR: 200

OUTPUT ADDR: 110

DATA:

MASK ADDR: 070

DATA:

STEP WORD 1

001

00000000 00000000

002

00000000 00000000

003

00000000 00000000

004

00000000 00000000

005

00000000 00000000

006

00000000 00000000

00000000 00000000

00000000 00000000

STEP: 001 SEQUENCER LENGTH: 006

FILE: 400- 413

201

00000000 00000000

071

00000000 00000000

WORD 2

00000000

00000000
00000000 00000000
00000000 00000000
00000000 00000000
00000000 00000000
00000000 00000000

A: 00000000 00000000

DAT

Related Publications

1-4

The publication index, publication SD 499, lists all available publications
to further inform you about products related to the Mini-PLC-2/02,
Mini-PLC-2/16, and Mini-PLC-2/17 processors. Consult your local
Allen-Bradley distributor or sales engineer for information regarding this
publication or any needed information.

Chapter

2

Fundamentals of a Programmable Controller

Chapter Objectives

Traditional Controls

In this chapter, you review general fundamentals common to our
programmable controllers. This chapter:

describes what a programmable controller does
describe the functions of a programmable controller
describes the four major sections of a programmable controller
gives an example of a simple program

You are probably familiar with the traditional methods of machine control.

Relays

Machine

Sensing
Devices

Sensing devices located on the machine detect changes in the machine’s
condition. For instance, a part arriving at a work station contacts and
closes a limit switch, the sensing device. As a result, an electrical circuit is
completed and a signal is sent to the control panel.

Control Panel

Output
Devices

11591

At the control panel, the electrical signal enters a bank of relays or other
devices, such as solid state modules. Circuits within the control panel open
or close causing additional electrical signals to be sent to output devices at
the machine. For example, a relay energized by the limit switch closed by
the arriving part may complete another circuit energizing the output
device, a clamp, which secures the part at the work station.

2-1

Chapter 2

Fundamentals of a
Programmable Controller

Programmable Systems

Systems run by programmable controllers operate in much the same way.
Programmable controllers can perform many of the functions of traditional
controls. Input sensing devices report machine conditions; output devices
respond to commands.

Programmable
Controller

Conditons

Machine

Sensing
Devices

Control Panel

Action
Command

Output
Devices

Wiring between the machine and the controller provides electrical paths
from the sensing devices to the controller and from the controller to the
output devices.

However, instead of wiring relays together to produce a desired response,
you simply tell your programmable controller how you want it to respond.

11592

The Four Major Sections

A program tells your programmable controller what you want it to do. A
program is nothing more than a set of instructions you give the
programmable controller telling it how to react to certain conditions within
the machine.

A typical programmable controller system usually consists of four
major sections:

processor
input modules
output modules
power supply

2-2

Chapter 2

Fundamentals of a
Programmable Controller

Power Supply

Processor

(Decision Making)

Information

Input Output

Limit, Proximity, Pressure,

•

Temperature Switches

•

Push Buttons

•

Logic

•

BCD

•

Analog

Action

Solenoids•

•

Motor Starters

•

Indicators

•

Alarms

•

Logic

•

BCD

•

Analog

Processor

The first section of a programmable controller is the processor. The
processor might be called the “brains” of the programmable controller. It
is divided into halves:

central processing unit
memory

CPU

Processor
Section

Data

Table

Program

Storage

Message

Storage

Memory

Central Processing Unit

The Central Processor Unit (CPU) makes decisions about what the
processor does according to the program you write.

2-3

Chapter 2

Fundamentals of a
Programmable Controller

Memory

Memory serves three functions:

stores information in the data table that the CPU may need
stores sets of instructions called a program
stores messages

Data Table

The area of memory where data is controlled and used, is called the data
table. The data table is divided into several smaller sections according to
the type of information to be remembered. These smaller sections are
called:

output image table
input image table
timer/counter storage

Data Table

Output Image Table

Input Image Table

Timer/Counter

Storage

This memory area:

output image tables The output image table controls the on or off status of the

input image tables The input image table duplicates the on or off status of the

timer/counter storage Timer and Counter instructions are output instructions. They

Serves this purpose:

output devices wired to the output module's terminals. If an
output image table bit is ON (1), its corresponding output
device is ON (energized). If a bit is OFF (0), its corresponding
output device is OFF (deenergized). Output image table bits
are controlled by the user's program.

input devices. If an input device is ON (closed), its
corresponding input image table bit is ON (1). If an input
image table bit is OFF (open), its corresponding input image
table bit is OFF (0). Input image table bits are monitored by the
user's program.

provide many of the capabilities available with timing relays
and solidstate timing and counting devices. Usually
conditioned by examine instructions, they keep track of timed
intervals or counted events according to the logic of the rung.

2-4

Chapter 2

Fundamentals of a
Programmable Controller

I/O Image Tables

The input image table reflects the status of the input terminals. The output
image table reflects the status of bits controlled by the program.

Each image table is divided into a number of smaller units called bits. A
bit is the smallest unit of memory. A bit is a tiny electronic circuit that the
processor can turn on or off. Bits in the image table are associated with a
particular I/O terminal in the input or output section.

When the processor detects a voltage at an input terminal, it records that
information by turning the corresponding bit on. Likewise, when the
processor detects no voltage at an input terminal, it records that
information by turning the corresponding bit off. If, while executing your
program, the CPU decides that a particular output terminal should be
turned on or off, it records that decision by turning the corresponding bit
on or off. In other words, each bit in the I/O image tables corresponds to
the on or off status of an I/O terminal.

When people who work with personal computers talk about turning a bit
on, they use the term “set.” For example - “The processor sets the bit”
means “turns it on.” On the other hand, we use the term “reset” when we
talk about turning the bit off - for example, “The processor reset the bit.”

Picture memory as a page that has been divided into many blocks. Each
block represents one bit. Since each bit is either on or off, we could show
the state of each bit by writing “on” or “off” in each block. However, there
is an easier way. We can agree that the numeral one (1) means on and that
the numeral zero (0) means off. We can show the status of each bit by
writing 1 or 0 into the appropriate block. For example, you might hear
expressions like, “The CPU responded by writing a one into the bit when
the limit switch closed.” Of course, the processor didn’t really write a one
into memory: it simply set the bit by turning it on.

When the I/O device is: The bit status is said to be:

on

on

off

1

set

off

0

reset

If you heard the expression, “The processor wrote a zero into that bit
location.” What actually happened? If you said the processor merely reset
the bit by turning it off, you’re right.

2-5

Chapter 2

Fundamentals of a
Programmable Controller

Program Storage

Program storage takes up the largest portion of memory. This is where the
user’s program is stored. Each program is made up of a set of statements.
Each statement does two things:

It describes an action to be taken. For instance, it might say, “Energize

motor starter number one.”

It describes the conditions that must exist in order for the action to

take place.

Statement

Statement

Statement

Statement

Statement

Statement

Program

Program Storage Area

of Memory

ActionConditions

Program
Statement

For example, you may want this action to take place: “Whenever a certain
limit switch closes.” So your condition could be: “If limit switch number
two is closed,...” The action would be: “energize motor starter number
one.” Therefore, when limit switch number two at the machine closes, the
programmable controller energizes the motor starter. If limit switch
number two does not close, the programmable controller does not energize
the motor starter. Thus, when limit switch number two opens, the
programmable controller de-energizes the motor starter because that action
is implied in the statement.

A program is made up of a number of similar statements. Typically, there
is one statement for each output device on the machine. Each statement
lists the conditions that must be met and then, states the action to be taken.

Each condition is represented by a specific instruction; therefore, each
action is represented by a specific instruction. These instructions tell the
processor to do something with the information stored in the data
table.Some instructions tell the processor to read what’s written in the
image table. When the processor is instructed to read from an image table,
it examines a specific bit to see if a certain I/O device is on or off.

2-6

Other instructions tell the processor to write information into the image
table. When the processor is instructed to write into the output image
table, it writes a one or a zero into a specific bit. The corresponding output
device will turn on or off as a result.

Chapter 2

Fundamentals of a
Programmable Controller

Message Storage

The third area of memory, message storage, begins after the end statement
in the user’s program. Two alphanumeric characters can be stored in a
word. Messages are entered into memory from either a 1770-T3 terminal
or a peripheral device.

Messages are displayed on a 1770-T3 terminal or a peripheral device each
time a message is required. The messages are activated through program
control by programming specific instructions in the ladder
diagram program.

Input Modules

The input modules of a programmable controller have four functions:

termination
indication
conditioning
isolation

Termination

The input provides terminals for the field wiring coming from the sensing
devices on the machine.

Indication

The input of most modules also provides a visual indication of the state of
each input terminal with LED indicators. The indicator is on when there is
a voltage applied to it terminal. The indicator is off when there is no
voltage applied to its terminal. Since the indicator reveals the status of its
terminal, it’s usually called an input status indicator.

Input indicators are only associated with terminals used for wiring sensing
devices to the input section. The terminal that’s used to provide a ground
for the sensing circuits has no indicator.

Conditioning

Another function of input modules is signal conditioning. Voltage levels
used at the machine are usually not compatible with the voltage levels used
within the programmable controller. The input modules receives the
electrical signal from the machine and converts it to a voltage level
compatible with the programmable controller’s circuitry.

Isolation

The input isolates the machine circuitry from the programmable
controller’s circuitry. Isolation helps protect the programmable controller’s
circuitry from unwanted and dangerous voltage levels that may occur
occasionally at the machine or in the plant’s wiring system.

2-7

Chapter 2

Fundamentals of a
Programmable Controller

Output Modules

The output modules of a programmable controller have four functions:

termination
indication
conditioning
isolation

Termination

The output provides terminals for the field wiring going to the output
devices on the machine.

Indication

The output of most modules provides a visual indication of the selected
state of each output device with LED indicators. The output status
indicator is on when the output device is energized. A common term
applied to either input status indicators or output status indicators is I/O
status indicators. I/O stands for either input or output.

In older modules, when power is present at the output terminals, the status
indicators are ON. In high density modules, power may not be present at
the output terminals for the status indicator to be ON.

Conditioning

The output conditions the programmable controller’s signals for the
machine. That is, it converts the low-level dc voltages of the
programmable controller to the type of electrical power used by the output
devices at the machine.

Isolation

The output isolates the circuitry of the programmable controller from
unwanted and dangerous voltages that occasionally occur at the machine
or the plant’s wiring system. Some situations require additional
external protection.

Power

Supply

The power supply provides low-level dc voltage for the electronic circuitry
of the processor, its input and output modules. It converts line voltages to
the lower logic voltages required by the processor and its input and
output modules.

2-8

Chapter 2

Fundamentals of a
Programmable Controller

Control Sequence

Let’s look at a simple example to see the sequence of events that take place
in controlling a machine with a programmable controller (Figure 2.1).
Suppose you are making a part. The motor driven conveyor carries a unit
to the work area. The limit switch detects wen the part arrives at the work
area. when that happens, we want the conveyor to stop so you can work on
the part.

Figure 2.1

Simplified Example of a Machine with a Programmable Controller

A

Controller

Input Output

Conveyor

Motor

Limit
Switch

Conveyor

Unit

11594

Notice how the limit switch and motor are wired to the programmable
controller. The limit switch, wired to terminal 02, is normally-closed. The
arriving part will open the switch. Therefore, the program statement
controlling the conveyor motor must read: “If there is voltage at input
terminal 02 (limit switch), then energize output terminal 02 (conveyer
motor).” The conveyor motor is wired to output terminal 02.

Important: Figure 2.1 is for demonstration purposes only. We do not
show the associated wiring, a motor starter, or an emergency stop button.

Since the limit switch is wired normally-closed, the conveyor motor runs
until the arriving part opens the switch. At that time, the condition for
energizing the motor is not longer met. Therefore, the motor is
de-energized.

When the condition is met, we say it is true. When the condition is not
met, we say it is false. There may be more than one condition which must
be met before an action is executed. When all the conditions are met, the
action is executed and we say the statement is true. When one or more of
the conditions are false, the action is not executed and we say the statement
is false.

2-9

Chapter 2

Fundamentals of a
Programmable Controller

Scan Sequence

I/O

Scan

On power up, the processor begins the scan sequence (Figure 2.2) with a
program pre-scan. This pre-scan is completed as if the entire program lies
within an active MCR zone. Next the processor completes the I/O scan.
During the I/O scan, data from input modules is transferred to the input
image table. Data from output image table is transferred to the
output modules.

Figure 2.2

Sequence

Scan

Output
Image
Table

Copy output image table status
into output terminal circuits.

Input

Terminals

Output

Terminals

Input
Image
Table

Program

Scan

Copy input terminal status into
input image table.

Program Statement

Execute each program rung in
sequence, writing into bits in the
data table, including the output
image table.

11597

2-10

Chapter 2

Fundamentals of a
Programmable Controller

Next, the processor scans the program. It does this statement by statement.
Each statement is scanned in this way:

1. For each input instruction, the processor checks, or “reads,” the

image table to see if the condition has been met.

2. If the set of conditions has been met, the CPU writes a 1 into the bit

location in the output image table corresponding to the output
terminal to be energized. On the other hand, if the set of conditions
has not been met, the processor writes a 0 into the bit location,
indicating that the output terminal should not be energized.

Here is a simple explanation of the program. If input 02 is on, then turn on
output 02. If input 02 is off, then turn off output 02. The program could
be written this way:

If (condition) Then (action)

Input bit 02 is on Turn output bit 02 on

In this example, the processor reads a 1 at input bit location 02 and knows
that the condition has been met. The processor then carries out the action
instruction by writing a 1 into output bit location 02.

If there were more statements in the program, the processor would
continue in this same manner scanning each statement and executing each
instruction until it reached the end of the program. Statement by
statement, the processor would write a 0 or a 1 into an output bit as
directed by the program. Then, the processor would read specific image
table bits to see if the proper set of conditions were met. After reading and
executing all program statements, the processor scans the output image
table and energizes or de-energizes output terminals. The processor then
goes to the input modules to update the input image table.

Now the entire process is repeated. In fact, it’s repeated over and over
again, many times a minute. Each time, the processor sets or resets output
bits. Next, the processor senses the status of the input terminals. Finally,
the processor scans the program and orders each output terminal on or off
according to the state of its corresponding bit in the output image table.

When forcing is attempted, the processor’s I/O scan slows down to do the
forcing (see chapter 19). When forcing is terminated, the processor
automatically switches back to the faster I/O scan mode.

When this example begins, the processor is energizing output terminal 02
because output bit 02 is on.

When the part is conveyed to the work station, it turns the limit switch off.
When the limit switch is off, there is no voltage at input terminal 02. The
processor scans the input image table, senses no voltage, and responds by
writing a zero into bit 02 in the input image table.

2-11

Chapter 2

Fundamentals of a
Programmable Controller

The processor scans the program. Our program states that if (conditions)
input bit 02 is on, turn on output 02. If input bit 02 is off then output bit 02
is off. Since the alter condition is not true, the processor turns off output
bit 02.

When the processor next scans the output image table, it sees the zero in
output bit 02 and responds by de-energizing output terminal 02. The
action causes the conveyor to stop.

2-12

Hardware Features

Chapter

3

Chapter Objectives

Major Features

Processor Features

This chapter is a summary of the Mini-PLC-2/02, -2/16, and -2/17
processors. In this chapter, you will read about:

major features
processor features
series changes
special features
optional equipment

A complete processor system consists of the following major components:

a processor
I/O chassis
power supply
as many as 16 I/O modules
industrial terminal (cat. no. 1770-T3)

This manual incorporates the features and instructions of three processors:
Mini-PLC-2/02, -2/16, and -2/17. Unless stated otherwise, assume that the
features or instructions are common to all processors.

1

memory and data table
memory protection above word address 177
self-contained 120/220V AC power supply in cat. nos. 1772-LWP and

1772-LXP; cat. no. 1772-LZP supplies an additional 4A to the

backplane for I/O
mode select key switch
diagnostic indicators

I/O capacity: 128 for Mini-PLC-2/02

256 for Mini-PLC-2/16
512 for Mini-PLC-2/17

1/2-, 1-, or 2-slot addressing

1 Series C of the T3 terminal gives you the additional features required to take full advantage of all of the
processor functions described.

See Industrial Terminal section of this chapter.

8

3-1

Chapter 3

Hardware Features

basic instruction set:

-relay-like instructions

-up to 488 timers and counters in the processors

-program control instructions

-data manipulation and comparison

-three-digit math (add, subtract, multiply, and divide)

advanced instruction set:

-jump instructions and subroutine programming

-block transfer instructions

-data-transfer file instructions

-sequencer instructions

-bit shift register instructions (bit shifts)

-EAF functions: 6-digit add, subtract, multiply and divide, square root,
Binary/BCD conversions, FIFO Load and Unload, log10, sine,
cosine, 10x

Series Changes

-The Mini-PLC-2/17 can perform these additional EAF functions:
loge, y+/- x and e+/- x, reciprocal of x, averaging, standard deviation,
PID, clock and calendar

The additional features of the various series of the processors are outlined
in Table 3.A.

Important: The processor features described in the previous section apply
to all series except where noted in Table 3.A.

3-2

Chapter 3

Hardware Features

MiniPLC2/02

Series A
Series D

MiniPLC2/16

Series A
Series B
Rev A or B
Series B
Rev C or later
Series C
Series D

MiniPLC2/17

Series A
Series B
Rev A or B
Series B
Rev C or later
Series C
Series D

AA

Batt

X X

X X

12.5msec/

Table 3.A
Additional

K Scan

X X

X

X

X

X

X

X

Features of MiniPLC2 Processors

1/2AA

Batt

X

X

X

X
X

X

X

X
X

Key

Switch

X
X

X

X

X
X

X

X

X
X

Last

State

X
X

X
X

X
X

1/2Slot

Addr

X
X

X

X
X

X

X

X
X

Bit

Shift

X
X

X

X
X

X

X

X
X

7.5msec/
K Scan

X

X

Memory

1K
2K

3K
3K

3K

3K
4K

6K
6K

6K

6K

7.75K

Special Features

Processors

on-line data change

on-line programming

selectable timed interrupt enables recurring subroutine

self-contained lithium battery for memory

full I/O forcing when using 2-slot addressing — I/O forcing only on

rack 1 addresses when using 1-slot or 1/2-slot addressing and a series B
1770-T3 terminal, or earlier. The series C 1770-T3 terminal allows full
I/O forcing when using 2-slot, 1-slot or1/2-slot addressing.

data highway interface

report generation

The front panels of the processors are nearly identical. The only visual
difference between them is the catalog number across the bottom of the
processor (Mini-PLC-2/02, Mini-PLC-2/16, or Mini-PLC-2/17).

3-3

Chapter 3

Hardware Features

Figure 3.1
Without

PROC

F
A
U
L
T

BATT

RUN

R/P

MEM

STORE

a Power Supply

PROC indicator lights green for normal operation
and red for a processor fault. Off indicates that
you are in Program Mode or a possible runtime
error. You reset this LED by cycling power.

R
U
N

BATT (Red) lights when battery should be replaced.

Key Switch selects one of four positions:

PROG: Program
R/P: Run/Program
RUN: Run
MEM STORE: Transfer program to MEM STORE backup EEPROM

BATTERY

INSTALLED

INTFC

MINI-PLC-2/17

Battery backup helps protect stored memory.

Interface Port allows you to connect information sources such as
a 1770T3 terminal, handheld terminal. Data Highway



or

Report Generation module.

10294-I

3-4