Rockwell Automation 1785-Lx0C15 User Manual

ControlNet PLC-5 Programmable Controllers

User Manual

(Catalog Numbers 1785-L20C15, 1785-L40C15, 1785-L46C15, 1785-L80C15)

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Allen-Bradley, ControlLogix, Data Highway Plus, DH+, FLEX I/O, PLC-2, PLC-3, PLC-5, Rockwell Automation, RSLinx, RSLogix, RSLogix 5000, RSLogix 5, RSNetWorx, RSNetworx for ControlNet, SLC, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

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

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Summary of Changes

The information below summarizes the changes to the ControlNet PLC-5 Programmable Controllers User Manual.

To help you find new and updated information, look for the revision bars as shown to the left of this paragraph.

Revised Information See the table in the Using the ControlNet PLC-5 Processor in a

ControlNet I/O System section on page 2-31 to see the revision to information about the ControlLogix ControlNet Bridge.

Software and Hardware Requirements

Use the following table to understand specific features that are only available with specific versions and releases of software and PLC-5 processors:

You need both of these

If you want this feature:

Standard functionality 2.2 or later 1.8 or later all Hot Backup (1771 and FLEX I/O) 3.21 or later 1.8 or later PLC-5/40 or -5/80 Multicast Outputs 3.21 or later 3.0 or later PLC-5/20, -5/40 or -5/80 SLC I/O (also with Hot Backup) 5.0 or later 3.0 or later PLC-5/40 or -5/80

versions of software:

RSLogix 5 RSNetWorx:

And this PLC-5 processor (ControlNet Series F, Revision A or later)

1785-UM022C-EN-P - February 2008

SOC-ii

Notes

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor

Chapter 1

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Identifying ControlNet PLC-5 Processor Components . . . . . . . . . . . . . 1-3

Before You Install the Programmable Controller . . . . . . . . . . . . . . . . . 1-5

Install or Remove the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Setting the I/O Chassis Backplane Switches. . . . . . . . . . . . . . . . . . . . 1-9

Setting the I/O Chassis Configuration Plug . . . . . . . . . . . . . . . . . . . . 1-10

Installing Keying Bands for the Processor. . . . . . . . . . . . . . . . . . . . . 1-10

Selecting the DH+ Station Address of Channel 1A . . . . . . . . . . . . . . 1-11

Specifying the Serial Interface of Channel 0. . . . . . . . . . . . . . . . . . . 1-12

Selecting the ControlNet Network Address of Channel 2 . . . . . . . . . 1-12

Inserting/Removing the Processor into/from the I/O Chassis. . . . . . . 1-13

Installing a Remote I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Installing a DH+ Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Connecting to a ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Connecting a Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . 1-19

DH+ Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Serial Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

ControlNet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Selecting Appropriate Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

DH+ Programming Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Remote I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

ControlNet Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Planning to Use Your ControlNet PLC-5 Processor

Chapter 2

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Understanding ControlNet I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Scheduled Data-Transfer Operations on a ControlNet Network. . . . 2-2

Unscheduled Data-Transfer Operations on a ControlNet Network . . 2-4

Using I/O Forcing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Using Immediate Data-Transfer Operations . . . . . . . . . . . . . . . . . . 2-8

Using Process Control Sample Complete . . . . . . . . . . . . . . . . . . . . 2-9

Clearing the PCSC New Data and PCSC Overflow Bits. . . . . . . . 2-11

Considerations When Using PCSC. . . . . . . . . . . . . . . . . . . . . . . 2-11

Understanding Scheduled Connection Types . . . . . . . . . . . . . . . . . . 2-11

Allowable Scheduled Connection Type Combinations . . . . . . . . . . 2-12

Multiple Processors Can Control I/O . . . . . . . . . . . . . . . . . . . . . 2-13

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ii Table of Contents – ControlNet PLC-5 Programmable Controllers

Understanding Multicast Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Understanding Multicast Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Using Multicast Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Understanding ControlNet I/O Mapping . . . . . . . . . . . . . . . . . . . . . . 2-16

Reserving Space for Non-ControlNet I/O. . . . . . . . . . . . . . . . . . . . 2-16

Processor-Resident Local I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Remote I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Supported ControlNet I/O Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Discrete I/O Data Transfer Mapping . . . . . . . . . . . . . . . . . . . . . 2-19

Non-Discrete I/O Data Transfer Mapping . . . . . . . . . . . . . . . . . 2-19

1771 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

1747 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

1794 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Other ControlNet Processors . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Using I/O Mapping Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Understanding Discrete Mapping . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Optimizing the I/O Image Table . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Optimizing the I/O Image Table without Slot Complementary . . 2-23

Optimizing the I/O Image Table with Slot Complementary. . . . . 2-27

Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Using the ControlNet PLC-5 Processor in a ControlNet I/O System . . 2-31

Distributed Keeper Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Converting from a Non-ControlNet Remote I/O System

to a ControlNet I/O System . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Converting from ControlNet Phase 1.0 or 1.25

to ControlNet Phase 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Understanding the ControlNet System Software

Chapter 3

Configuring and Programming Your ControlNet System . . . . . . . . . . . 3-1

Using ControlNet Message Instructions . . . . . . . . . . . . . . . . . . . . . . . 3-1

I/O Configuration Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Uploading and Downloading Software Projects. . . . . . . . . . . . . . . . 3-3

Using RSNetWorx to Perform Verification Activities. . . . . . . . . . . . . 3-4

For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

1785-UM022C-EN-P - February 2008

Table of Contents – ControlNet PLC-5 Programmable Controllers iii

Programming Your ControlNet System

Monitoring and Troubleshooting Your ControlNet System

Chapter 4

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Using ControlNet Message Instructions . . . . . . . . . . . . . . . . . . . . . . . 4-1

Multihop Messaging Via the MSG Instruction . . . . . . . . . . . . . . . . . 4-2

Option to Close Communication Connection when MSG is Done. . . 4-3

Understanding the ControlNet PLC-2 Compatibility File . . . . . . . . . 4-3

Using the ControlNet I/O Transfer Instruction . . . . . . . . . . . . . . . . . . . 4-3

Sending Continuous Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1771 ControlNet Transfers in PIIs and STIs. . . . . . . . . . . . . . . . . . . 4-5

Using ControlNet Immediate Data Input and Output Instructions. . . . . 4-6

Using Selectable Timed Interrupts with a Program

on a ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Recovering from Major Fault 200 and 201 . . . . . . . . . . . . . . . . . . . . . 4-9

Chapter 5

Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Using the General Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Using the ControlNet Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . 5-3

Using the DH+/RIO Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Monitoring ControlNet Configuration and Status. . . . . . . . . . . . . . . . . 5-6

Processor Specifications Appendix A

Processor Status File Appendix B

S:0 - S:2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

S:3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

S:11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

S:12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

S:13-S:24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

S:26-S:35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

S:36-S:78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

S:79-S127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15

ControlNet Instruction Set

Appendix C

ControlNet I/O Transfer Instruction . . . . . . . . . . . . . . . . . . . . . . . . C-1

Message Instructions on a ControlNet Network . . . . . . . . . . . . . . . C-1

Immediate Data I/O Instructions . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Instruction Timing and Memory Requirements . . . . . . . . . . . . . . . . . . C-2

1785-UM022C-EN-P - February 2008

iv Table of Contents – ControlNet PLC-5 Programmable Controllers

ControlNet I/O Map-Entry Status Words and Error Messages

Appendix D

I/O Map-Entry Status Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Fault Codes Appendix E

Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Additional Major Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

ControlNet Diagnostics

Appendix F

File Layout

1785-UM022C-EN-P - February 2008

Preface

Introduction This manual describes how to install your programmable controller

and how to plan for, configure, and use the features of a 1785-L20C15, 1785-L40C15, 1785-L46C15 or 1785-L80C15 programmable controller that are unique to the ControlNet network.

When we refer to ControlNet PLC-5 programmable controllers (or “processors”) in this manual, we mean the phase 1.5 programmable controllers:

• Catalog number 1785-L20C15 (or PLC-5/20C)

• Catalog number 1785-L40C15 (or PLC-5/40C)

• Catalog number 1785-L46C15 (or PLC-5/46C)

• Catalog number 1785-L80C15 (or PLC-5/80C) For detailed information about features that the ControlNet PLC-5

processors share with Ethernet and Enhanced processors, see the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12.

Audience The information in this manual is intended for engineers and

technicians who are installing, programming, and maintaining a control system that includes a ControlNet PLC-5 programmable controller.

You should have a background in control-system applications and a basic knowledge of:

• programmable real-time control systems

• the PLC-5 control system

• your operation’s required systems and applications

1785-UM022C-EN-P - February 2008

Preface-2

Terminology

Ter m Description

Actual Packet Interval (API) the actual time it takes for the ControlNet network to update the requested data. The largest

binary multiple of the Network Update Time (NUT), smaller or equal to the Requested Packet Interval (RPI). For more information, see Scheduled Data-Transfer Operations on a ControlNet Network on page 2-2.

ControlNet network communication architecture that allows the exchange of data between Allen-Bradley

ControlNet PLC-5 processors references PLC-5/20C, PLC-5/40C, PLC-5/46C and PLC-5/80C programmable controllers

connection opened communication path between two nodes on a ControlNet network

DData Input File (DIF) integer file used by ControlNet PLC-5 processors to store discrete and non-discrete input

Data Output File (DOF) integer file used by ControlNet PLC-5 processors to store discrete and non-discrete output

discrete I/O data transfer type of data transfer in which single units of I/O have discrete relationships with values in

frame single data transfer on a ControlNet link

drop cable cable that connects a ControlNet node to the trunk cable; integral part of 1786 taps

I/O map table (scanlist configuration)

keeper device that stores and distributes ControlNet configuration data to all nodes on the network.

link collection of ControlNet nodes with unique network addresses in the range of 01-99; segments

Company, Inc. products and certified third-party products

phase 1.5

data. The DIF cannot be forced

data. The DOF cannot be forced

the processor’s data table; uses the processor’s input- and output-image tables (I and O files); configured on a per-node basis in the ControlNet I/O map table

table that you configure using the programming software to map data from an I/O chassis and other devices on the ControlNet network to particular data table file addresses

A minimum of one keeper device is required on each ControlNet network.

connected by repeaters make up a link; links connected by bridges make up a network

map table entry (scanlist entry)

network access port (NAP) port that provides a temporary ControlNet-network connection through an RJ45 connector

network address node’s address on the ControlNet network

network update interval (NUI) single occurrence of the ControlNet Network Update Time (NUT)

network update time (NUT)

node port of a physical device connecting to the ControlNet network that requires a network

non-discrete I/O data transfer type of data transfer in which blocks of data transferred to or from a single I/O module use

owner device that controls the outputs of an adapter

processor

redundant media dual-cable system that allows you to receive the best signal over a ControlNet network

1785-UM022C-EN-P - February 2008

one entry in the I/O map table that you configure using the programming software to map data from one I/O chassis or other device on ControlNet to particular data table file addresses

smallest repetitive time interval in which data can be sent on the ControlNet network

address in order to function on the network; a link may contain a maximum of 99 nodes

integer input and output data table files that you specify; scheduled transfers are configured in the ControlNet I/O map table, unscheduled transfers make use of ControlNet I/O Transfer (CIO) instructions

any one of the ControlNet PLC-5 programmable controllers

Preface-3

Ter m Description

repeater two-port active physical-layer device that reconstructs and retransmits all traffic that it

hears on one ControlNet segment to another segment

Requested Packet Interval (RPI)

scheduled maximum node (SMAX)

scheduled transfers deterministic and repeatable transfers that are continuous and asynchronous to the ladder-

scheduled connection types rack connection - scheduled connection made from the PLC-5C to I/O adapters to some or

segment trunkline section of ControlNet network with terminators at each end; a segment does not

tap component that connects products to the ControlNet trunk cable; a tap is required for each

terminator 75W resistor—mounted in a BNC plug—placed on each end of a ControlNet segment to

trunk cable bus or central part of the ControlNet cable system

trunk-cable section length of trunk cable between any two ControlNet taps

unscheduled maximum node (UMAX)

the maximum time allowed for the ControlNet network to update requested data. The RPI is user-selectable on a per connection basis. For more information, see page 2-2.

the maximum ControlNet node number that can transmit and receive scheduled data

logic program scan

all of the discrete I/O on the adapter module connection - scheduled connection made from the PLC-5C to I/O adapters to

individual modules

include repeaters; segments connected by repeaters make up a link

node and for each side of a repeater

prevent reflections from occurring at the ends of the cable

the maximum ControlNet node number that can transmit and receive unscheduled data

unscheduled transfers non-deterministic data transfers through ladder-initiated communication or programming

devices

1785-UM022C-EN-P - February 2008

Preface-4

Related PLC-5 Publications The 1785 PLC-5 programmable-controller and ControlNet

documentation is organized into manuals according to the tasks that you perform:

Publication Publication Number

Enhanced and Ethernet PLC-5 Programmable Controllers User Manual

ControlNet Cable System Planning and Installation Manual 1785-6.2.1

1785-PLC-5 Programmable Controllers Quick Reference 1785-7.1

1785-6.5.12

For more information about 1785 PLC-5 programmable controllers, contact your local Rockwell Automation sales office or distributor.

To view or order these publications online, visit: www.literature.rockwellautomation.com

Related ControlNet Publications For detailed information about different aspects of planning and

installing your ControlNet network, see the following publications:

Publication Publication Number

ControlNet Coax Cable System Planning and Installation Manual 1786-6.2.1

ControlNet Network Access Cable Installation Instructions 1786-2.6

ControlNet System Overview CNET-SO001

ControlNet PLC-5 Hot Backup System User Manual 1785-UM024

ControlNet Fiber Planning Installation Guide CNET-IN001

Industrial Automation Wiring and Grounding Guidelines 1770-4.1

System Design for Control of Electrical Noise GMC-RM001

To view or order these publications online, visit: www.literature.rockwellautomation.com or contact your local Rockwell Automation sales office or distributor.

1785-UM022C-EN-P - February 2008

Using This Chapter

Chapter 1

Installing Your ControlNet PLC-5 Processor

Topic Page

Preventing Electrostatic Discharge 1-2

Identifying the processor components 1-3

What to do before you begin installation 1-5

Installing and disposing of the processor battery 1-6

Setting the I/O chassis backplane switches 1-11

Setting the I/O chassis configuration plug 1-10

Installing keying bands for the processor 1-10

Selecting the Data Highway Plus (DH+) station address of Channel 1A

Specifying the serial interface for Channel 0 1-12

Selecting the ControlNet network address of Channel 2 1-12

Inserting/removing the processor into/from the I/O chassis 1-13

Installing a remote I/O link 1-13

Installing a DH+ link 1-15

Connecting to a ControlNet network 1-17

Connecting a programming terminal 1-19

Selecting appropriate cables 1-22

1-11

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

1785-UM022C-EN-P - February 2008

1-2 Installing Your ControlNet PLC-5 Processor

Prevent Electrostatic Discharge

ATTENTION

This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment:

• touch a grounded object to discharge potential static

• wear an approved grounding wrist strap

• do not touch connectors or pins on component boards

• do not touch circuit components inside the equipment

• if available, use a static-safe workstation

• when not in use, store the equipment in appropriate static-safe packaging

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-3

Identifying ControlNet PLC-5 Processor Components

Keyswitch-selects processor mode ControlNet I/O Status Indicator

(Green/Red)

Channel 2 ControlNet Status Indicators

(Green/Red)

ControlNet Network Access Port

(NAP)-RJ45 connector

Channel 2

ControlNet Redundant Media Ports BNC; dedicated

Channel 0

Serial Port-25-pin D-shell; supports standard EIA RS-232C and RS-423; is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports processor programming:

Figure 1.1 and Figure 1.2 show the front panels of the ControlNet PLC-5 processors.

Figure 1.1 PLC-5/20C Processor Front Panel

Battery Status Indicator

(Red)

Processor RUN/FAULT Status Indicator

(Green/Red)

Force Status Indicator

(Amber)

Channel 0 Communication ACTIVE/ FAULT Status Indicator

(Green/Red)

Memory Module Space

DF1 point-to-point 2400 bit/s no parity

Channel 1 Status Indicators (Green/Red) DH+ Programming Terminal Connection

to Channel 1A

8-pin mini-DIN, parallel with 3-pin connectors of Channel 1A

Channel 1A

3 pin; dedicated DH+

Channel 0 is optically coupled (provides high electrical noise immunity) and can be used with most RS-422A

equipment as long as: termination resistors are not used the distance and transmission rate are reduced to

comply with RS-423 requirements

one stop-bit BCC error check no handshaking

Battery Compartment

Channel 1B

3 pin; default is remote I/O scanner; configurable for: remote I/O scanner remote I/O adapter DH+ communication unused

1785-UM022C-EN-P - February 2008

1-4 Installing Your ControlNet PLC-5 Processor

Figure 1.2 PLC-5/40C, -5/46C, and -5/80C Processors Front Panel

Keyswitch-selects processor mode ControlNet I/O Status Indicator

(Green/Red)

Channel 2 ControlNet Status Indicators

(Green/Red)

ControlNet Network Access Port

(NAP)-RJ45 connector

Battery Status Indicator

(Red)

Processor RUN/FAULT Status Indicator

(Green/Red)

Force Status Indicator

(Amber)

Channel 0 Communication ACTIVE/FAULT

Status Indicator (Green/Red)

Channel 2

ControlNet Redundant Media Ports* BNC; dedicated

Channel 1 Status Indicators (Green/Red) DH+ Programming Terminal Connection

to Channel 1A

8-pin mini-DIN, parallel with 3-pin connectors of Channel 1A; use only when Channel 1A is configured for DH+ communications

Channel 1A

3 pin; default is DH+; configurable for: remote I/O scanner remote I/O adapter DH+ communication unused

Channel 1B

3 pin; default is remote I/O scanner; configurable for: remote I/O scanner remote I/O adapter DH+ communication unused

Channel 0

Serial Port-25-pin D-shell; supports standard EIA RS-232C and RS-423; is RS-422A compatible

Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port’s default configuration supports processor programming:

DF1 point-to-point 2400 bps no parity

Memory Module Space

Battery Compartment

Channel 0 is optically coupled (provides high

electrical noise immunity) and can be used with most

RS-422A equipment as long as: termination resistors are not used the distance and transmission rate are reduced to

comply with RS-423 requirements

one stop-bit BCC error check no handshaking

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-5

Before You Install the Programmable Controller

Before installing your ControlNet PLC-5 processor:

1. Check your processor package, and make sure that you have the

following:

Processor

Contents of Tray 1 Lithium Battery, 1770-XYC

Documentation

ControlNet PLC-5® Programmable Controller, 1785-L20C15, -L40C15, -L46C15, or -L80C15

1 DIN connector cover 4 Terminating resistors—150Ω 2 or 42Terminating resistors—82Ω 2 or 423-pin connectors

2Keys 1 Battery cover with screw 1 1784-CP7 cable adapter for 1784-CP,

-CP5 cables

ControlNet PLC-5 Programmable Controllers Quick Start, publication number 1785-10.6

Identified by four colored bands: brown, green, brown, and gold

Two with a PLC-5/20C processor, four with PLC-5/40C, -5/46C and -5/80C processors

Identified by four colored bands: gray, red, black, and gold

If any items are missing or incorrect, contact your local Rockwell Automation sales office or distributor.

2. Install and connect a chassis and power supply. Use the following table to find more information about completing

these tasks:

Chassis Type Chassis Document Power Supply Power Supply Document

1771-A1B, -A2B, -A3B, - A3B1, -A4B 1771-2.210 1771-P1 1771-2.6

1771-P2 1771-2.7 1771-P3 1771-2.111 1771-P4 1771-2.111 1771-P4R 1771-5.3 1771-P4S 1771-2.13 1771-P5 1771-2.111 1771-P6R 1771-5.3 1771-P6S 1771-5.11 1771-P7 1771-5.56

1785-UM022C-EN-P - February 2008

1-6 Installing Your ControlNet PLC-5 Processor

Install or Replace the Battery A 3.0 volt lithium battery (cat. no. 1770-XYC) is included with your

processor. If the LED on the front of the processor indicates BATT, it means that

the battery must be replaced. You must use an exact replacement battery (cat. no. 1770-XYC).

ATTENTION

Important: In non-hazardous environments, it may be possible to

replace the battery while the processor is powered so that your programs are maintained in memory. You may lose your programs if you remove the battery when power is removed.

WARNING

Lithium battery requirements:

• do not short, recharge, heat above 85° C, disassemble or expose contents to water

• use only the 1770-XYC battery in the processor. DO NOT use any other type or size of battery.

When you connect or disconnect the battery, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

• For safety information on the handling of lithium batteries, including handling and disposal of leaking batteries, refer to Guidelines for Handling Lithium Batteries, publication AG-5.4

1785-UM022C-EN-P - February 2008

• Store batteries in a cool, dry environment. We recommend 25° C with 40% or 60% relative humidity. You may store batteries up to 30 days between -45° - 85° C, such as during transportation. To avoid possible leakage, do not store batteries above 60° C for more than 30 days.

Installing Your ControlNet PLC-5 Processor 1-7

To install or replace the battery:

1. Remove the battery from the shipping bag.

2. Remove the battery cover from the processor.

3. If you are replacing an existing battery, detach the wired clip

from the mating connector on the processor and remove the battery.

4. Connect the new or replacement battery by attaching the wired

clip to the mating connector on the processor.

5. Place the battery and tuck the wires inside the battery area on the

processor.

6. Replace the battery cover.

7. Use a pencil or erasable pen to write the battery installation date

on the battery cover.

WARNING

• For safety information on the handling of lithium batteries, including handling and disposal of leaking batteries, refer to Guidelines for Handling Lithium Batteries, publication AG-5.4

• Store batteries in a cool, dry environment. We

recommend 25° C with 40% or 60% relative humidity. You may store batteries up to 30 days between -45° - 85° C, such as during transportation. T o avoid possible l eakage, do not store batteries above 60° C for more than 30 days.

1785-UM022C-EN-P - February 2008

1-8 Installing Your ControlNet PLC-5 Processor

Estimated Battery Lifetimes

Processor Temperature Power Off 100% Power Off 50% Battery Duration

PLC-5/20C 60° C 173 days 346 days 70 hours

PLC-5/40C 60° C 92.5 days 185 days 38 hours

PLC-5/46C 60° C 92.5 days 185 days 38 hours

PLC-5/80C 60° C 80 days 160 days 33 hours

Dispose of a Battery

Worst-Case Battery-Life Estimates

25° C 1.69 years 3.38 years 14.5 days

25° C 1.25 years 2.5 years 10.8 days

25° C 1.18 years 2.36 years 10 days

The battery status indicator (BATT) warns you when the battery is low. These durations are based on the battery supplying the only power to the processor—power to the chassis is off—once the status indicator first lights.

If you need to dispose of a battery, follow the procedures described in Guidelines for Handling Lithium Batteries, (pub. no. AG-5.4).

ATTENTION

Follow these precautions to prevent the battery from exploding. An exploding battery exposes to xic, corrosive and flammable chemicals and causes burns.

• do not incinerate or expose the battery to high temperatures

• do not solder the battery or leads

• do not open, puncture or crush the battery

• do not charge the battery

• do not short positive or negative terminals together

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-9

Setting the I/O Chassis Backplane Switches

7 8

Set the I/O chassis backplane switches using a ball-point pen to set each switch.

Important: Do not use a pencil because the tip can break off and

short the switch.

Switch

OFF

Always OFF

Switches

OFF OFF OFF ON

ON OFF

ON ON

Outputs of this I/O chassis remain in their last state when a hardware failure occurs.

Outputs of this I/O chassis are turned off when a hardware failure occurs.

Addressing

2-slot 1-slot 1/2- slot

Not allowed

Last State

OFF

Switches

OFF OFF

ON ON

ON OFF

Switch

OFF

Regardless of this switch setting, outputs are turned off when any of the following occurs:

Processor memory protection disabled.

Processor memory protection enabled.

EEPROM memory transfer to processor memory at powerup.

EEPROM memory transfers to processor memory if processor memory not valid.

EEPROM memory does not transfer to processor memory.

Processor Memory Protection

EEPROM Transfer

processor detects a runtime error an I/O chassis backplane fault occurs you select Program or Test mode you set a status file bit to reset a local rack

If an EEPROM module is not installed and processor memory is valid, the processor's

PROC indicator blinks and the processor sets bit S:11/9 in the major fault status word. To clear this fault, change the processor from Program mode to Run mode and back to Program mode.

If the processor's keyswitch is set in Remote, the processor enters Remote Run mode

after it powers up and has its memory updated by the EEPROM module.

A processor fault (solid red PROC LED) occurs if processor memory is not valid.

You cannot clear processor memory when this switch is on.

19309

1785-UM022C-EN-P - February 2008

1-10 Installing Your ControlNet PLC-5 Processor

Setting the I/O Chassis Configuration Plug

Installing Keying Bands for the Processor

Set the I/O chassis configuration plug as follows:

USING A POWER-SUPPLY MODULE IN THE CHASSIS?

Set Y when you install a power-supply module in the chassis.

You receive plastic keying bands with each I/O chassis. Insert the keying bands as follows:

Set N when you use an external power supply.

1. Locate the chassis configuration plug (between the two left most slots of

the chassis).

2. Set the I/O chassis configuration plug.

The default setting is N (not using a power-supply module in the chassis).

Important: You cannot power a single I/O chassis with both a power-supply module and an external power supply.

17075

I/O Chassis Backplane Connector

Keying Bands (1771-RK)

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56

Use these numbers as a guide.

Install a keying band in the left-most slot between the following pins:

40 and 42 54 and 56

ATTENTION: A module inserted into a wrong slot could be damaged by improper voltages connected

through the wiring arm. Use keying bands to prevent damage to the module.

12062

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-11

Selecting the DH+ Station Address of Channel 1A

To select the DH+ station address of Channel 1A, set the switches of assembly SW1.

Side View of PLC-5/20C, -5/40C, -5/46C, -5/80C Switch Assembly SW1

To select: Set switch: To:

DH+ Station Number 1 through 6 (See below) Channel 1A DH+ Configuration 7 on (bottom)

off (top)

on on on on off off off off on on on on off off off off on on on on off off off off on on on on off off off off

Switch

on on on on on on on on off off off off off off off off on on on on on on on on off off off off off off off off

DH+ DH+ Station Number

0 1 2 3 4 5 6

7 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37

on off on off on off on off on off on off on off on off on off on off on off on off on off on off on off on off

on on off off on on off off on on off off on on off off on on off off on on off off on on off off on on off off

on on on on on on on on on on on on on on on on off off off off off off off off off off off off off off off off

57.6 kbps

230.4 kbps

on on on on on on on on on on on on on on on on on on on on on on on on on on on on on on on on

Station Number

40 41 42 43 44 45 46 47 50 51

52 53 54 55 56 57 60 61 62 63 64 65 66 67 70 71 72 73 74 75 76 77

off on off on off on off on off on off on off on off on off on off on off on off on off on off on off on off

on off off on on off off on on off

off on on off off on on off off on on off off on on off off on on off off

Switch

on on on off off off off on on on

on off off off off on on on on off off off off on on on on off off off off

Toggle pushed toward TOP

OFF

Toggle pushed toward BOTTOM

on on on on on on on off off off

off off off off off on on on on on on on on off off off off off off off off

on on on on on on on on on on

on on on on on off off off off off off off off off off off off off off off off

off

off off off off off off off off off off

off off off off off off off off off off off off off off off off off off off off off

1785-UM022C-EN-P - February 2008

1-12 Installing Your ControlNet PLC-5 Processor

Specifying the Serial Interface of Channel 0

Front of processor

Toggle pushed toward TOP

OFF

Toggle pushed toward BOTTOM

Specify RS-232C, RS-422A, or RS-423 communication for Channel 0 by setting the switches of assembly SW2.

Bottom View of PLC-5/20C Processor Switch Assembly SW2

To Specify:

RS-232C

RS-422A

Bottom View of PLC-5/40C, -5/46C, -5/80C Processor Switch Assembly SW2

Front of processor

Set Switches:

1 2 3 4 5 6 7 8 9 10

ON ON ON

OFF OFF

OFF OFF OFF OFF OFF

ON ON

OFF

Selecting the ControlNet Network Address of Channel 2

For optimum throughput, assign addresses to your ControlNet nodes in a sequential order starting with 01.

ON ON ON

OFF OFF

OFF

RS-423

Select your processor’s ControlNet network address by setting the two 10-digit rotary switches on the top of the processor.

20 30

7080

NET ADDRESS

Network address 01

is shown

You can select from as many as 99 network addresses (from 01 to 99) for a processor on a ControlNet link. 0 is invalid.

Important: Do not power-up the processor if the processor’s

ControlNet network address is set to 0. If you do, you will not be able to communicate with your processor and your ladder program will be lost, even if you have a battery installed. If this happens, select a valid network address for the processor and cycle power.

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-13

Inserting/Removing the Processor into/from the I/O Chassis

Card Guides

To insert/remove the processor into/from the chassis, do the following:

WARNING

If you insert or remove the processor while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the

Locking Bar

area is nonhazardous before proceeding.

To insert a processor into the chassis:

1. Lift the locking bar and the ejector tab.

Ejector Tab

2. Slide the processor into the left-most slot of the I/O chassis.

3. Press down on the ejector tab, and then close the locking bar over the processor.

To remove a processor from the chassis:

1. Save processor memory.

2. Remove power to the processor-resident chassis.

3. Disconnect all cables from the processor's ports.

4. Lift the locking bar and the ejector tab, and then

slide the processor from the chassis.

Installing a Remote I/O Link

Trunk-cable/drop-cable considerations: When using a trunk-cable/drop-cable

configuration, use 1770-SC station connectors and follow these cable-length guidelines:

• trunk-cable length—depends on the communication rate of the link; see Table Table 1.A

• drop-cable length—30.4 m (100 cable-ft) maximum

Important: When using a trunk-cable/ drop-cable configuration, set your communication rate to 57.6K bit/s.

For more information about designing trunk-cable/drop-cable configurations, see the Data Highway/Data Highway Plus/Data Highway II/Data Highway 485 Cable Installation Manual, publication 1770-6.2.2.

Install a remote I/O link using 1770-CD cable and either a daisy-chain or trunk-cable/drop-cable configuration.

Verify that your system’s design plans specify cable lengths within allowable measurements.

Important: The maximum cable length for remote I/O depends on

the transmission rate. Configure all devices on a remote I/O link to communicate at the same rate.

Table 1.A Correct Cable Length Based on Communication Rate

A remote I/O link using this communication rate:

57.6K bit/s 3,048 m (approximately 10,000 ft)

115.2K bit/s 1,524 m (approximately 5,000 ft)

230.4K bit/s 762 m (approximately 2,500 ft)

Cannot exceed this cable length:

For proper operation, terminate both ends of a remote I/O link by using the external resistors shipped with the programmable controller . Use either a 150Ω or 82Ω terminator.

1785-UM022C-EN-P - February 2008

1-14 Installing Your ControlNet PLC-5 Processor

The maximum number of

logical rack

If your remote I/O link:

Use this resistor rating:

physical devices that you can connect on the link is:

numbers that you can scan on the link is:

Operates at 230.4K bit/s Operates at 57.6K or 115.2K bit/s, and no devices listed below are linked

Scanners 1771-SN; 1772-SD, -SD2;

1775-SR, -S4A, -S4B;

82Ω 32 16

6008-SQH1, -SQH2 Adapters 1771-AS; 1771-ASB (Series A Only); 1771-DCM Miscellaneous 1771-AF

Connects to any device listed below:

Scanners 1771-SN; 1772-SD, -SD2;

1775-SR, -S4A, -S4B;

6008-SQH1, -SQH2

150Ω 16 16

Adapters 1771-AS; 1771-ASB (Series A Only); 1771-DCM Miscellaneous 1771-AF

Operates at 57.6K or 115.2K bit/s, and you do not require over 16 physical devices

You can install a remote I/O link two ways:

- trunk cable/drop cable--from the drop cable to the connector screw terminals on the remote I/O connectors of the processor

- daisy chain--to the connector screw terminals on the remote I/O connectors of the processor and then to the remote I/O screw terminals of the next remote I/O device

To connect remote I/O cable, use the Phoenix MTSB2.5/3-ST 3-pin header connector provided in the accessory kit.

1. Run the 1770-CD cable from the processor to each remote I/O adapter module or processor in the remote I/O system.

2. Connect the signal conductor with blue insulation to the 3-pin connector terminal labeled 1 on the processor and to each remote I/O adapter module (or PLC-5 adapter) in the remote I/O system.

3. Connect the shield drain wire to the center terminal of the 3-pin connector.

4. Connect the signal conductor with clear insulation to the 3-pin connector terminal labeled 2.

5. Tie-wrap the remote I/O network cable to the chassis to relieve strain on the cable.

6. Terminate the remote I/O link by connecting an external terminator resistor between the remote I/O terminals labeled 1 and 2.

Blue

1770-CD

To another I/O link device

Shield

Clear

PLC-5/40C, -5/46C,

-5/80C Processor

Blue

Shield

Clear

1770-CD

PLC-5/20C Processor

82W or 150W resistor

Terminate both ends of a remote I/O link

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-15

WARNING

If you connect or disconnect the 1770-CD cable with power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

When used in a Class I, Division 2, hazardous location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes.

Installing a DH+ Link Use 1770-CD cable to connect the processor to a DH+ link.

Follow these guidelines while installing DH+ communication links:

• do not exceed these cable lengths:

– trunk-cable length—3,048 m (app r oximately 10,000 cable-ft) – drop-cable length—30.4 m (approximately 100 cable-ft)

• do not connect more than 64 stations on a single DH+ link

1785-UM022C-EN-P - February 2008

1-16 Installing Your ControlNet PLC-5 Processor

Use the 3-pin connector on the processor to connect a DH+ link. The connector’s port must be configured to support a DH+ communication link.

You can install a DH+ link two ways:

- trunk cable/drop cable--from the drop cable to the connector screw terminals on the DH+ connectors of the processor.

- daisy chain--to the connector screw terminals on the DH+ connectors of the processor.

To make connections, use the Phoenix connector MTSB2.5/3-ST 3-pin header connector provided in the accessory kit.

1. Connect the signal conductor with clear insulation to the 3-pin connector terminal 1 at each end of each cable segment.

2. Connect the shield drain wire to the center terminal of the 3-pin connector at both ends of each cable segment.

3. Connect the signal conductor with blue insulation to the 3-pin connector terminal 2 at each end of each cable segment.

PLC-5/40C, -5/46C or -5/80C processor

Clear

Shield

Blue

PLC-520C processor

Clear

Shield

Blue

82W or 150W resistor

WARNING

82W or 150W resistor

When used in a Class I, Division 2, hazardous location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes.

1785-UM022C-EN-P - February 2008

Installing Your ControlNet PLC-5 Processor 1-17

Connecting to a ControlNet Network

Connect a ControlNet PLC-5 processor to a ControlNet network via a tap with a 1-m (39.4-in) drop cable.

WARNING

If you connect or disconnect the ControlNet tap cable with power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location

WARNING

installations. Be sure that power is removed or the area is nonhazardous before proceeding.

When used in a Class I, Division 2, hazardous location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes.

Four taps are available from Rockwell Automation:

Straight T-tap

Straight Y-tap

Right-angle T-tap

Right-angle Y-tap

Important: ControlNet taps contain passive electronics and must be

After terminating your segments, you connect your node to the network.

Remove the tap’s dust cap – located on the straight or right-angle connector – and set it aside.

If your network supports:

nonredundant media to the channel A connector on the

redundant media • from trunk-cable A to channel A

Rockwell Automation recommends using channel A for nonredundant media.

Connect the tap’s straight or right-angle connector:

processor – channel B is not used

on the processor

and

•from trunk-cable B to channel B

on the processor

1786-TPS

Nonredundant Media

1786-TPYS

1786-TPR

1786-TPYR

purchased from Rockwell Automation for the network to function properly.

BATT

CH 0

Redundant Media

CH 0

1785-UM022C-EN-P - February 2008

1-18 Installing Your ControlNet PLC-5 Processor

For detailed information about planning and installing your ControlNet system, see the following publications:

ControlNet Cable System Component List AG-2.2

ControlNet Cable System Planning and Installation Manual 1786-6.2.1

ControlNet Network Access Cable Installation Instructions 1786-2.6

ControlNet Fiber Planning and Installation Guide CNET-IN001A-EN-P

System Design for Control of Electrical Noise GMC-RM001A-EN-P

Industrial Automation Wiring and Grounding Guidelines 1770-4.1

Terminating Your ControlNet Coaxial Cables CD-ROM CNET-DM001A-EN-C

To view or order these publications online, visit: http://literature.rockwellautomation.com

Publication Publication Number

1785-UM022C-EN-P - February 2008

+ 118 hidden pages