Rockwell Automation 1785-LTx, D17856.2.1 User Manual

AllenBradley

Classic 1785 PLC5
Programmable

User

Controllers

(1785LT,

L

T2, LT3, L

Manual

T4)

Important User Information

Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this control
equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and
safety requirements, including any applicable laws, regulations, codes,
and standards.

The illustrations, charts, sample programs, and layout examples shown in
this guide are intended solely for purposes of example. Since there are
many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability
(to include intellectual property liability) for actual use based on the
examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,
Installation, and Maintenance of Solid State Control (available from your
local Allen-Bradley office), describes some important differences between
solid-state equipment and electromechanical devices that should be taken
into consideration when applying products such as those described in
this publication.

Reproduction of the contents of this copyrighted publication, in whole
or in part, without written permission of Allen-Bradley Company, Inc.,
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.

Attention statements help you to:

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

This manual has been revised to cover only Classic PLC-5 programmable
controllers: PLC-5/10, -5/12, -5/15, and -5/25.

It has also been revised to include the accompanying design worksheets
that were formerly available as a separate publication: 1785-5.2. This
separate publication is no longer available; see Appendix B for these
worksheets.

For information about Enhanced and Ethernet PLC-5 processors, see the
Enhanced and Ethernet PLC-5 Programmable Controllers User Manual,
publication 1785-6.5.12.

i

Table of Contents

Summary of Changes

Classic PLC5 Programmable Controllers

Purpose
Manual Organization
How to Use this Manual

of this Manual

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Understanding Your System 11. . . . . . . . . . . . . . . . . . . . . . .

Using this Chapter 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Understanding the Terms Used in this Chapter 11
Designing Systems 12
Preparing Your Functional Specification 13
Introducing Classic PLC5 Processor Modules 15
Using the Classic PLC5 Processor as a Remote I/O Scanner 18
Using the Classic PLC5 Processor as a Remote I/O Adapter 19

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

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

. . . .

. . . .

Choosing Hardware 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Selecting
Selecting I/O Adapter Modules 24
Selecting
Selecting an Operator Interface 26
Choosing a Classic PLC5 Processor for Your Application 29
Selecting Power Supplies 29
Selecting Memory Modules 213
Selecting a Replacement Battery 213
Selecting
Selecting a PLC5 Processor Backup System 214
Selecting Link Terminators 215
Connecting a Programming Terminal to a Processor Module 215
Choosing Cables 215

Objectives

I/O Modules

I/O Chassis

Complementary I/O

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

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

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

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26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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213. . . . . . . . . . . . . . . . . . . . . . . . . . .

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iii

iii
iv
iv

i

Placing System Hardware 31. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Determining the Proper Environment 31
Protecting Your Processor 34
Avoiding Electrostatic Damage 34
Laying
Planning
Laying Out the Backpanel Spacing 36
Grounding

Objectives

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

Out Y

our Cable Raceway 34. . . . . . . . . . . . . . . . . . . . . . . . .

Cabling

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

Configuration

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

35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Table of Contentsii

Assigning Addressing Modes, Racks, and Groups 41. . . . . .

Chapter
Placing
Understanding the Terms Used in this Chapter 42
Choosing the Addressing Mode 43
Assigning Racks 49
Addressing

Choosing

Chapter
Identifying Classic PLC5 Processor Channels/Connectors 51
Configuring
Configuring a DH+ Link 53
Connecting a DH+ Link to Data Highway 510
Choosing Programming Terminal Connection 510

Objectives

I/O Modules in Chassis

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

Complementary I/O

Communication

Objectives

Communication for Y

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

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

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

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412. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

. . . . . .

our Processor 53. . . . . . . . . . . . . .

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Planning Your System Programs 61. . . . . . . . . . . . . . . . . . . .

Chapter
Planning Application Programs 61
Using SFCs with PLC5 Processors 61
Preparing the Programs for Your Application 63
Addressing Data T
Using the Processor Status File 69

Objectives

able Files

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

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67. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Selecting Interrupt Routines 71. . . . . . . . . . . . . . . . . . . . . . .

Chapter
Using Programming Features 71
Writing
Understanding ProcessorDetected Major Faults 711

Objectives

a Fault Routine

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

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

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

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

Transferring Discrete and BlockTransfer Data 81. . . . . . . . .

Chapter
Transferring Data Using Adapter Mode 81
Programming Discrete Transfer in Adapter Mode 84
Programming Block Transfer in Adapter Mode 87
Transferring Data Using Scanner Mode 816
Programming Discrete Transfer in Scanner Mode 816
Programming Block Transfer in Scanner Mode 817
Programming Considerations 821

Objectives

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

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Table of Contents iii

Calculating

Chapter
Introduction to Classic PLC5 Processor Scanning 91
I/O ScanningDiscrete and Block Transfer 95
Instruction Timing and Memory Requirements 97
Program Constants 913
Direct and Indirect Elements 913

Program T

Objectives

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

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

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Maximizing System Performance 101. . . . . . . . . . . . . . . . . . . .

Chapter
Components of Throughput 101
Input and Output Modules Delay 101
I/O Backplane Transfer 102
Remote
Processor Time 106
Calculating Throughput 106

Objectives

I/O Scan T

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

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

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ime 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Selecting Switch Settings A1. . . . . . . . . . . . . . . . . . . . . . . . .

Chassis Backplane with Classic PLC5 Processor A1. . . . . . . . . . . . .

Chassis Backplane with Adapter Module A2
Chassis Configuration Plug for Power Supply A3
Remote I/O Adapter Module 1771ASB Series C without

Complementary I/O

Remote I/O Adapter Module 1771ASB Series C with

Complementary I/O

SW1 A7

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

AdapterMode ProcessorsSW2 in a PLC5 or Scanner Module A8
AdapterMode ProcessorsSW2 in a PLC2/20, 2/30,

or Sub I/O Scanner Module System A9

AdapterMode ProcessorsSW2 in a PLC3 or PLC5/250

System with 8Word Groups A10

AdapterMode ProcessorsSW2 in a PLC3 or PLC5/250

System with 4Word Groups A11

SW3 A12

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A4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

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

Design Worksheets B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventions Used in These Worksheets B1. . . . . . . . . . . . . . . . . . .

Prepare
Determine Control Strategy B4
Identify Chassis Locations B6
Select Module T
Total
Assign I/O Modules to Chassis and Assign Addresses B10
Select Adapter Modules B12
Place System Hardware B14

a Functional Specification

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

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

ypes and List I/O Points

I/O Module Requirements

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

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

B2. . . . . . . . . . . . . . . . . . . . . . . .

B7. . . . . . . . . . . . . . . . . . . .

B9. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

Table of Contentsiv

Configure
Determine Communication Requirements B17
Select a Classic PLC5 Processor B21
Select Power Supplies B23
Choose a Programming Terminal B24
Select Programming T
Select Operator Interface B26
Develop Programming Specifications B28

Switch Settings

erminal Configuration

B15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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B25. . . . . . . . . . . . . . . . .

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Preface

Classic PLC5 Programmable Controllers

How to Use
Your Documentation

Your Classic PLC-5 Programmable Controllers documentation is organized
into manuals according to the tasks you perform. This organization lets
you easily find the information you want without reading through
information that is not related to your current task. The arrow in Figure 1
points to the book you are currently using.

Figure 1
Classic

PLC5 Programmable Controllers Documentation Library

Classic 1785 PLC5

Programmable Controllers

User Manual

Explanation of processor

functionality, system

design, and programming

considerations and worksheets

17856.2.1

6200 or AI Series Software

Classic 1785 PLC5

Programmable Controllers

Hardware Installation

How to install and set

switches for chassis,

PLC5 processor, how

to wire and ground

your system

17856.6.1

Instruction Set

Reference

Instruction execution,

parameters, status

bits and examples

1785 PLC5

Programmable Controllers

Quick Reference

Quick access to switches,

status bits, indicators,

instructions, SW screens

17857.1

Purpose

of this Manual

17856.1

For more information on 1785 PLC-5 programmable controllers or the
above publications, contact your local Allen-Bradley sales office,
distributor, or system integrator.

This manual is intended to help you design a Classic PLC-5 programmable
controller system. Use this manual to assist you in:

selecting the proper hardware components for your system

determining the important features of classic PLC-5 processors and how

to use those features

planning your classic PLC-5 system layout

iii

Preface

Manual Organization

Chapter

/

Appendix

1 Understanding Your System Provides an overview of Classic PLC5 processors in different system configurations. Provides

2 Choosing Hardware Provides information on your hardware choices when you design a Classic PLC5 processor

3 Placing System Hardware Describes proper environment, Classic PLC5 processor protection, and prevention of

4 Assigning Addressing Mode,

Rack, and Groups

5 Choosing Communication Identifies each Classic 5 processor channel/connector, and explains how to configure your

6 Planning Your System Programs Explains the use of sequential function charts (SFCs). Provides guidelines and examples for

This manual has ten chapters and two appendices. The following table
lists each chapter or appendix with its corresponding title and a brief
overview of the topics covered in it.

Title Topics Covered

an introduction to Classic PLC5 processors and their primary features and configurations. Also
provides information on using a Classic PLC5 processor as a remote I/O scanner or a remote
I/O adapter.

system.

electrostatic damage for your Classic PLC5 programmable controller system. Also covers
raceway and cable layout, backpanel spacing, and grounding configurations.

Describes the I/O addressing modes that you can choose for your chassis. Explains how you
assign group and rack numbers to your I/O chassis. Also covers how you configure
complementary I/O by assigning rack and group addresses.

Classic PLC5 processor. Provides additional information about the Data Highway Plust
(DH+t) link, programming software, and programmingterminal connections.

preparing system programs. Provides a map of data table files and methods to address the
data table files. Explains how to use the processor status file.

7 Selecting Interrupt Routines Summarizes the conditions for which you would choose fault routines for your application.

Provides a definition of fault routines.

8 Transferring Discrete and

BlockTransfer Data

9 Calculating Program Timing Provides an overview of processor scan timing. Lists execution times and memory

10 Maximizing System Performance Explains how to calculate throughput, and provides methods for optimizing I/O scan time.

A Selecting Switch Settings Describes the switch settings for configuring a Classic PLC5 programmable controller system.

B Design Worksheets Provides worksheets to help the designer plan the system and the installer to install the system.

How to Use this Manual

Explains how your CLassic PLC5 processor transfers discrete and blocktransfer data in both
scanner and adapter modes.

requirements for bit and word instructions as well as file instructions.

The following flow chart demonstrates a thought process that you can use
when you plan your Classic PLC-5 programmable controller system.

iv

System Design
Determined

Select I/O
modules, terminals

Place
hardware

Preface

Assign
addressing

Configure processor
communication

Assigning
Addressing Mode,
Racks, and Groups

Select adapter modules

Select I/O chassis

Select power supply

Select PLC5 processor

Select batteries and
memory modules

Complementary I/O
selected?

Backup system
selected?

Choosing
Hardware
and
Placing
System
Hardware

Configure Data
Highway Plus

Select programming
software

Design SFCs

Data table layout and
processor status

Use fault routines

Transfer data in adapter
and scanner modes

I/O update and ladder
program scan times

Choosing
Communication

Planning Your
System Programs

Transferring
Discrete and
Block Data

Calculating
Program Timing
and Maximizing
System
Performance

Since your decisions cannot always be made as a part of a strictly linear
process, you can choose to complete tasks in parallel. When you select
your I/O modules, for example, you can also begin to lay out and address
your modules. Consult chapter 3, “Placing System Hardware,” to
determine environmental requirements, enclosures needed, cable layout,
and grounding requirements for your chassis and I/O links. Also, you can
choose to assess block-transfer timing when you determine where you will
place your block-transfer modules (in the processor-resident local I/O
chassis, extended-local I/O chassis, or remote I/O chassis).

v

Chapter

Understanding Your System

1

Using this Chapter

Understanding the Terms
Used in this Chapter

If you want to read about: Go to page:

Terms used in this chapter 11

Designing systems 12

Preparing your functional specification 13

Identifying Classic PLC5 processor features 15

Using the Classic PLC5 processor as a remote I/O scanner 18

Using the Classic PLC5 processor as a remote I/O adapter 19

Become familiar with the following terms and their definitions.

Term Definition

Processorresident
local I/O chassis

Processorresident
local I/O

Remote I/O link a serial communication link between a PLC5 processor port in scanner

the I/O chassis in which the PLC5 processor is installed

I/O modules located in the same chassis as the PLC5 processor

mode and an adapter as well as I/O modules that are located remotely
from the PLC5 processor

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

are located remotely on a serial communication link to a PLC5
processor in scanner mode

Discretetransfer data data (words) transferred to/from a discrete I/O module

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

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

1-1

Chapter 1

Understanding Your System

Designing

Centralized

Systems

control

is a
hierarchical system where control
over an entire process is
concentrated in one processor

Distributed

control

is a system in
which control and management
functions are spread throughout a
plant. Multiple processors handle
the control and management
functions and use a Data
Highway

or a bus system

for communication.

You can use Classic PLC-5 processors in a system that is designed for
centralized control or in a system that is designed for distributed control.

HP 9000
or VAX
Host

.

Programming
Terminal with

ControlView

Software

Remote I/O Link

Chassis with Chassis with

1771ASB

Remote I/O

Adapter

r

6200 VMS
INTERCHANGE

Software



Pyramid
Integrator

To DECnet



DH+ Link

Classic PLC5
Processor

1771ASB

Remote I/O

Adapter

Programming
Terminal

Programming Terminal

ControlView

INTERCHANGE
Software

DH+ Link

PanelView
Operator
Terminal

SLC 5/01 Processor
7slot Modular System
with 1747DCM Module



Remote I/O Link

Series 8600
CNC with

Remote I/O

Consider the following items as general guidelines when designing
your system.

Will your processor(s) be used in a centralized or distributed system?
What type of process(es) will be controlled by the PLC-5 system?
What processes will be controlled together?
What are the environmental and safety concerns?
What is the flow and functionality of your system?

18084

1-2

System Design
Determined

Select I/O
modules, terminals

Place
hardware

Chapter 1

Understanding Your System

Determine the general criteria for your system. Use the chapters that
follow to guide you through the criteria and choices for selecting the major
Classic PLC-5 programmable controller system elements, as shown in
Figure 1.1.

Figure 1.1

Processor System Design Flow

PLC5

Assign
addressing

Configure processor
communication

Assigning
Addressing Mode,
Racks, and Groups

Select adapter modules

Select I/O chassis

Select power supply

Select Classic PLC5
processor

Select batteries and
memory modules

Complementary I/O

selected?

Backup system
selected?

Preparing Your
Functional Specification

Choosing
Hardware
and
Placing
System
Hardware

Configure Data
Highway Plus

Select programming
software

Design SFCs

Data table layout and
processor status

Use fault routines

Transfer data in adapter
and scanner modes

I/O update and ladder
program scan times

Choosing
Communication

Planning Your
System Programs

Transferring
Discrete and
Block Data

Calculating
Program Timing
and Maximizing
System
Performance

We recommend that you first develop a specification that defines your
hardware selection and your programming application. The specification
is a conceptual view of your system. Use it to determine your:

control strategy
hardware selection, layout, and addressing
sequential function chart (SFC)
special programming features
ladder-logic requirements

1-3

Chapter 1

Understanding Your System

Figure 1.2 illustrates a program-development model that you can use.

Figure 1.2
ProgramDevelopment

Functional
Specification
(General Conception)

Model

Acceptance
Signoff

Detailed
Anaylsis

Program

Development

Testing

This model allows for the interaction of activities at the different levels.
Each section represents an activity that you perform. Prepare a functional
specification to start; then, prepare the detailed analysis.

Based on the detailed analysis, you can also develop your programs, enter
your programs, and test them. When testing is complete, you are ready to
implement the programs in your application. The detailed analysis can be
used as the basis for developing your testing procedures and requirements.
Because the functional specification is well thought out, it can be used as
the program sign-off document.

Functional Specification Content

1-4

The functional specification represents a very general view of your process
or a description of operation. Identify the events and the overall order in
which they must occur. Identify the equipment that you will need for your
process/operation. Generally indicate the layout of your system. If your
application requires a distributed control system, for example, indicate
where you will need remote I/O links. Also, you can have a process that is
located close to your processor. The process can require faster update time
than that provided by a remote I/O link, so you can select an extended­local I/O link for that process.

Important: Choose a communication rate for your remote I/O link at
which every device on the link can communicate.

Chapter 1

Understanding Your System

The program-development portion of your functional specification can be
in any form: written statement; flowchart; or rough-draft MCPs, SFCs,
and subroutines. Use the form that is most familiar to you. We
recommend, however, that you generate rough-draft SFCs and subroutines
so that you have a better correspondence between your beginning diagrams
and your finished program.

Detailed Analysis

In this phase, you identify the logic needed to plan your programs. This
includes inputs, outputs, specific actions, and transitions between actions
(i.e., the bit-level details needed to write your program).

Program Development

Introducing

Classic PLC5

Processor Modules

You enter the programs either offline into your computer or online into a
processor. In the next phase, you test the programs that you have entered.
Once testing is complete, your resulting programs should match your
functional specification.

Checking for Completeness

When you complete the functional specification and the detailed analysis,
review them and check for missing or incomplete information such as:

input conditions
safety conditions
startup or emergency shutdown routines
alarms and alarm handling
fault detection and fault handling
message display of fault conditions
abnormal operating conditions

The following is a list of the PLC-5 processors and their catalog numbers.

Processor Catalog Number

PLC5/10t

PLC5/12t

PLC5/15t

PLC5/25t

1785LT4

1785LT3

1785LT

1785LT2

For information on other PLC-5 processors (Enhanced, Ethernet, or
ControlNet), see your Allen-Bradley representative.

1-5

Chapter 1

Understanding Your System

Classic PLC5 Family Processor Features

From the family of PLC-5 processors, you can choose the processor(s)
that you need for your application. Features common to all Classic PLC-5
processors are:

same physical dimensions
use of the left-most slot in the 1771 I/O chassis
can use any 1771 I/O module in the processor-resident local I/O chassis

with up to 32 points per module
same programming software and programming terminals
same base set of instructions
ladder programs and SFCs can be used by any of the PLC-5 processors

Check with your Allen-Bradley sales office or distributor if you have
questions regarding any of the features of your PLC-5 processor.

Subprogram Calls

Use a subroutine to store recurring sections of program logic that can be
accessed from multiple program files. A subroutine saves memory
because you program repetitive logic only once. The JSR instruction
directs the processor to go to a separate subroutine file within the logic
processor, scan that subroutine file once, and return to the point
of departure.

For detailed information about how you generate and use subroutines, see
your programming software documentation set.

Sequential Function Charts

Use SFCs as a sequence-control language to control and display the state
of a control process. Instead of one long ladder program for your
application, divide the logic into steps and transitions. A step corresponds
to a control task; a transition corresponds to a condition that must occur
before the programmable controller can perform the next control task. The
display of these steps and transitions lets you see what state the machine
process is in at a given time.

1-6

For detailed information about how you generate and use SFCs, see you
programming software.

Ladder Logic Programs

A main program file can be an SFC file numbered 1-999; it can also be a
ladder-logic file program numbered 2-999 in any program file.

Chapter 1

Understanding Your System

Consider using this technique:

SFC

Ladder Logic

If you are:

• defining the order of events in a sequential process

• more familiar with ladder logic than with programming

languages such as BASIC

• performing diagnostics

• programming discrete control

For detailed information about how you use ladder logic, see your
programming software documentation.

Backup System

The following diagram shows a typical PLC-5 backup system:

Local I/O Chassis

1785BCM Module

PLC5
Processor

1771P4S
Power Supply

HSSL

DH+ Link

Remote I/O Link

Local I/O Chassis

1785BCM Module

PLC5
Processor

1771P4S
Power Supply

DH+ LInk

Remote I/O Chassis Remote I/O Chassis

Remote I/O Link

18691

In a PLC-5 backup system configuration, one system controls the operation
of remote I/O and DH+ communications. This system is referred to as the
“primary system.” The other system is ready to take control of the remote
I/O and DH+ communications in the event of a fault in the primary system.
This is referred to as the “secondary system.”

See chapter 2, “Choosing Hardware,” to select backup system hardware.
See the PLC-5 Backup Communication Module User Manual, publication
1785-6.5.4, for more information on configuring a PLC-5 backup system.

1-7

Chapter 1

Understanding Your System

Using the Classic PLC5
Processor as a Remote I/O
Scanner

Use scanner mode whenever you want a Classic PLC-5 processor to scan
and control remote I/O link(s). The scanner-mode processor also acts as a

supervisory processor for other processors that are in adapter mode.

The scanner-mode processor scans the processor memory file to read
inputs and control outputs. The scanner-mode processor transfers
discrete-transfer data and block-transfer data to/from the processor-resident
local rack as well as to/from modules in remote I/O racks.

A PLC-5 processor scans processor-resident local I/O synchronously to the
program scan. A PLC-5 processor scans remote I/O asynchronously to the
program scan, but the processor updates the input/output image data table
from the remote I/O buffer(s) synchronously to the program scan. This
occurs at the end of each program scan.

ProcessorResident
Local I/O Scan

Synchronous to
Program Scan

ScannerMode
PLC5
Processor

Input

Output

Remote
I/O
Buffer

Input
Output

Processor

Resident

I/O

Remote I/O
Scan

Asynchronous to
Program Scan

OutputInput

Remote I/O

Link

The scanner-mode PLC-5 processor can also:

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

Configure the PLC-5/15 or -5/25 processor for scanner mode by setting
switch assembly SW1.

1-8

Chapter 1

Understanding Your System

Using the Classic PLC5
Processor
as a Remote I/O Adapter

Use a Classic PLC-5 processor (except the PLC-5/10 processor) in adapter
mode when you need predictable, real-time exchange of data between a
distributed control PLC-5 processor and a supervisory processor. You
connect the processors via the remote I/O link (see Figure 1.3). You can
monitor status between the supervisory processor and the adapter-mode
PLC-5 processor at a consistent rate (i.e., the transmission rate of the
remote I/O link is unaffected by programming terminals and other

non-control-related communications).

Figure 1.3
AdapterMode

Supervisory
Processor

1

The following programmable controllers can operate as supervisory processors:

PLC2/20t and PLC2/30t processors

PLC3t and PLC3/10t processors

PLC5/11, 5/15, 5/20, 5/25, and 5/30 processors as well as PLC5/VMEt processors
PLC5/40, 5/40L, 5/60, 5/60L, and 5/80 processors as well as PLC5/40BVt and
PLC5/40LVt processors
PLC5/20Et, 5/40Et
PLC5/250t

2

All PLC5 family processors, except the PLC5/10, can operate as remote I/O adapter modules.

Communication

1

Remote I/O Link

PLC5
Processor
in Adapter

2

Mode

1771

I/O

Remote I/O Link

DL40
Message
Display

The PLC-5 processor in adapter mode acts as a remote station to the
supervisory processor. The adapter-mode PLC-5 processor can monitor
and control its processor-resident local I/O while communicating with the
supervisory processor via a remote I/O link.

The supervisory processor communicates with the PLC-5/12, -5/15, or

-5/25 adapter with either eight or four I/O image table words.

A PLC-5 processor transfers I/O data and status data using discrete
transfers and block transfers. You can also use block-transfer instructions
to communicate information between a supervisory processor and an
adapter-mode processor. The maximum capacity per block transfer is
64 words.

1-9

Choosing Hardware

Chapter

2

Chapter

Objectives

Selecting I/O Modules

Use this chapter to guide you in the selection of system hardware for
your application.

To select: Go to page:

I/O modules 21

I/O adapters 24

Chassis 26

Operator interface 26

PLC5 processor 29

Power supplies 29

Memory modules 213

Batteries 213

Complementary I/O 213

Backup system 214

Termination resistor 215

Cables 215

System Design
Determined

Choosing Hardware

Placing System
Hardware

Assigning Addressing
Mode, Racks,
and Groups

Choosing
Communication

Planning Your
System Programs

Selecting Interrupt
Routines

Transferring Discrete
and Block Data

Calculating Program
Timing

You select I/O modules to interface your PLC-5 processor with machines
or processes that you have previously determined.

Use the following list and Table 2.A as guidelines for selecting I/O
modules and/or operator control interface(s).

How much I/O is required to control the process(es)?
Where will you concentrate I/O points for portions of an entire process

(when an entire process is distributed over a large physical area)?
What type of I/O is required to control the process(es)?

What is the required voltage range for each I/O module?
What is the backplane current required for each I/O module?
What are the noise and distance limitations for each I/O module?
What isolation is required for each I/O module?

2-1

Chapter 2

Choosing Hardware

Table 2.A
Guidelines

Choose this type of
I/O module:

Discrete input module
and block I/O module

Discrete output module
and block I/O module

Analog input module Temperature transducers, pressure transducers, load cell transducers,

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

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

1

A 1791 block I/O module is a remote I/O device that has a power supply, remote I/O adapter, signal conditioning circuitry, and I/O
connections. A block I/O module does not require a chassis mount. It is used to control concentrated discrete remote I/O such as control
panels, pilot lights, and status indications.

For these types of field devices or operations (examples): Explanation:

Selector switches, pushbuttons, photoelectric eyes, limit switches,

1

circuit breakers, proximity switches, level switches, motor starter
contacts, relay contacts, thumbwheel switches

Alarms, control relays, fans, lights, horns, valves, motor

1

starters, solenoids

humidity transducers, flow transducers, potentiometers

analog meters

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

for Selecting I/O Modules

Important: Determine addressing in conjunction with I/O module
selection. The selection of addressing and the selection of I/O module
density are mutually dependent.

Input modules sense ON/OFF or OPENED/
CLOSED signals. Discrete signals can be either
ac or dc.

Output module signals interface with ON/OFF or
OPENED/CLOSED devices. Discrete signals can
be either ac or dc.

Convert continuous analog signals into input
values for PLC processor.

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

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

Selecting I/O Module Density

The density of an I/O module is the number of processor input or output
image table bits to which it corresponds. A bidirectional module with 8
input bits and 8 output bits has a density of 8. Table 2.B provides
guidelines for selecting I/O module density.

Table 2.B
Guidelines

Choose this I/O density: If you:

8point I/O module

16point I/O module

32point I/O module

for Selecting I/O Module Density

• currently use 8point modules

• need integral, separatelyfused outputs

• want to minimize cost per module

• currently use 16point modules

• need separately fused outputs with a special wiring arm

• currently use 32point modules

• want to minimize number of modules

• want to minimize the space required for I/O chassis

• want to minimize cost per I/O point

2-2

Chapter 2

Choosing Hardware

Master/Expander I/O Modules

Some I/O modules (called “masters”) communicate with their expanders
over the backplane. These master/expander combinations either:

can time-share the backplane, or
cannot time-share the backplane

For masters that can time-share the backplane, you can use two masters in
the same chassis. For a master/expander combination that cannot
time-share the backplane, you cannot put another master/expander
combination in the same I/O chassis.

Example: The stepper-controller module (cat. no. 1771-M1, part of a
1771-QA assembly) and the servo-controller module (cat. no. 1771-M3,
part of a 1771-QC assembly) always act as masters and cannot time-share
the backplane. Therefore, you cannot put a second master module in the
same chassis with either of these modules.

Table 2.C summarizes the compatibility of master modules within a single
I/O chassis.

Table 2.C
Compatibility

1st Master

Module

1771IX

1771IF

1771OF

1771M1

1771M3

1

2

of Master Modules within a Single I/O Chassis

2nd Master Module

1

1771IX

1

1

1

1771IF1 1771OF1 1771M1 1771M3

2

Valid

2

Valid

2

Valid

These

modules have been superseded by 1771IXE, IFE, and OFE master modules that
do not exhibit the master/expander conflict in a chassis as 1771IX, IF
modules shown in this table.

These are the only master combinations that you can use in a single I/O chassis. These
combinations are valid with or without the module'
M3 have expander modules). Y
chassis; you can use any other intelligent I/O modules not shown here with these masters.

2

Valid

2

Valid

ou can use a maximum of two masters in the same

2

Valid

2

Valid

2

Valid

s associated expanders (1771M1 and

, and OF master

Important: Density is not relevant to an expander module because it
communicates only with its master; an expander module does not
communicate directly with an adapter.

2-3

Chapter 2

Remote I/O Adapter

I/O Density

Choosing Hardware

Selecting I/O Adapter
Modules

ASB

ALX

Select I/O adapter modules to interface your PLC-5 processor with I/O
modules. Use Table 2.D as a guide when you select I/O adapter modules.

Table 2.D
Guidelines

Choose: When your requirements are:

1771AS or 1771ASB
Remote I/O Adapter Module
(or 1771AM1, AM2 chassis
with integral power supply and
adapter module)

1771ALX ExtendedLocal I/O
Adapter Module

1

1771ASB

series C and later have 230.4 kbps communication rate in addition to 57.6 kbps and 1

for Selecting Adapter Modules

1

a remote I/O link with:

• 57.6 kbps with a distance of up to 10,000 cable feet or

• timing that isn't critical enough to place I/O modules in a processor local

I/O chassis or an extendedlocal I/O chassis

an extendedlocal I/O link with timing that is critical and all extendedlocal
I/O chassis are located within 100 ft of the processor.

17 71AS/ASB Remote I/O Adapter Modules

Table 2.E shows the I/O density per module and addressing modes you can
use with I/O chassis and remote I/O adapter modules.

Table 2.E

Chassis/Adapter Module Combinations

I/O

15.2 kbps.

Remote I/O Adapter I/O Density

Module Cat. No.

1771AS 8

1771ASB

Series A

1771ASB

Series B, C, and D

1771AM2 8

1

Conditional

adjacent slots (even/odd pair) of the I/O chassis beginning with slot 0. If you cannot pair the
modules this way

module placement; you must use an input module and an output module in two

, leave the adjacent slot empty

per Module

16
32

8
16
32

8
16
32

16
32

.

2Slot 1Slot 1/2Slot

Yes

1


No

Yes

1


No

Yes

1


No





Addressing

No
No
No

Yes
Yes

1



Yes
Yes

1



Yes
Yes

1



No
No
No

No
No
No

Yes
Yes
Yes

Yes
Yes
Yes

Using the 1771-ASB Series C or D adapter module, you can choose one of
three communication rates: 57.6 kbps, 115.2 kbps, or 230.4 kbps.

2-4

Chapter 2

Module C

I/O Density

Choosing Hardware

1771ALX ExtendedLocal I/O Adapter Module

Table 2.F shows the I/O density per module and addressing modes you can
use with I/O chassis and extended-local I/O adapter modules.

Table 2.F

Chassis/Extended Local I/O Adapter Module Combinations

I/O

at. No.

1771ALX

Series A

1

Conditional

module placement; you must use an input module and an output module in two adjacent slots (even/
odd pair) of the I/O chassis beginning with slot 0. If you cannot pair the modules this way
empty.

I/O Density
per Module

8
16
32

2Slot 1Slot 1/2Slot

Yes

1


No

Addressing

Yes
Yes

1



, leave the adjacent slot

Other Devices on an I/O Link

Other devices that you can use on a remote I/O link are:

PLC-5 processor in adapter mode
PLC-5/250 remote scanner in adapter mode
PLC interface module for digital ac and dc drives
remote I/O adapter for Bulletin 1336 drives
RediPANELt pushbutton and keypad modules
Datalinert
PanelView (see operator interface)
F30D option module (for T30 plant-floor terminal)
8600 or 9/SERIES CNC with remote I/O adapter option
CVIMt in adapter mode
Pro-Spect 6000 Fastening System with remote I/O adapter option
1747-DCM module (to SLC-500 rack)
1771-DCM module
1771-GMF robot (remote I/O interface module)

Yes
Yes
Yes

See the appropriate Allen-Bradley product catalog for more information on
these devices.

2-5

Chapter 2

Choosing Hardware

Selecting

I/O Chassis

4-Slot

1771A1B

An I/O chassis is a single, compact enclosure for the processor,
power-supply modules, remote and extended-local I/O adapter modules,
and I/O modules. The left-most slot of the I/O chassis is reserved for the
processor or adapter module. Consider the following when selecting
a chassis:

When you determine the maximum number of I/O in your application,

allow space for the I/O slots dedicated to power-supply modules,
communication modules, and other intelligent I/O modules.

You must use series B or later chassis with 16- and 32-point

I/O modules.

Allow space for future addition of I/O modules to chassis.

I/O chassis available are:

4-slot (1771-A1B)
8-slot (1771-A2B)
12-slot—rack mount (1771-A3B), panel mount (1771-A3B1)
16-slot (1771-A4B)

You can also choose a chassis with an integral power supply and remote
I/O adapter (show at left). The two types are:

1771AM1

1771AM2

Selecting an Operator
Interface

1-slot (1771-AM1)
2-slot (1771-AM2)

PanelView and ControlView are operator interface products or packages
that communicate with a PLC-5 processor. Use Table 2.G as a guideline
when selecting either PanelView or ControlView for your PLC-5
programmable controller system. Use Table 2.H for a comparison of
PanelView and ControlView features.

2-6

Table 2.G
Guidelines

Chapter 2

Choosing Hardware

for Selecting an Operator Interface

Choose this
operator interface:

PanelView

1

For these types of
operations (examples):

Starts/stops, auto/manual operations,
setpoints, outputs, alarms

Explanation:

Used as an operator window to enter commands that make process adjustments such
as starts/stops and loop changes. Can also be used for alarming operations. Can
communicate with a single PLC5 processor on a remote I/O link. Has a fixed number
of devices and amount of data that it can handle. Has builtin error checking. Is an
industrialhardened CRT with pushbuttons, solid state memory and processor, and no
moving parts (i.e., disk drive).

Utilizes pass through, which is the ability to download/upload via DH+/remote I/O links.

ControlView

1

Refer

1

Store, display, and manipulate data
on process performance (i.e., trends,
process graphics, formulas, reports,
and journals)

to your local AllenBradley sales of

Used as an operator window that communicates with a PLC5 processor on Data
Highway Plus (DH+) link. Designed for use as an information link. Can communicate
to multiple PLC processors. ControlView is a software package that runs on an IBMr
DOSbased personal computer.

fice or AllenBradley distributor for more information on PanelV

iew and ControlV

iew.

Table 2.H
Comparison

of PanelV

Category PanelView ControlView

Communication with
PLC processor

Remote I/O

5 block transfers per terminal maximum (32 words per transfer)

1 discrete transfer per terminal (64 words maximum, one way)
This is 8 racks of transfer

Graphics Character graphics

Create screens with PanelBuilder software
Monochrome or color (8 of 16 colors displayed at a time)

Number of
Screens per
Terminal/Workstation

8 to 12 screens of medium complexity typical
200 objects maximum per screen
Limited by terminal memory size: 128 Kbytes

Data Capacity 200 objects maximum per screen 10,000 points maximum in database

Communication

Limited by blocktransfer and discretetransfer timing

Rate

Depends on PLC processor and remote I/O link size

Hardware Keypad or Touchscreen terminals, color or monochrome

AllenBradley, IBM, or compatible computer required for
PanelBuilder software

Programming PanelBuilder software

Menudriven with fillintheblank information entry

Use PanelBuilder to create application file that defines
screens, messages, alarms, then download application file to
PanelView terminal

Messages 496 maximum per terminal Not Applicable

Alarms 496 maximum per terminal 2000 points with Alarming option

Security 8 levels 16 levels with individual operator login capability

Options Remote serial port

EEPROM or EPROM memory

iew and ControlV

DH+ link
Data Highway
Data Highway II Native Mode

Pixel Graphics
Create screens with Mouse Grafix editor option or C Toolkit
EGA, VGA, or equivalent with 256K RAM
Monochrome or color monitor

Limited only by hard disk capacity
50 data entry locations per screen
50 tags per command list per screen
300 tags/points maximum per screen

8 scan classes, each with userconfigurable foreground and
background update times; limited by performance of Data
Highway, DH+, or Data Highway II link

AB, IBM, or compatible computer with 286 or 386
processor, math coprocessor, hard disk required at each
operator station

Create data base online via the menu. Menudriven,
fillintheblank information entry, or import data via the ASCII
import capability

Create screens with the mouse GRAFIX editor option or C
toolkit option

Individual objects with security
Screen lockout

Lots of software options

iew Features

2-7

Chapter 2

Choosing Hardware

For more information on selecting and configuring PanelView, see:

PanelView Operator Terminal and PanelBuilder Development Software

User Manual, cat. no. 2711-ND002 version C, PN40061-139-01—
request latest revision

Replacing Node Adapter Firmware for PanelView Terminals Installation

Data, PN40062-236-01—request latest revision

For more information on selecting and configuring ControlView, see:

ControlView Core User Manual, publication 6190-6.5.1

ControlView Allen-Bradley Drivers User Manual,

publication 6190-6.5.5

ControlView Networking User Manual, publication 6190-6.5.9

Other Operator Interfaces

You can use the following as operator interfaces in your PLC-5
processor system:

RediPANEL pushbutton and keypad modules
Dataliner
1784-T47 and 1784-T53 programming terminals

See the appropriate Allen-Bradley product catalog for more information on
these operator interfaces.

2-8

Chapter 2

Choosing Hardware

Choosing

a Classic PLC5
Processor for Your
Application

Processor/

No.

Cat.

PLC5/10
(1785LT4)

PLC5/12
(1785LT3)

PLC5/15
(1785LT)

PLC5/25
(1785LT2)

Processor/
Cat. No.

PLC5/10
(1785LT4)

PLC5/12
(1785LT3)

PLC5/15
(1785LT)

PLC5/25
(1785LT2)

Maximum User
Memory Words

6 K

6 K

6 K expandable
to 10 K or 14 K

13 K
expandable to
17 K or 21 K

Number of Remote I/O, ExtendedLocal
I/O, and DH+ Ports

•

1 DH+

•

1 DH+

•

1 Remote I/O (Adapter Only)

•1

DH+

•

1 Remote I/O (Adapter or Scanner)

•1

DH+

•

1 Remote I/O (Adapter or Scanner)

EEPROM Module
Memory (W
Module Number

8 K (1785MJ)

8 K (1785MJ)

8 K (1785MJ)

8 K (1785MJ) or
16 K (1785MK)

ords) &

Choose from the following PLC-5 processors.

Table 2.I

PLC5 Processor Selection ChartPart 1

Classic

Total I/O Maximum
(any mix)

•

512 (32I/O modules)

•

256 (16I/O modules)

•

128 (8I/O modules)

•

512 (32I/O modules)

•

256 (16I/O modules)

•

128 (8I/O modules)

•

512 (any mix) or

•

512 in + 512 out
(complementary)

•

1024 (any mix) or

•

1024 in + 1024 out
(complementary)

Table 2.J

PLC5 Processor Selection ChartPart 2

Classic

Maximum
Number of
I/O Racks

1 1 0 0 0  2.5A

4 1 0 0 0

4 13 0 12 0

8 17 0 16 0

Analog
I/O Max

256

256

512

1024

Maximum Number of I/O
Chassis

Total

Program Scan T
K W

2 ms (discrete logic)
8 ms (typical)

2 ms (discrete logic)
8 ms (typical)

2 ms (discrete logic)
8 ms (typical)

2 ms (discrete logic)
8 ms (typical)

Ext Local

ord

Remote

ime /

Number of
RS232/
422/ 423
ports

I/O Scan time/Rack
(in a single Chassis,
extlocal or remote)

N/A

•

10 ms @ 57.6 kbps
(remote)

•

10 ms @ 57.6 kbps
(remote)

•

10 ms @ 57.6 kbps
(remote)

Remote I/O
Transmission

1

Rates

57.6 kbps

57.6 kbps

57.6 kbps

Multiple
MCPs /
Quantity

No / 1

No / 1

No / 1

No / 1

Backplane
Current
Load

2.5A

2.5A

2.5A

Selecting Power Supplies

1771P7

Use the following steps as guidelines for selecting a power supply for a
chassis that contains a PLC-5 processor, a 1771-AS or -ASB remote I/O
adapter module, or a 1771-ALX extended-local I/O adapter module.

1. Determine the input voltage for the power supply.

2. Calculate the total backplane current draw for I/O modules by

adding together the backplane current draw for each I/O module in
that chassis.

2-9

Chapter 2

Choosing Hardware

3. Add to the total of the I/O module backplane current draw either:

a. 3.3 Amps when the chassis will contain a PLC-5 processor

(maximum current draw for any PLC-5 processor) or

b. 1.2 Amps when the chassis will contain either a remote I/O

1771-AS or -ASB module or a 1771-ALX extended-local I/O
adapter module

4. If you leave slots available in your chassis for future expansion:

a. list backplane current draw for future I/O modules

b. add the total current draw for all expansion I/O modules to the

total calculated in step 3.

5. Determine whether the available space for the power supply is in the

chassis or mounted external to the chassis.

Choose your power supply from Table 2.K or Table 2.L using the input
voltage requirement and the total backplane current draw as determined in
the previous steps, 1 through 5.

See the Automation Products Catalog, publication AP100, for more
information on power supplies.

Powering a Chassis Containing a PLC5 Processor

Table 2.K lists the power-supply modules that you can use with a Classic
PLC-5 processor.

2-10

Chapter 2

Power

Input

Output Current

Power Supply

Choosing Hardware

Table 2.K
Powering

Power

Input Output Current

Supply

1771P3 120V ac 3 6 11 11 chassis, 1slot

1771P4 120V ac 8 11 16 16 chassis, 2slot

1771P4S 120V ac 8 11 16 16

1771P4S1 100V ac 8 16

1771P4R 120V ac 8/16/24

1771P5 24V dc 8 16 chassis, 2slot

1771P6S 220V ac 8 16

1771P6S1 200V ac 8 16

1771P6R 220V ac 8/16/24

1771P7 120/220V ac 16

1771PS7 120/220V ac 16

1

See

publication 17712.136 for more information.

2

Y

ou cannot use an external power supply and a slotbased power supply module to power the same chassis;

they are not compatible.

Power

a Chassis Containing a Classic PLC5 processor

Output Current (in Amps) When Parallel with:

(in Amps)

P3 P4 P4S P4S1 P5 P6S P6S1

1

1

Power Supply
Location

chassis, 1slot

chassis, 1slot

2

external

2-11