Bradley Smoker PLC-5 - page 360

Publication 1785-UM012D-EN-P - July 2005

F-12 Troubleshooting

Notes

Contents

Main Important User Information Summary of Changes Summary of Changes Changes to this Manual Find the New Information Additional Ethernet PLC-5 Controller Enhancement Page Table of Contents Chapter 4 Addressing I/O and Controller Memory Chapter 5 Communicating with Controller-Resident I/O Chapter 6 Communicating with Remote I/O Page Chapter 10 Communicating with Devices on a Serial Link Chapter 11 Communicating with Devices on an Ethernet Network Chapter 12 Protecting Your Programs Chapter 13 Programming Considerations Chapter 14 Preparing Power-Up Routines Chapter 15 Preparing Fault Routines Page Appendix C Maximizing System Performance Appendix D Instruction Set Quick Reference Appendix E Switch Setting Reference Appendix F Troubleshooting Page Preface Using This Manual Purpose of This Manual Related PLC-5 Documentation Terms Used in This Manual Become familiar with the following terms and definitions which are used throughout this manual. Manual Overview This manual has three main sections: Design Operate Maintain Page Understanding Your Programmable Controller Lay Out the System Identifying Controller Components Understanding Your Programmable Controller 1-3 PLC-5/11, -5/20, and -5/26 Controller Front Panels PLC-5/11 Controller PLC-5/20 or -5/26 Controller 1-4 Understanding Your Programmable Controller PLC-5/30 Controller Front Panel Understanding Your Programmable Controller 1-5 PLC-5/40, -5/46, -5/60, -5/80, and -5/86 Controller Front Panel 1-6 Understanding Your Programmable Controller PLC-5/20E Controller Front Panel Understanding Your Programmable Controller 1-7 PLC-5/40E and -5/80E Controller Front Panels 1-8 Understanding Your Programmable Controller PLC-5/40L and -5/60L Controller Front Panels Use the keyswitch to change the mode in which a controller isop era ting. Programming Features This table highlights the programming features of a PLC-5 programmable controller. Understanding Your Programmable Controller 1-11 Using a Controller Channel as a Remote I/O Scanner A controller transfers I/O data and status data using: Using a Controller Channel as a Remote I/O Adapter Understanding Your Programmable Controller 1-13 1-14 Understanding Your Programmable Controller Using a PLC-5/40L, -5/60L Programmable Controller as an Extended-Local I/O Scanner Selecting and Placing I/O Selecting I/O Modules Selecting I/O Module Density Selecting and Placing I/O 2-3 Placing I/O Modules in a Chassis Page Placing System Hardware Determining the Proper Environment 3-2 Placing System Hardware Protecting Your Controller Preventing Electrostatic Discharge Laying Out Your Cable Raceway Categorize Conductors Route Conductors Placing System Hardware 3-5 Laying Out Your Backpanel Spacing Use 6.35 mm (0.25 inch) mounting bolts to attach the I/O chassis to the enclosure backpanel. Side Chassis Dimensions (Series B) 3-6 Placing System Hardware Grounding Your System I/O Chassis and External Power Sup ply Dimensions Recommended Grounding Configuration for Remote I/O Systems Required Grounding Configuration for Extended-Local I/O Systems Page Addressing I/O and Controller Memory I/O Addressing Concept 4-2 Addressing I/O and Controller Memory I/O Addressing as It Relates to an I/O Terminal | | ( ) I:014/12 Addressing I/O and Controller Memory 4-3 Choosing an Addressing Mode 4-4 Addressing I/O and Controller Memory 18-and 16-point Example Termi nals 0 1 2 3 4 5 6 7 Addressing I/O and Controller Memory 4-5 32-point Example 0 1 4-6 Addressing I/O and Controller Memory Example of Efficient I/O Image Table Use. Addressing Block-Transfer Modules Use this table as a quick reference for addressing. Addressing Summary Assigning Racks The number of racks in a chassis depends on the chassis size and the addressing mode: TIP TIP When assigning remote I/O rack numbers, use these guidelines: Understanding PLC-5 Controller Memory Controller memory is divided into two basic areas: Understanding Data Storage (Data-Table Files) Page Addressing File Types The following two tables show the available file types and the amount of memory used by each. Page Understanding Program-File Storage Addressing Valid formats for addressing data files are: For more information about entering addresses, see the documentation for your programming software. Specifying I/O Image Addresses The I/O image address corresponds to the physical location of the I/O circuit in the I/O chassis: Specifying Logical Addresses Specifying Indirect Addresses Page Specifying Indexed Addresses Specifying Symbolic Addresses 4-22 Addressing I/O and Controller Memory Optimizing Instruction Execution Time and Controller Memory Addressing I/O and Controller Memory 4-23 The following examples illustrate these concepts: Effectively Using I/O Memory Communicating with Controller-Resident I/O Introduction to PLC-5 Controller Scanning a. b. c. Program Scanning Transferring Data to Controller-Resident I/O Transferring Discrete Data to Controller-Resident I/O Transferring Immediate I/O Requests Transferring Block-Transfer Data to Controller-Resident I/O Configuring the System for Controller-Resident I/O Communicating with Remote I/O Selecting Devices That You Can Connect The following table lists some of the devices you can use on a remote I/O link: Communicating with Remote I/O 6-3 Introduction to Remote I/O Designing a Remote I/O Link Link Design Guidelines Cable Design Guidelines Configuring a Controller Channel as a Scanner Define an I/O Status File Specify Channel Configuration Information Page Specify the Scan List A scan list includes the following: Page Communicating with Remote I/O 6-11 Communicating to a Remote I/O Node Adapter Remote I/O Scan and Program Scan Loops. IMPORTANT The remote I/O scan for each channel configured for scanner mode is independent and asynchronous to the remote I/O scan for any other channel Appendix E 3.Connect the remote I/O cable. your controller installation instructions Troubleshooting Remote I/O Communication Difficulties Publication 1785-UM012D-EN-P - July 2005 Communicating with Remote I/O 6-13 Transferring Block Data Remote I/O Page Block-Transfers of Remote I/O Data 6-16 Communicating with Remote I/O The figure below shows the remote I/O block-transfer sequence. IMPORTANT If you split remote rack addresses between scanner ][ () ][ Communicating with Remote I/O 6-17 Block-Transfer Sequence with Status Bits The following figure describes the different states of the block-transfer status bits. 6-18 Communicating with Remote I/O Block-Transfer Programming Considerations General Considerations For Controller-Resident Local Racks Monitoring Remote I/O Scanner Channels Monitoring transmission retries Page Monitoring messages Addressing the I/O Status File Bit Layout Diagrams for the First Word Allotted to a Remote I/O Rack or an Extended-Local I/O Rack Bit Layout Diagrams for the Second Word Allotted to a Remote I/O Rack or an Extended Local I/O Rack Communicating with a PLC-5 Adapter Channel 7-2 Communicating with a PLC-5 Adapter Channel Configuring Communication to a PLC-5 Adapter Channel Specify an Adapter Channels Communication Rate, Address, and Rack Size Page Specify the Discrete Transfer Configuration Files Page Communicating with a PLC-5 Adapter Channel 7-7 Discrete Data and Block-Transfer Status . Page Page Programming Discrete Transfers in Adapter Mode Programming Block-Transfers of Data to an Adapter Channel Configure Block-Transfer Requests Page Communicating with a PLC-5 Adapter Channel 7-13 IMPORTANT Adapter-mode block-transfer reads and block-transfer writes in the same group/module location must have the same length. 7-14 Communicating with a PLC-5 Adapter Channel Examples of Block-Transfer Ladder Logic Example Bidirectional Repeating Block Transfer in PLC-5 Supervisory Controller Communicating with a PLC-5 Adapter Channel 7-15 Example Bidirectional Repeating Block Transfer in PLC-5/250 Supervisory Controller Page Monitoring the Status of the Adapter Channel Monitoring the Status of the Supervisory Controller Monitoring Remote I/O Adapter Channels Page Communicating with Extended-Local I/O Selecting Devices That You Can Connect Cabling Addressing and Placing I/O Page Transferring Data Communicating with Extended-Local I/O 8-5 Discrete Data Transfer PLC-5/40L and -5/60L Extended-Local I/O Scan Time Remote I/O Scan Transferring Block Data Calculating Block-Transfer Completion Time Considerations for Extended-local Racks Configuring the Controller as an Extended-Local I/O Scanner Page Page Use the following table for information about creating/modifying your scan list: Monitoring Extended-Local I/O Status inhibit bits in the controller status file. Page Communicating with Devices on a DH+ Link Link Design For daisy chain configurations, use this table to determine the total cable length you can use. Configuring the Channel for DH+ Communication Page Using the Global Status Flag File Page Monitoring DH+ Communication Channels Monitoring messages Monitoring Data Sent with Acknowledgment Page Page Monitoring General Status Estimating DH+ Link Performance Nodes Size and Number of Messages 9-14 Communicating with Devices on a DH+Link Message Destination Internal Processing Time Average DH+ Link Response Time Test Results +++++++ Application Guidelines +++++++ Page Communicating with Devices on a Serial Link Choosing Between RS-232C, RS-422A, and RS-423 Configuring the Controller Serial Port Using Channel 0 User Mode System Mode Page Master Station to Remote Station Communication Methods A PLC-5 master station can communicate with remote stations in twoways: Polling Inactive Priority Stations Cabling Changing Modes Configuring Channel 0 Configure Channel 0 for DF1 Point-to-Point Page Page Configure Channel 0 as a Slave Station Page Page Configure Channel 0 as a Master Station Page Page Page Page Page Configure Channel 0 for User Mode (ASCII Protocol) Page Page Configure Channel 0 for a Communication Mode Change Page System Mode (DF1 Master) Status Screen Descriptions of System Mode Status Screen Fields Using the User Mode (ASCII) Status Display Communicating with Devices on an Ethernet Network Media and Cabling Assigning Your IP Address Network Addressing Configuring Channel 2 for Ethernet Communication Manually Configuring Channel 2 Page Page Using BOOTP to Enter Configuration Information Page Editing the BOOTPTAB Configuration File Page Using Advanced Ethernet Functions Using Broadcast Addressing Page Using Subnet Masks and Gateways Manually Configuring Channel 2 for Controllers on Su bnets Communicating with Devices on an Ethernet Network 11-13 Using BOOTP to Configure Channel 2 for Controllers on Subnets IMPORTANT Because BOOTP requests are seen only on the local subnet, each subnet needs its own BOOTP server and BOOTPTAB file. The BOOTPTAB files that correspond to this example looks like: Using Domain Name Service Page Page Page Details of each counter on the General Ethernet Counters page are described in the following table. Page Page Generating User Provided Web Pages HTML Pages Page Generating Custom Data Table Monitor Pages Page Importing User Page Files to the PLC-5 Controller Page Page Using Multihop Messaging Multihop Examples The following examples use this system configuration: The following table shows the multihop path you enter to communicate over these scenarios. Page Comparing Multihop and Non-Multihop Messages Over Ethernet Communicating with ControlLogix Devices TCP/IP Interpreting Error Codes Interpreting Ethernet Status Data Monitoring general Ethernet status Page Page Page Protecting Your Programs About Passwords and Privileges Defining Privilege Classes Assigning a Privilege Class to a Channel or Offline File Assigning a Privilege Class to a Node Page Page Programming Considerations Forcing Forcing Inputs and Outputs Forcing SFC Transitions Extended Forcing Page Increased Program Scan Time I/O Force Privileges Using Protected Controllers Using Selectable Timed Interrupts (STIs) and Controller Input Interrupts (PIIs) Setting Up and Using Extended Forcing Step 1 - Select Which Group of Data You Want to Force Page Step 3 - Use the Programming Software to Enter Force Values for the Specified Data Table Files Step 4 - Enable or Disable the Forces Using Extended Forcing with Time-Critical Applications Page 13-10 Programming Considerations Using Special Programming Routines Deciding When to Use Special Routines Priority Scheduling for Interrupts and MCPs Program Execution States Programming Considerations 13-13 Influencing Priority Scheduling Page Page Preparing Power-Up Routines Setting Power-Up Protection Allowing or Inhibiting Startup Defining a Controller Power-Up Procedure Page Page Preparing Fault Routines Understanding the Fault Routine Concept Responses to a Major Fault Understanding Controller-Detected Major Faults Fault in a Controller-Resident or Extended-Local I/O Rack Fault in a Remote I/O Chassis Defining a Fault Routine Defining a Watchdog Timer Avoiding Multiple Watchdog Faults Programming a Fault Routine Setting an Alarm Clearing a Major Fault Page Changing the Fault Routine from Ladder Logic Using Ladder Logic to Recover from a Fault Block-Transfers in Fault Routines Monitoring Faults Testing a Fault Routine Monitoring Major/Minor Faults and Fault Codes Interpreting Minor Faults Interpreting Major Faults For a description of the major faults (S:11), see Appendix B. Monitoring Status Bits Page Using Main Control Programs Selecting Main Control Programs Understanding How the Controller Interprets MCPs Configuring MCPs You configure MCPs on the controller configuration screen in your programming software. Page Monitoring MCPs Page Using Selectable Timed Interrupts Using a Selectable Timed Interrupt Writing STI Ladder Logic STI Application Example Block-Transfers in Selectable Timed Interrupts (STIs) Defining a Selectable Timed Interrupt Monitoring Selectable Timed Interrupts Using Processor Input Interrupts Using a Processor Input Interrupt Writing PII Ladder Logic PII Application Examples Block-Transfers in Processor Input Interrupts (PIIs) Design Considerations Defining a Controller Input Interrupt To define a PII, use the controller configuration screen in your programming software. must toggle the mode to program, then back to run mode for the change to take effect. Monitoring Controller Input Interrupts Use the controller status screen in your programming software to monitor PIIs. A System Specifications Controller Specifications Memory and Channel Specifications Page Battery Specifications Memory Backup Devices EEPROM Compatibility Page Page B Processor Status File S:0 - S:2 Processor status data is stored in data file 2. description in this manual or the documentat i on for your programming software. Page S:3-10 S:11 S:12 This word stores the following fault codes: Page Page Page S:13-S:24 S:26-S:35 S:36-S:78 S:35) does not update inhibit bits in the I/O status file. S:79-S:127 C Maximizing System Performance Program Scan Effects of False Logic versus True Logic on Logic Scan Time Other instructions may have a greater or lesser effect. Effects of Different Input States on Logic Scan Time Effects of Different Instructions on Logic Scan Time Effects of Using Interrupts on Logic Scan Ti me Effects of Housekeeping Time Editing While in Remote Run Mode Putting Block-Transfer Modules in Controller-Resident Chassis Using Global Status Flag Files Calculating Throughput Input and Output Modules Delay I/O Backplane Transfer Remote I/O Scan Time Communication Rate Number of Rack Entries Block-Transfers Calculating Worst-Case Remote I/O Scan Time Optimizing Remote I/O Scan Time Page Maximizing System Performance C-11 Controller Time AdapterAdapter Adapter System Optimized for Block-Data Transfer Housekeeping Example Calculation Performance Effects of Online Operations Effect of Inserting Ladder Rungs at the 56K-word Limit Using Program Control Instructions Using JMP/LBL Instructions Using FOR/NXT Instructions D Instruction Set Quick Reference instructions, see the PLC-5 Programming Software Instruction Set Reference, publication 1785-6.1. Relay Instructions Timer Instructions Counter Instructions Compare Instructions Page Compute Instructions Page Page Page Page Page Page Logical Instructions Conversion Instructions Bit Modify and Move Instructions File Instructions Page Diagnostic Instructions Shift Register Instructions Sequencer Instructions Program Control Instructions Page Page Process Control, Message Instructions Block Transfer Instructions Page ASCII Instructions Page Page Bit and Word Instructions Page File, Program Control, and ASCII Instructions Page Page Page Page Page Page E Switch Setting Reference E-2 Switch Setting Reference Controller Switches Switch 1 toggle pushed down on toggle pushed up off Switch 2 E-4 Switch Setting Reference I/O Chassis Backplane PLC-5 Controller in the I/O Chassis Switch Setting Reference E-5 1771-ASB Remote I/O Adapter or 1771-ALX Extended-Local I/O Adapter I/O Chassis Configuration Plug Switch Setting Reference E-7 Remote I/O Adapter Module (1771-ASB Series C and D) without Complementary I/O First I/O Group Number: 7 8 0on on 2on off 4off on 6off off (1771-ASB Series C and D) I/O Rack Number - without Complementary I/O Extended-Local I/O Adapter Module (1771-ALX) Switch SW1 (1771-ALX) Configuration Plug F Troubleshooting PLC-5 Controller General Problems Page Controller Communication Channel Troubleshooting Extended-Local I/O Troubleshooting Ethernet Status Indicator Ethernet Transmit LED Remote I/O System Troubleshooting Guide for the 1771-ASB Series C and D Adapter Module Page Troubleshooting Guide for the 1771-ASB Series C and D Adapter Module (continued) Extended-Local I/O System Troubleshooting Guide for the 1771-ALX Adapter Module Unexpected Operation when Entering Run Mode Instructions with Unique Prescan Operations Suggested Action Page G Cable Reference Channel 0 Pin Assignments Pin RS-232C RS-422A RS-423 Pin RS-232C RS-422A RS-423 G-2 Cable Reference Serial Cable Pin Assignments Cable Reference G-3 Connecting Diagrams 9-Pin Serial Port Workstation G-4 Cable Reference 25-Pin Serial Port Workstation Programming Cable Specifications G-6 Cable Reference Cable - 1784-CP6 Connects Workstation Using 1784-KT, -KT/2, -KL, or -KL/B to Controller Cable Reference G-7 Cable - 1784-CP10 Connects Workstation to Controller Using Serial Port G-8 Cable Reference Cable - 1784-CP11 Controller to Workstation Using a Serial Port Cable - 1784-PCM5 Controller to Workstation (using a 1784-PCMK) Ethernet Cable Connections The table below describes Allen-Bradley transceivers: Page Index Numerics A B C D E F G H I K L M N O P R S T U W Page How Are We Doing? 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