Rockwell Automation 1785-Lxxx User Manual
Enhanced and
Ethernet PLC-5
Programmable
Controllers
1785-L11B, -L20B, -L30B, -L40B,
-L40L, -L60B, -L60L, -L80B, -L20E,
-L40E, -L80E, -L26B, -L46B, -L86B
User Manual
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://www.ab.com/manuals/gi) 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 manua l , 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
Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment,
which may lead to personal injur y 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
• recognize the consequence
Labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may
be present.
Labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfa ces may be
dangerous temperatures.
Summary of Changes
Summary of Changes
Changes to this Manual
Find the New Information
This user manual contains new and updated information.
The black revision bars, as shown on the left, indicate the changes.
For specific locations of the new information, refer to the table below.
This New and Updated Information Is on Page
Domain Name Service 11-15
User Provided Web Pages 11-16
Multihop Messaging over Ethernet 11-29
TCP/IP Communications 11-32
Additional Ethernet Diagnostics 11-35
Memory Card Diagnostics B-12
Troubleshooting and Diagnostics F-2
Additional Ethernet PLC-5 Controller Enhan ce ment
Ethernet PLC-5 controllers support use of the 1785-RC Relay Cartridge.
The relay cartridge serves as an interface from the controller to a user-supplied
external device such as an Allen-Bradley 700P relay. When the controller is in
run mode, it monitors online ladder program edits and I/O forcing activity.
When either of these is detected, the controller opens the relay on the relay
cartridge for one second.
1 Publication 1785-UM012D - EN-P - July 2005
Summary of Changes 2
Notes
Publication 1785-UM012D-EN-P - July 2005
Table of Contents
Preface
Understanding Your
Programmable Controller
Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Related PLC-5 Documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Terms Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Manual Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Chapter 1
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Lay Out the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Identifying Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
PLC-5/11, -5/20, and -5/26 Controller Front Panels. . . . . . . . . 1-3
PLC-5/40, -5/46, -5/60, -5/80, and -5/86
Controller Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
PLC-5/20E Controller Front Panel . . . . . . . . . . . . . . . . . . . . . . 1-6
PLC-5/40E and -5/80E Controller Front Panels . . . . . . . . . . . 1-7
PLC-5/40L and -5/60L Controller Front Panels . . . . . . . . . . . 1-8
Programming Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Using a Controller Channel as a Remote I/O Scanner . . . . . . . . . . 1-11
Using a Controller Channel as a Remote I/O Adapter . . . . . . . . . . 1-12
Using a PLC-5/40L, -5/60L Programmable Controller as an
Extended-Local I/O Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Selecting and Placing I/ O
Placing Syste m Hardware
Chapter 2
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Selecting I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Guidelines for Selecting I/O Modules . . . . . . . . . . . . . . . . . . . . 2-2
Selecting I/O Module Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Placing I/O Modules in a Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Chapter 3
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Determining the Proper Environment . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Protecting Your Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Preventing Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Laying Out Your Cable Raceway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Categorize Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Route Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Laying Out Your Backpanel Spacing . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Chassis Dimensions (Series B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
I/O Chassis and External Power Supply Dimensions . . . . . . . 3-6
Grounding Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
1 Publication 1785-UM012D - EN-P - July 2005
T able of Contents 2
Addressing I/ O and Controller
Memory
Chapter 4
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
I/O Addressing Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Choosing an Addressing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Addressing Block-Transfer Modules. . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Addressing Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Assigning Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Understanding PLC-5 Controller Memory. . . . . . . . . . . . . . . . . . . . 4-10
Understanding Data Storage (Data-Table Files) . . . . . . . . . . . . 4-11
Addressing File Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Understanding Program-File Storage . . . . . . . . . . . . . . . . . . . . . 4-15
Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Specifying I/O Image Addresses . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Specifying Logical Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Specifying Indirect Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Specifying Indexed Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Specifying Symbolic Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Optimizing Instruction Execution Time
and Controller Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Effectively Using I/O Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Communicating with
Controller-Resident I/O
Communicating with Remote I/O
Chapter 5
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Introduction to PLC-5 Controller Scanning. . . . . . . . . . . . . . . . . . . . 5-1
Program Scanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Transferring Data to Controller-Resident I/O. . . . . . . . . . . . . . . . . . 5-3
Transferring Discrete Data to Controller-Resident I/O . . . . . . . 5-3
Transferring Immediate I/O Requests. . . . . . . . . . . . . . . . . . . . . 5-3
Transferring Block-Transfer Data to Controller-Resident I/O . 5-4
Configuring the System for Controller-Resident I/O . . . . . . . . . . . . 5-4
Chapter 6
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 6-2
Introduction to Remote I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Designing a Remote I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Configuring a Controller Channel as a Scanner . . . . . . . . . . . . . . . . . 6-6
Define an I/O Status File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Specify Channel Configuration Information . . . . . . . . . . . . . . . . 6-7
Specify the Scan List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Communicating to a Remote I/O Node Adapter . . . . . . . . . . . . . . 6-11
Troubleshooting Remote I/O Communication Difficulties. . . 6-12
Transferring Block Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Block-Transfers of Remote I/O Data . . . . . . . . . . . . . . . . . . . . . . . 6-15
Block-Transfer Sequence with Status Bits . . . . . . . . . . . . . . . . . . . . 6-17
Publication 1785-UM012D-EN-P - July 2005
Communicating with a PLC-5
Adapter Channel
Table of Contents 3
Block-Transfer Programming Considerations . . . . . . . . . . . . . . . . . 6-19
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
For Controller-Resident Local Racks . . . . . . . . . . . . . . . . . . . . . 6-20
Monitoring Remote I/O Scanner Channels. . . . . . . . . . . . . . . . . . . 6-21
Monitoring transmission retries . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Addressing the I/O Status File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Chapter 7
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Configuring Communication to a PLC-5 Adapter Channel . . . . . . . 7-2
Specify an Adapter Channel’s Communication Rate,
Address, and Rack Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Specify the Discrete Transfer Configuration Files. . . . . . . . . . . . 7-5
Programming Discrete Transfers in Adapter Mode. . . . . . . . . . . . . 7-10
Programming Block-Transfers of Data to an Adapter Channel . . . 7-10
Configure Block-Transfer Requests . . . . . . . . . . . . . . . . . . . . . . 7-11
Examples of Block-Transfer Ladder Logic
Effects of Programming Block-Transfers to an Adapter-Mode
Controller Channel on Discrete Data Transfer . . . . . . . . . . . . . 7-15
Monitoring the Status of the Adapter Channel . . . . . . . . . . . . . 7-17
Monitoring the Status of the Supervisory Controller. . . . . . . . . 7-18
Monitoring Remote I/O Adapter Channels. . . . . . . . . . . . . . . . . . . 7-19
Communicating with
Extended-Local I/O
Communicating with Devices on a
DH+ Link
Chapter 8
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 8-1
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Addressing and Placing I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Transferring Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Discrete Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Transferring Block Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Calculating Block-Transfer Completion Time . . . . . . . . . . . . . . . 8-7
Considerations for Extended-local Racks. . . . . . . . . . . . . . . . . . . 8-8
Configuring the Controller as an Extended-Local I/O Scanner. . . . 8-9
Monitoring Extended-Local I/O Status. . . . . . . . . . . . . . . . . . . . . . 8-12
Chapter 9
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Selecting Devices That You Can Connect . . . . . . . . . . . . . . . . . . . . . 9-1
Link Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Configuring the Channel for DH+ Communication . . . . . . . . . . . . . 9-3
Using the Global Status Flag File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Monitoring DH+ Communication Channels. . . . . . . . . . . . . . . . . . . 9-7
Monitoring Data Sent with Acknowledgment . . . . . . . . . . . . . . . 9-8
Monitoring Data Sent without Acknowledgment . . . . . . . . . . . 9-10
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T able of Contents 4
Communicating with Devices on a
Serial Link
Monitoring General Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Estimating DH+ Link Performance. . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Size and Number of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Message Destination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Internal Processing Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Average DH+ Link Response Time Test Results . . . . . . . . . . . 9-16
Application Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Chapter 10
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Choosing Between RS-232C, RS-422A, and RS-423 . . . . . . . . . . . . 10-1
Configuring the Controller
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Using Channel 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
System Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Master Station to Remote Station Communication Methods . . 10-4
Polling Inactive Priority Stations. . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Changing Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Configuring Channel 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Configure Channel 0 for DF1 Point-to-Point . . . . . . . . . . . . . . 10-6
Configure Channel 0 as a Slave Station . . . . . . . . . . . . . . . . . . . 10-9
Configure Channel 0 as a Master Station . . . . . . . . . . . . . . . . . 10-12
Configure Channel 0 for User Mode (ASCII Protocol). . . . . . 10-18
Configure Channel 0 for a Communication Mode Change. . . 10-21
Monitoring Channel 0 Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Using the System Mode Status Display . . . . . . . . . . . . . . . . . . 10-22
Using the User Mode (ASCII) Status Display . . . . . . . . . . . . . 10-24
Communicating with Devices on
an Ethernet Networ k
Publication 1785-UM012D-EN-P - July 2005
Chapter 11
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Media and Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Assigning Your IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Network Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Configuring Channel 2 for Ethernet Communication. . . . . . . . . . . 11-2
Manually Configuring Channel 2 . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Using BOOTP to Enter Configuration Information. . . . . . . . . 11-5
Editing the BOOTPTAB Configuration File. . . . . . . . . . . . . . . 11-7
Using Advanced Ethernet Functions . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Using Broadcast Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Using Subnet Masks and Gateways . . . . . . . . . . . . . . . . . . . . . 11-11
Manually Configuring Channel 2 for Controllers on Subnets. 11-12
Table of Contents 5
Using BOOTP to Configure Channel 2
for Controllers on Subnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Using Domain Name Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Using the Embedded Web Server. . . . . . . . . . . . . . . . . . . . . . . . . . 11-16
Generating User Provided Web Pages . . . . . . . . . . . . . . . . . . . 11-22
Importing User Page Files to the PLC-5 Controller . . . . . . . . 11-26
Using Multihop Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29
Multihop Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
Comparing Multihop and Non-Multihop Messages
Over Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
Communicating with ControlLogix Devices . . . . . . . . . . . . . . . . . 11-32
TCP/IP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
Interpreting Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
Interpreting Ethernet Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Monitoring general Ethernet status . . . . . . . . . . . . . . . . . . . . . 11-35
Monitoring Ethernet commands. . . . . . . . . . . . . . . . . . . . . . . . 11-36
Monitoring Ethernet replies . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
Ethernet PLC-5 Performance Considerations . . . . . . . . . . . . . . . . 11-37
Performance: Host to Ethernet PLC-5 Controller. . . . . . . . . . 11-37
Performance: Ethernet PLC-5 Controller to Ethernet
PLC-5 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-38
Protecti ng Your Programs
Programming Considerations
Chapter 12
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
About Passwords and Privileges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Defining Privilege Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Assigning a Privilege Class to a Channel or Offline File . . . . . . . . . 12-4
Assigning a Privilege Class to a Node. . . . . . . . . . . . . . . . . . . . . . . . 12-4
Assigning Read/Write Privileges to a Program File. . . . . . . . . . . . . 12-5
Assigning Read/Write Privileges to a Data File . . . . . . . . . . . . . . . . 12-5
Chapter 13
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Forcing Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Forcing SFC Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Extended Forcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Increased Program Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
I/O Force Privileges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Using Protected Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Using Selectable Timed Interrupts (STIs)
and Controller Input Interrupts (PIIs) . . . . . . . . . . . . . . . . . . . . 13-5
Setting Up and Using Extended Forcing . . . . . . . . . . . . . . . . . . . . . 13-5
Step 1 - Select Which Group of Data You Want to Force . . . . 13-6
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T able of Contents 6
Preparing Power-U p Routi nes
Step 2 - Use the Programming Software to Enter
or Edit the Data You Want to Force in the Extended Force
Configuration Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
Step 3 - Use the Programming Software to Enter
Force Values for the Specified Data Table Files . . . . . . . . . . . . 13-8
Step 4 - Enable or Disable the Forces . . . . . . . . . . . . . . . . . . . . 13-8
Using Extended Forcing with Time-Critical Applications. . . . . 13-8
Using Special Programming Routines. . . . . . . . . . . . . . . . . . . . . . . 13-10
Priority Scheduling for Interrupts and MCPs. . . . . . . . . . . . . . . . . 13-11
Program Execution States. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
Influencing Priority Scheduling. . . . . . . . . . . . . . . . . . . . . . . . . 13-14
Defining and Programming Interrupt Routines. . . . . . . . . . . . . . . 13-15
Chapter 14
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Setting Power-Up Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Allowing or Inhibiting Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Defining a Controller Power-Up Procedure. . . . . . . . . . . . . . . . . . . 14-2
Preparing Fault Routi nes
Chapter 15
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Understanding the Fault Routine Concept. . . . . . . . . . . . . . . . . . . . 15-1
Responses to a Major Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Understanding Controller-Detected Major Faults . . . . . . . . . . . . . . 15-2
Fault in a Controller-Resident or Extended-Local I/O Rack . . 15-3
Fault in a Remote I/O Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Defining a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Defining a Watchdog Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Avoiding Multiple Watchdog Faults. . . . . . . . . . . . . . . . . . . . . . 15-6
Programming a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Setting an Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Clearing a Major Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Changing the Fault Routine from Ladder Logic . . . . . . . . . . . . 15-9
Using Ladder Logic to Recover from a Fault. . . . . . . . . . . . . . 15-10
Block-Transfers in Fault Routines . . . . . . . . . . . . . . . . . . . . . . 15-11
Testing a Fault Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Monitoring Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Monitoring Major/Minor Faults and Fault Codes. . . . . . . . . . 15-12
Interpreting Major Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Interpreting Minor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
Monitoring Status Bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Publication 1785-UM012D-EN-P - July 2005
Using Main Control Programs
Using Selectable Timed Interrupts
Using Processor Input Interrupts
Table of Contents 7
Chapter 16
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Selecting Main Control Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Understanding How the
Controller Interprets MCPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Configuring MCPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
Monitoring MCPs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-5
Chapter 17
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Using a Selectable Timed Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Writing STI Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
STI Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Block-Transfers in Selectable Timed Interrupts (STIs) . . . . . . . 17-2
Defining a Selectable Timed Interrupt . . . . . . . . . . . . . . . . . . . . . . . 17-3
Monitoring Selectable Timed Interrupts. . . . . . . . . . . . . . . . . . . . . . 17-4
Chapter 18
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Using a Processor Input Interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Writing PII Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
PII Application Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
Block-Transfers in Processor Input Interrupts (PIIs) . . . . . . . . 18-3
Design Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4
Defining a Controller Input Interrupt. . . . . . . . . . . . . . . . . . . . . . . . 18-5
Monitoring Controller Input Interrupts . . . . . . . . . . . . . . . . . . . . . . 18-6
System Specifications
Processor Status File
Appendix A
Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Memory and Channel Specifications. . . . . . . . . . . . . . . . . . . . . . A-2
Memory Backup Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
EEPROM Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
S:0 - S:2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
S:3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
S:11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
S:12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
S:13-S:24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
S:26-S:35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
S:36-S:78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
S:79-S:127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
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T able of Contents 8
Maximizing System Performance
Appendix C
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Program Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Effects of False Logic versus True Logic on Logic Scan Time. . C-2
Effects of Different Input States on Logic Scan Time . . . . . . . . C-2
Effects of Different Instructions on Logic Scan Time . . . . . . . . C-3
Effects of Using Interrupts on Logic Scan Time. . . . . . . . . . . . . C-3
Effects of Housekeeping Time. . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Editing While in Remote Run Mode . . . . . . . . . . . . . . . . . . . . . . C-4
Putting Block-Transfer Modules in Controller-Resident Chassis C-5
Using Global Status Flag Files . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Calculating Throughput. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Input and Output Modules Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
I/O Backplane Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Remote I/O Scan Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Communication Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Number of Rack Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Block-Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Calculating Worst-Case Remote I/O Scan Time. . . . . . . . . . . . . C-9
Optimizing Remote I/O Scan Time. . . . . . . . . . . . . . . . . . . . . . . C-9
Controller Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Performance Effects of Online Operations . . . . . . . . . . . . . . . . . . . C-12
Effect of Inserting Ladder Rungs at the 56K-word Limit. . . . . . . . C-13
Using Program Control Instructions. . . . . . . . . . . . . . . . . . . . . . . . . C-14
Using JMP/LBL Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Using FOR/NXT Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Instruction Set Quick Reference
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Appendix D
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Relay Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Timer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Counter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Compare Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
Compute Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Logical Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14
Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
Bit Modify and Move Instructions . . . . . . . . . . . . . . . . . . . . . . D-16
File Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17
Diagnostic Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19
Shift Register Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20
Sequencer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
Program Control Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . D-22
Process Control, Message Instructions. . . . . . . . . . . . . . . . . . . D-25
Block Transfer Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25
Switch Setting Reference
Table of Contents 9
ASCII Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-27
Bit and Word Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
File, Program Control, and ASCII Instructions. . . . . . . . . . . . D-32
Appendix E
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Controller Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
I/O Chassis Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
PLC-5 Controller in the I/O Chassis . . . . . . . . . . . . . . . . . . . . . . E-4
1771-ASB Remote I/O Adapter or 1771-ALX
Extended-Local I/O Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
I/O Chassis Configuration Plug. . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Remote I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
(1771-ASB Series C and D) without Complementary I/O . . . . . E-7
(1771-ASB Series C and D) I/O Rack Number -
without Complementary I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Extended-Local I/O Adapter Module . . . . . . . . . . . . . . . . . . . . . . . . E-9
(1771-ALX) Switch SW1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
(1771-ALX) Configuration Plug . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Troubleshooting
Appendix F
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
PLC-5 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Controller Communication Channel Troubleshooting . . . . . . . . F-4
Extended-Local I/O Troubleshooting. . . . . . . . . . . . . . . . . . . . . F-5
Ethernet Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Ethernet Transmit LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Remote I/O System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Troubleshooting Guide for the 1771-ASB Series C and D
Adapter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Troubleshooting Guide for the 1771-ASB Series C and D
Adapter Module (continued). . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Extended-Local I/O System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9
Troubleshooting Guide for the 1771-ALX Adapter Module . . . F-9
Unexpected Operation when Entering Run Mode. . . . . . . . . . . . . . . F-9
Instructions with Unique Prescan Operations. . . . . . . . . . . . . . F-10
Suggested Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11
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T able of Contents 10
Cable Reference
Index
Appendix G
Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Channel 0 Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Serial Cable Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Connecting Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Programming Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
Publication 1785-UM012D-EN-P - July 2005
Using This Manual
Preface
Purpose of This Manual
Related PLC-5 Documentation
The purpose of this manual is to help you design, operate and maintain an
Enhanced and Ethernet PLC-5 programmable controller system. Use this
manual to:
• determine the features of the controllers and how you use them
• design your PLC-5 system
• operate and maintain your PLC-5 system
The following docume nts contain additional i nformation rela ted to the
procedures described in this document..
Publication Title Publication Number
Industrial Automation Wiring and Grounding Guidelines 1770-4.1
PLC-5 Programmable Controller Instruction Set Reference 1785-6.1
Configuring Complementary I/O for PLC-5 Controllers 1785-6.8.3
Data Highway Cable Installation Manual 1770-6.2.2
SCADA System Selection Guide, AG-SG001
PLC-5 Protected Controllers Product Data 1785-2.28
PLC-5 Protected Controller Supplement 1785-6.5.13
1771 Remote I/O Adapter Module User Manual 1771-UM001
ControlNet PLC-5 Programmable Controllers User Manual 1785-UM022
To get this documentation, you can either:
• view or download an electronic version from the internet at
www.rockwellautomation.com/literature
• contact y our local di stri but or or Rockwell Auto mation representative to
place an order
1 Publication 1785-UM012D - EN-P - July 2005
Preface 2
Terms Used in This Manual
Term Definition
Block-transfer data data transferred, in blocks of data up to 64 words, to/from a block-
Discrete-transfer data data (words) transferred to/from a discrete I/O module
Enhanced PLC-5 controllers references PLC-5/11, -5/20, -5/26, -5/30, -5/40, -5/46, -5/40L,
Ethernet a local area network with a baseband communication rate of 10M
Ethernet PLC-5 controllers references PLC-5/20E, -5/40E, and -5/80E controllers
Become familiar with the following terms and definitions which are used
throughout this manual.
transfer I/O module (for example, an analog module)
-5/46L, -5/60, -5/60L, -5/80, and -5/86 controllers
PLC-5/26, -5/46, and -5/86 controllers are protected
controllers. See the PLC-5 Protected Controllers Supplement,
publication 1785-6.5.13
This term also refers to the PLC-5/V30B, -5/V40B, -5/V40L, and
-5/V80B controllers when applicable. See the PLC-5/VME VMEbus
Programmable Controllers User Manual, publication 1785-6.5.9,
for more information
bps designed for the high-speed exchange of information between
computers and related devices
Extended-local I/O I/O connected to a controller across a parallel link to achieve
higher throughput, thus limiting its distance from the controller
Extended local I/O link a parallel link for carrying I/O data between a PLC-5/40L or -5/60L
controller and extended-local I/O adapters
PLC-5 controller used to generically reference Enhanced PLC-5 and Ethernet PLC-5
controllers in this manual only
Controller-resident local I/O
chassis
Remote I/O link a serial communication link between a PLC-5 controller port in
Remote I/O chassis the hardware enclosure that contains an adapter and I/O modules
the I/O chassis in which the PLC-5 controller is installed
scanner mode and an adapter as well as I/O modules that are
located remotely from the PLC-5 controller
that are located remotely on a serial communication link to a PLC-5
controller in scanner mode
Publication 1785-UM012D-EN-P - July 2005
Preface 3
Manual Overview
This manual has three main sections:
• Design
• Operate
• Maintain
Section: For information about: See Title:
Design An overview of the PLC-5 controllers’ capabilities and keyswitch Chapter 1 Understanding Your Controller
Guidelines for selecting and placing I/O modules Chapter 2 Selecting and Placing I/O
The proper environment for your PLC-5 system Chapter 3 Placing System Hardware
Choosing addressing mode, assigning rack numbers, and understanding
PLC-5 memory
Operate Configuring the controller for controller-resident I/O, transferring data, and
monitoring status
Configuring a system for remote I/O communication, designing a remote
I/O link, transferring data, and monitoring status
Configuring a PLC-5 adapter channel, transferring data, and
monitoring status
For PLC-5/40L, -5/46L, and -5/60L Controllers only: Configuring an
extended-local I/O system, transferring data, and monitoring status
Configuring a system for Data Highway Plus™ and monitoring
channel status
Configuring a system for serial communications and monitoring
channel status
Chapter 4 Addressing I/O and Controller Memory
Chapter 5 Communicating with Controller-Resident I/O
Chapter 6 Communicating with Remote I/O
Chapter 7 Communicating with a PLC-5
Adapter Channel
Chapter 8 Communicating with Extended-Local I/O
Chapter 9 Communicating with Devices on a DH+ Link
Chapter 10 Communicating with Devices on a
Serial Link
For PLC-5/20E, -5/40E, and -5/80E Controllers only:
Configuring a system for Ethernet communications and monitoring
channel status
Assigning passwords and privileges Chapter 12 Protecting Your Programs
PLC-5 programming feature overview Chapter 13 Programming Considerations
Defining power-up procedure Chapter 14 Preparing Power-Up Routines
Defining, programming, and monitoring fault routines Chapter 15 Preparing Fault Routines
Configuring and monitoring main control programs Chapter 16 Using Main Control Programs
Using, defining, and monitoring selectable timed interrupts Chapter 17 Using Selectable Timed Interrupts
Using, defining, and monitoring Controller input interrupts Chapter 18 Using Controller Input Interrupts
Maintain System specifications Appendix A System Specifications
Listing of the controller status file words and meaning Appendix B Controller Status File
General and specific performance considerations Appendix C Maximizing System Performance
Guide to ladder instructions and execution times Appendix D Instruction Set Quick Reference
How to set system switches Appendix E Switch Setting Reference
Potential problems and recommended solutions Appendix F Troubleshooting
Guidelines for choosing and making cables Appendix G Cable Reference
Chapter 11 Communicating with Devices on an
Ethernet Network
Publication 1785-UM012D - EN-P - July 2005
Preface 4
Notes
Publication 1785-UM012D-EN-P - July 2005
Using This Chapter
Chapter
1
Understanding Your Programmable Controller
For Information About Go to Page
Lay Out the System 1-1
Identifying controller components 1-2
Programming features 1-10
Using a controller channel as a remote I/O scanner 1-11
Using a controller channel as a remote I/O adapter 1-12
Using a PLC-5/40L, -5/60L programmable controller as an
extended-local I/O scanner
1-14
Lay Out the System
Lay out the system by determining the network configuration and the
placement of components in each location. Decide at this time whether each
location will have its own controller.
Place each controller’s I/O on an isolated network to maximize the
performance and to more ea sily accommodate future network or system
configuration changes. If you plan to share I/O, make sure the I/O is on a
network that each controller can access.
Assume that Network A and Netw or k B both re quir e a c ontr oller and its I/O.
Both controllers interact with time critical information.
RSView
Network C
Panel C
Network B
Panel B
chassis 1
Panel B
chassis 2
Panel A
chassis 1
Network A
Panel A
chassis 2
Panel A
chassis 3
Panel
View
1 Publication 1785-UM012D - EN-P - July 2005
Panel
View
1-2 Understanding Your Programmable Controller
For a PLC-5 controller to control I/O modules, both the contro ller and the
I/O modules must be directly attached to the same network.
Identifying Controller Components
I/O Location Controller in
Panel A, chassis 1
Panel A, chassis 1 yes yes
Panel A, chassis 2 yes no
Panel A, chassis 3 yes no
Panel B, chassis 1 yes yes
Panel B, chassis 2 no yes
Panel C, chassis 1 yes yes
Controller in
Panel B, chassis 1
Evaluate what communications need to occur between controllers. If there is
sporadic information that is not time-critical, use a message-based network
such as an EtherNet/IP (the information portion) or Data Highway Plus
TM
.
To become familiar with the controller’s front panels, use these figures:
For the Front Panels Of Page
PLC-5/11, -5/20 and -5/26 controllers 1-3
PLC-5/30 controllers 1-4
PLC-5/40, -5/46, -5/60, -5/80 and -5/86 controllers 1-5
PLC-5/20E controllers 1-6
PLC-5/40E and -5/80E controllers 1-7
PLC-5/40L and -5/60L controllers 1-8
Publication 1785-UM012D-EN-P - July 2005
Understanding Your Programmable Controller 1-3
PLC-5/11, -5/20, and -5/26 Controll er Front Panels
keyswitch; selects controller mode
channel 0-25-pin D-shell serial port;
supports standard EIA RS-232C and
RS-423 and is RS-422A compatible
1
Use this port with ASCII or DF1
full-duplex, half-duplex master, and
half-duplex slave protocols. The port's
default configuration supports controller
programming:
DF1 point-to-point
2400 bps
no parity
one stop-bit
BCC error check
no handshaking
PLC-5/11 Controller
PLC-5/20 or -5/26 Controller
battery indicator (red when
the battery is low)
controller RUN/FAULT
indicator (green when
running; red when faulted)
force indicator (amber when
I/O forces are enabled)
channel 0 communication
status indicator (green when
the channel is communicating)
Install memory module here.
Install battery here
channel 1A status indicator
(lights green and red)
8-pin mini-DIN, DH+ programming
terminal connection parallel to
channel 1A
channel 1A communication port; for
the PLC-5/11 controller, the default
configuration is DH+
2
channel 1A communication port;
this 3-pin port is a dedicated DH+ port
1
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
Configure these 3-pin ports for:
2
remote I/O scanner
remote I/O adapter,
DH+ communication
unused
channel 1B status indicator
(lights green and red)
channel 1B communication port;
its default configuration is remote
I/O scanner
2
PLC-5 family member designation
Publication 1785-UM012D - EN-P - July 2005
1-4 Understanding Your Programmable Controller
keyswitch; selects controler mode
channel 1A status indicator
(lights green and red)
PLC-5/30 Controller Front Panell
battery indicator (lights red when the
battery is low)
controller RUN/FAULT indicator (green
when running; red when faulted)
force indicator (amber when
I/O forces are enabled)
channel 0 communication status indicator
(green when the channel is communicating)
channel 0-25-pin D-shell serial port; supports standard
EIA RS-232C and RS-423 and 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
one stop-bit
BCC error check
no handshaking
1
8-pin mini-DIN, DH+ programming terminal
connection parallel to channel 1A
channel 1A communication port;
its default configuration is DH+
channel 1B communication port;
its default configuration is remote I/O scanner
2
2
Install battery here
Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422
1
equipment as long as:
termination resistors are not used
the distance and transmission rate are reduced to comply with RS-423 requirements
2
Configure these 3-pin ports for:
remote I/O scanner,
remote I/O adapter,
DH+ communication
unused
channel 1B status indicator (lights green and red)
Install memory module here
Use these labels to write information about the
channel: communication mode, station addresses, etc.
PLC-5 family member designation
Publication 1785-UM012D-EN-P - July 2005
keyswitch; selects controller mode
channel 2A status indicator
(lights green and red)
Understanding Your Programmable Controller 1-5
PLC-5/40, -5/46, -5/60, -5/80, and -5/86 Controller Front Panel
battery indicator (red when the battery is low)
controler RUN/FAULT indicator (green when
running; red when faulted)
force indicator (amber when I/O forces are enabled)
channel 0 communication status indicator
(green when the channel is communicating)
8-pin mini-DIN, DH+ programming
terminal connection parallel to channel
2A when channel 2A is configured for
DH+ communications
channel 2A communication port;
its default configuration is unused
2
channel 2B communication port;
its default configuration is unused
2
channel 1A status indicator
(lights green and red)
8-pin mini-DIN, DH+ programming terminal
connection parallel to channel 1A
channel 1A communication port;
its default configuration is DH+
at 57.6 kbps
2
channel 1B communication port;
its default configuration is remote I/O scanner
channel 2B status indicator (lights green and red)
channel 0-25-pin D-shell serial port; supports standard
EIA RS-232C and RS-423 and is RS-422A compatible
1
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
one stop-bit
BCC error check
no handshaking
channel 1B status indicator (lights green and red)
Use these labels to write information about the
channel: communication mode, station addresses etc.
Install memory module here
2
Install battery here
1
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
2
Configure these 3-pin ports for:
remote I/O scanner,
remote I/O adapter,
DH+ communication
unused
PLC-5 family member designation
Publication 1785-UM012D - EN-P - July 2005
1-6 Understanding Your Programmable Controller
external transceiver fuse
keyswitch; selects controller mode
channel 2 Ethernet status indicator (green when
functioning normally; red when not functioning)
channel 2 communication port;
a 15-pin Ethernet port
channel 0*25-pin D-shell serial port; supports standard
EIA RS-232C and RS-423 and 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 controller programming:
DF1 point-to-point
2400 bps
no parity
one stop-bit
BCC error check
no handshaking
PLC-5/20E Controller Front Pa ne l
1
battery indicator (red when the battery is low)
controller RUN/FAULT indicator (green when
running; red when faulted)
force indicator (amber when I/O forces
are enabled)
channel 0 communication status indicator
(green when the channel is communicating)
channel 2, Ethernet transmit indicator
(green when the channel is communicating)
Install memory module here
Install battery here
channel 1A status indicator
(lights green and red)
8-pin mini-DIN, DH+ programming terminal
connection parallel to channel 1A
channel 1A communication port; its default
configuration is DH+ communication
1
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
2
Configure these 3-pin ports for:
remote I/O scanner
remote I/O adapter
DH+ communication
unused
Configure this 3-pin port for:
3
remote I/O adapter
DH+ communication
3
PLC-5/20E
Programmable
Controller
channel 1B status indicator
(lights green and red)
channel 1B communication port;
its default configuration is remote I/O scanner
PLC-5 family member designation
2
Publication 1785-UM012D-EN-P - July 2005
external transceiver fuse
keyswitch; selects controller mode
channel 2 Ethernet status indicator (green when
functioning normally; red when not functioning)
PLC-5/40E and -5/80E Con troller Front Panels
Understanding Your Programmable Controller 1-7
battery indicator (red when the battery is low)
controller RUN/FAULT indicator (green when
running; red when faulted)
force indicator (amber when I/O forces
are enabled)
channel 0 communication status indicator
(green when the channel is communicating)
channel 2, Ethernet transmit indicator (green when
the channel is communicating)
channel 2 communication port;
a 15-pin Ethernet port
channel 1A status indicator
(lights green and red)
8-pin mini-DIN, DH+ programming terminal
connection parallel to channel 1A
channel 1A communication port; its default
configuration is DH+ communication
2
channel 1B communication port; its default
configuration is remote I/O scanner
2
Install battery here
PLC-5/40E
Programmable
Controller
Channel 0 is optically-coupled (provides high electrical noise immunity) and can be used with most RS-422A
1
equipment as long as:
termination resistors are not used
the distance and transmission rate are reduced to comply with RS-423 requirements
2
Configure these 3-pin ports for:
remote I/O scanner
remote I/O adapter
DH+ communication
unused
channel 0-25-pin D-shell serial port; supports standard
EIA RS-232C and RS-423 and 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 controller programming:
DF1 point-to-point
2400 bps
no parity
one stop-bit
BCC error check
no handshaking
channel 1B status indicator (lights green and red)
Install memory module here
Use these labels to write information about the
channel: communication mode, station addresses etc.
PLC-5 family member designation
1
Publication 1785-UM012D - EN-P - July 2005
1-8 Understanding Your Programmable Controller
PLC-5/40L and -5/6 0L Controller Front Panels
battery indicator (red when the battery is low)
controller RUN/FAULT indicator (green when
running; red when faulted)
force indicator (amber when I/O forces
are enabled)
keyswitch; selects controller mode
channel 2 extended-local I/O status indicator
(green when functioning normally; red when
not functioning)
channel 2 communication port; a 50-pin,
dedicated extended-local I/O port
channel 1A status indicator
(lights green and red)
8-pin mini-DIN, DH+ programming terminal
connection parallel to channel 1A
channel 1A communication port; its default
2
configuration is DH+ communication
channel 1B communication port; its default
configuration is remote I/O scanner
2
channel 0 communication status indicator
(green when the channel is communicating)
channel 0*25-pin D-shell serial port; supports standard
EIA RS-232C and RS-423 and 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 controler programming:
DF1 point-to-point
2400 bps
no parity
one stop-bit
BCC error check
no handshaking
channel 1B status indicator (lights green and red)
Install memory module here
Use these labels to write information about the
channel: communication mode, station addresses etc.
1
Install battery here
1
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
Configure these 3-pin ports for:
2
remote I/O scanner,
remote I/O adapter,
DH+ communication
unused
Publication 1785-UM012D-EN-P - July 2005
PLC-5 family member designation
Understanding Your Programmable Controller 1-9
Use the keyswitch to change the mode in which a controller is operating.
If You Want to Turn the Keyswitch to
• Run your program.
Outputs are enabled. (Equipment being controlled by the I/O
addressed in the ladder program begins operation.)
• Force I/O.
• Save your programs to a disk drive (during operation).
• Enable outputs.
• Edit data table values.
Notes:
• You cannot create or delete a program file, create or delete
data files, edit online, or change the modes of operation
through the programming software while in run mode.
• You can prevent forcing and data table changes by
usingRSLogix5 programming software to set user control bit
S:26/6.
• Disable outputs (outputs are turned off).
• Create, modify, and delete ladder files, SFC files, or data
files.
• Download to/from a memory module.
• Save/restore programs.
Notes:
• The controller does not scan the program.
• You cannot change the mode of operation through the
programming software while in program mode.
Change between remote program, remote test, and remote run
modes through the programming software.
RUN
PROG
R
E
M
RUN
PROG (program)
PROG
R
E
M
RUN
REM (remote)
Remote run
• Enable outputs.
• Save/restore programs.
• Edit while operating.
Remote program
See the program-mode description above.
Remote test
• Execute ladder programs with outputs disabled.
• Cannot create or delete ladder programs or data files.
• Save/restore programs.
• Edit while operating.
PROG
R
E
M
RUN
Publication 1785-UM012D - EN-P - July 2005
1-10 Understanding Your Programmable Controller
Programming Features
This Capability Lets You
Ladder logic program using a language that is representative of relay logic.
Subroutines store recurring sections of program logic that can be accessed from multiple program
Sequential Function Charts
(SFCs)
This table highlights the programming features of a PLC-5 programmable
controller.
Choose this language
• if you are more familiar with ladder logic than with programming languages such
as BASIC
Your plant personnel may be more familiar with ladder logic; consider their needs
as well.
• performing diagnostics
• programming discrete control
files.
A subroutine saves memory because you program repetitive logic only once. The JSR
instruction directs the controller to go to a separate subroutine file within the logic
controller , scan that subroutine file once, and return to the point of departure.
use sequence-control language to control and display the state of a sequential process.
Instead of using 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 via a flowchart form.
SFCs offer constructs that enable execution of multiple paths of logic, or a single
selected path of logic, as well as the ability to jump forwards and backwards.
Troubleshooting can be reduced to a small routine of logic instead of an entire ladder
file.
SFCs are best for defining the order of events in a sequential process.
Structured text program using a language similar to BASIC.
Choose structured text if you are:
• more familiar with programming languages such as BASIC than with ladder logic
• using complex mathematical algorithms
• using program constructs that repeat or “loop”
• creating custom data-table monitoring screens
Main Control Programs
(MCPs)
separate sequential logic from ladder logic and structured text as a way of modularized
your process and making troubleshooting easier.
Use several main control programs (MCPs) to define one main control program for each
particular machine or function of your process. MCPs accommodate independent or
non-sequential activities.
A main control program can be an SFC file numbered 1-999 or a ladder-logic file or
structured-text program numbered 2-999.
One data table is used by all MCPs (i.e., you do not have a separate data table for each
MCP).
Publication 1785-UM012D-EN-P - July 2005
Understanding Your Programmable Controll er 1-11
Using a Controller Channel
Configure a remote I/O channel for scanner mode to read and write I/O
information between a controller and an I/O device remotely located from the
as a Remote I/O Scanner
A controller with a channel configured for scanner mode
acts as a supervisory controller for other controllers that
are in adapter mode as well as remote I/O adapter modules.
The scanner-mode PLC-5 controller can:
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
controller.
PLC-5/40
1771-ASB
Remote I/O
Link Cable:
Belden 9463
PLC-5/20
The scanner-mode PLC-5 controller:
transfers discrete data and block-transfer data
to/from modules in remote I/O racks as well as
to/from controllers in adapter mode.
scans remote I/O buffers asynchronously to the
program scan.
updates the input/output image data table from
the remote I/O buffer(s) synchronously to the
program scan
PLC-5 data table
is updated
synchronously to
program scan
(at housekeeping).
Remote I/O buffers
are updated
asynchronously to
the program scan.
PLC-5
Data Table
Output
Remote I/O
Buffer
Output Input
Input
Remote I/O
Link
Controller
-resident
I/O
Publication 1785-UM012D - EN-P - July 2005
1-12 Understanding Your Programmable Controller
A controller transfers I/O data and status data using:
Using a Controller Channel as a Remote I/O Adapter
In this example, a PLC-5/40 controller channel is
the supervisory (scanner-mode) controller of the
1771-ASB module and the PLC-5/20 controller.
• discrete
data transfers of 8 words per rack
transfers
occur automatically on the remote I/O network
• block-transfers special data transfers that require ladder logic
instructions to achieve the transfer
allow a transfer of a maximum of 64 words of data
also used to communicate information between a
scanner channel and an adapter-mode controller
channel
Configure a controller channel for adapter mode when you need predictable,
real-time exchange of data between a distributed control adapter-mode
controller channel and a supervisory controller. The remote I/O adapter
channel exchanges data with a supervisory controller.
PLC-5/40
Connect the controllers via the remote I/O link.
You can monitor status between the
supervisory controller and the adapter-mode
PLC-5 controller channel 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).
The adapter-mode PLC-5 controller can monitor
and control its controller-resident local I/O while
communicating with the supervisory controller via
a remote I/O link.
1771-ASB
Remote I/O
Link Cable:
Belden 9463
PLC-5/20
Publication 1785-UM012D-EN-P - July 2005
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