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 conventionschapter 1
clarification to switch settings for 1772LSPchapter 3
description of keys on keytop overlay (1770KCB)chapter 3
corrections to the discussion about
automatic restart
corrections to the discussion about
program control
addition of ZCL to glossaryappendix B
new formatall chapters and appendices
chapter 18
chapter 18
To help you find new information in this publication, we have included
change bars as shows to the left of this paragraph.
i
Part
Hardware Overview
Industrial Terminal
(rear view)
Channel A
PLC2 Family
1Before You Begin
2An Introduction to Programmable Controllers
3Hardware
MiniPLC2/05
Program Panel
Interconnect Cable
Interface
RUN
P
R
O
C
FAULT
ON
MEMORY
STORE
ON
AB
INTFC
MINI PLC2/05
W/O Power Supply
P
R
O
P/S
C
ACTIVE
MEMORY
STORE
P/S
PARALLEL
AB
POWER
ON
OFF
I.0A 125V
SLOW BLOW
120V
GND
MINI PLC2/05
W Power Supply
AC
RUN
FAULT
ON
ON
INTFC
L1
N
4Memory Organization
5Scan Theory
6Relay-type Instructions
7Program Control Instructions
8Timers and Counters
9Data Manipulation Instructions
10Math Instructions
11Data Transfer File Instructions
12Sequencers
13Jump
Instructions and
Subroutines
14Block Transfer
15Selectable Timed Interrupt
Part
Memory / Instruction Set
Data Table
Main Program
User Program
Subroutine
Message Storage Area
110
110110
00
10
11
110
110
12
11
110
13
010
00
16Program Editing
Part
Program Editing
( )
( P )
FOR
USE WITH PLC2 F
1982 ALLENBRADLEY 97534302
AMILYCAT
. NO. 1770 KCB
Part
Report Generation /
Application Programming Techniques
17Report Generation
18Programming Techniques
MS.0
198 MESSAGES SELECTED
MESSAGE CONTROL WORDS ( ENTER 5 DIGIT WORD ADDRESS)
This appendix contains defines terms and abbreviations that because of their
complexity or recent introduction are not widely understood. These terms are:
AC Input Module
An I/O module that converts various AC signals originating at user devices to the
appropriate logic level signal for use within the processor.
AC Output Module
An I/O module that converts the logic level signal of the processor to a usable
output signal to control a user AC device.
Important: Read this chapter before you use the Mini-PLC-2/05 Processor (cat.
no. 1772-LS,-LSP). It tells you how to use this manual.
Purpose
To the Reader
The Mini-PLC-2/05 processor is functionally similar to the Mini-PLC-2/15
processor. The Mini-PLC-2/05 processor has some additional features:
selectable timed interrupt
memory protect switch
fast I/O scan
user selectable PROM/RAM backup
3K memory
expanded mathematics
However, this processor does not have a mode select switch.
This manual is divided into six parts (Table 1.A).
Table 1.A
of the MiniPLC2/05 Processor Programming and Operations Manual
Parts
PartTitleWhat's Covered
AHardware Overviewbasic theory concerning the hardware features available when using
this processor
BMemory/Instruction Setdescribes the memory and informs you about the techniques you can
use when programming this processor
CProgram Editinghow to edit your program once it has been entered into the memory
DReport Generation/Application
Program Techniques
EProgram Troubleshootingacts as a guide so you can minimize production down time
FAppendicescontains tables and reference information useful when programming
how to do report generation and use special program techniques
your processor
This manual is procedure oriented. It tells you how to program and operate your
Mini-PLC 2/05 Processor. If you need to learn more about the Mini-PLC-2/05
Processor, contact your local Allen-Bradley representative or distributor.
11
Chapter 1
Before You Begin
Vocabulary
Conventions
To make this manual easier to read and understand, we refer to the:
We Refer to the:As the:
MiniPLC2/05 Processorprocessor
Electrically Erasable Programmable
Read Only Memory
Execute Auxiliary FunctionEAF
Complementary Metal Oxide
Semiconductor Random Access Memory
A glossary at the back of this manual clarifies technical terms.
A word equals 16 bits; a byte equals 8 bits (1/2 a word).
Words in [ ] denote the key name or symbol. Words in < > denote information
that you must provide - for example, an address value.
Word values are displayed in:
decimal (0-9) for timers, counters, and mathematics
010
00
Decimal
030
CTU
PR 555
AC 123
hexadecimal values (0-9, A-F) for gets and puts
010
010
011012
GG
00
00
Hexadecimal
030
00FFF123
Important: Numbers 0-9 are displayed the same in decimal and hexadecimal.
octal for byte values
0101030
B
237
Octal
00
12
Chapter 1
Before You Begin
Keystroke directions are divided into two columns:
tells you what key or keys to press
Related Publications
tells you the processor’s action.
The publication index, publication SD 499, lists all available publications to
further inform you about products related to the Mini-PLC-2/05 processor.
Consult your local Allen-Bradley distributor or sales engineer for information
regarding this publication or any needed information.
13
Chapter
2
An Introduction to Programmable Controllers
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 four major sections of a programmable controller
describes how the four major sections of a programmable controller interact
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.
21
Chapter 2
An Introduction to
Programmable Controllers
Programmable Controls
Programmable controllers can perform many of the functions of traditional
controls. Sensing devices report to the processors. The output devices at the
machine operate the same as they would with traditional controls.
Programmable
Controller
Conditons
Machine
Sensing
Devices
Control Panel
Output
Devices
Action
Command
11592
The field wiring between the machine and the control panel provides electrical
paths from the sensing devices to the control panel, and from the control panel
to the output devices.
However, inside the control panel you’ll find a programmable controller rather
than relays or discrete solid state devices. Instead of wiring those devices and
relays together to produce a desired response, you simply tell your
programmable controller by means of a program how you want it to respond to
the same conditions.
The Four Major Sections
22
Programming is telling 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 different conditions within the machine.
Let’s take a closer look at a typical programmable controller. It usually consists
of four major sections:
processor
input
output
power supply
Power Supply
Processor
(Decision Making)
Chapter 2
An Introduction to
Programmable Controllers
Information
InputOutput
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.
23
Chapter 2
An Introduction to
Programmable Controllers
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:
At this time, we will only discuss the input and output image tables and
program storage.
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.
24
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.”
Chapter 2
An Introduction to
Programmable Controllers
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.
Program Storage
The other major area of memory, program storage, takes up the largest portion
of memory. You’ll recall that this is where your instructions to the
programmable controller are stored. You’ll also recall that this set of
instructions is called a program.
Program Language
A program is made up of 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
Program
Statement
Program Storage Area
of Memory
ActionConditions
Program
Statement
25
Chapter 2
An Introduction to
Programmable Controllers
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.” The entire
statement is then: “If limit switch number two is closed, then 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.
Instructions
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.
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.
Input
The second section is the input, which serves four very important 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 indicators. The indicator is on when there is a voltage
applied to it terminal. It 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.
26
Chapter 2
An Introduction to
Programmable Controllers
You should also notice another important characteristic of input indicators. They
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 the input is signal conditioning. The electrical power used
at the machine is usually not compatible with the signal power used within the
programmable controller. Therefore, the input section receives the electrical
signal from the machine and converts it to a voltage 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.
Output
The third section is the output, which serves functions similar to those of the
input image table:
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 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 addition, the output section of modules with fuses has blown fuse indicators.
When one of the fuses in the group opens, the blown fuse indicator lights.
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.
27
Chapter 2
An Introduction to
Programmable Controllers
Isolation
The output isolates the more sensitive electronic 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 fourth section is the power supply. It provides a low level dc voltage
source for the electronic circuitry of the processor. It converts the higher level
line voltages to low level logic voltages required by the processor’s
electronic circuitry.
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
InputOutput
Conveyor
Motor
Limit
Switch
28
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.
Chapter 2
An Introduction to
Programmable Controllers
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 will run
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.
Scan Sequence
On power up, the processor begins the scan sequence (Figure 2.2) with 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.
29
Chapter 2
An Introduction to
Programmable Controllers
Figure 2.2
Sequence
Scan
I/O
Scan
Program
Scan
Output
Image
Table
Copy output image table status
into output terminal circuits.
Input
Terminals
Copy input terminal status into
input image table.
Program Statement
Output
Terminals
Input
Image
Table
210
Execute each program rung in
sequence, writing into bits in the
data table, including the output
image table.
11597
Chapter 2
An Introduction to
Programmable Controllers
Next, the processor scans the program. It does this statement by statement.
Each statement is scanned in this way:
1.For each condition, 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 one 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 zero 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 onTurn 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.
211
Chapter 2
An Introduction to
Programmable Controllers
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.
Chapter Summary
We reviewed fundamentals common to A-B processors. The next chapter
summarizes hardware features of the Mini-PLC-2/05 processors.
212
Hardware
Chapter
3
Chapter Objectives
Major Features
General Features
This chapter is a summary of the Mini-PLC-2/05 Processor Assembly and
Installation Manual, publication 1772-6.6.6. In this chapter, you will
read about:
major features
general features
hardware features
optional features
A complete processor system consists of the following major components:
Mini-PLC-2/05 processor
I/O chassis
power supply
I/O modules (up to 16 modules)
industrial terminal (cat. no. 1770-T3)
The processor has the following features:
3K CMOS RAM memory
488 timers
up to 2944 word capacity data table (23 blocks)
ladder diagram and functional block instruction set
four function arithmetic capabilities
remote mode selection
on-line programming
block transfer capability
70 message storage (with the 1770-T3 terminal only)
198 message storage with the PLC-2 Family Report Generation Module
(catalog number 1770-RG)
data highway compatibility
selectable timed interrupts
expanded math capability
3-1
Chapter 3
Hardware
Hardware Features
MiniPLC2/05 Processor (cat. no. 1772LS)
The Mini-PLC-2/05 Processor (cat. no. 1772-LS) comes equipped with the
following hardware features (Figure 3.1):
Figure 3.1
MiniPLC2/05
Processor (cat. no. 1772LS)
RUN
P
R
O
C
FAULT
ON
MEMORY
STORE
ON
AB
INTFC
3-2
MINI PLC2/05
W/O Power Supply
10663I
Chapter 3
Hardware
Processor
Status Indicator
PROC RUN/FAULT: This red/green LED keeps you informed of the
processor’s operating conditions.
Table 3.A
Indication
Status
Status
Indicator
PROC RUN/FAULTGreen
P/S ACTIVEGreen
If the
color is
Blinking Green
Red
Off
Off
MEMORY STORE (Switch)
Purpose: Enables you to backup or copy the program into the optional
EEPROM Memory Module.
Then the Indication represents
The processor module is in the run mode and will
begin operation.
The EEPROM memory module (if present) is being
programmed.
There is a fault. Recycle power to reset the
processor module.
Either program mode of operation, run time error,
memory error or a program error.
AC and DC is all right.
There has been a power supply fault, overcurrent
condition, improper input voltage or the module has
been turned off.
Hardware: An optional EEPROM Memory Module (cat. no. 1772-MJ) can
be installed in the module.
INTFC
(Interface socket)
Purpose: The 15 pin socket, labeled INTFC, provides communication
between the processor and the programming terminal (1770-T3 or
1784-T50), the 1770-RG report generation module, the 1770-T11 hand
held terminal, the 1772-KG interface module or 1771-KA communications
interface module.
Processor Module and:Through:Catalog Number:
Industrial Terminal (cat. no. 1770T3)PLC2 Program Panel
Interconnect Cable
Industrial Terminal (cat. no. 1784T50)PLC2 Program Panel
Interconnect Cable
Data Highway Communication ModulesData Highway/Processor Cables1771CN, CO, or CR
PLC2 Family Report Generation Module
(cat. no. 1770RG)
PLC2 Program Panel
Interconnect Cable
1772TC
1772TC or 1784CP2
1772TC
(with external ground wire only)
The 1784-T50 also requires PLC-2 6200 programming software (cat. nos.
6201-PLC2, 6203-PLC2, 6211-PLC2, or 6213-PLC2).
Function: Provides interface to the above devices.
3-3
Chapter 3
Hardware
MiniPLC2/05 Processor (cat. no. 1772LSP)
The Mini-PLC-2/05 Processor (cat. no. 1772-LSP) contains all the
hardware features of the LS processor and in addition contains the
following (Figure 3.2):
Figure 3.2
MiniPLC2/05
RUN
P
R
O
P/S
C
FAULT
ACTIVE
MEMORY
STORE
P/S
PARALLEL
AB
INTFC
POWER
ON
OFF
I.0A 125V
SLOW BLOW
120V
AC
L1
N
GND
MINI PLC2/05
W Power Supply
Processor with Power Supply (cat. no. 1772LSP)
ON
ON
10717I
3-4
Processor
Status Indicator
P/S ACTIVE: This green LED keeps you informed of the power supply
section’s operating conditions (table 3.A).
P/S PARALLEL (socket)
Purpose: Enables paralleling connections between these two sockets on
two power supply modules.
POWER (switch)
Purpose: This is on/off toggle switch lets you provide power to
your processor.
If the switch is:Then you are:
OnSupplying power to your processor module.
OffNot supplying power to your processor module.
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