Main
Important User Information
Summary of Changes
Summary of Changes
Changes to this Manual
Find the New Information
Additional Ethernet PLC-5 Controller Enhancement
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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
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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
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Appendix C Maximizing System Performance
Appendix D Instruction Set Quick Reference
Appendix E Switch Setting Reference
Appendix F Troubleshooting
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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
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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
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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
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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)
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Addressing File Types
The following two tables show the available file types and the amount of memory used by each.
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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
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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
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Specify the Scan List
A scan list includes the following:
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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
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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
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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
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Specify the Discrete Transfer Configuration Files
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Communicating with a PLC-5 Adapter Channel 7-7
Discrete Data and Block-Transfer Status .
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Programming Discrete Transfers in Adapter Mode
Programming Block-Transfers of Data to an Adapter Channel
Configure Block-Transfer Requests
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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
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Monitoring the Status of the Adapter Channel
Monitoring the Status of the Supervisory Controller
Monitoring Remote I/O Adapter Channels
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Communicating with Extended-Local I/O
Selecting Devices That You Can Connect
Cabling
Addressing and Placing I/O
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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
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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.
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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
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Using the Global Status Flag File
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Monitoring DH+ Communication Channels
Monitoring messages
Monitoring Data Sent with Acknowledgment
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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
+++++++
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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
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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
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Configure Channel 0 as a Slave Station
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Configure Channel 0 as a Master Station
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Configure Channel 0 for User Mode (ASCII Protocol)
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Configure Channel 0 for a Communication Mode Change
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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
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Using BOOTP to Enter Configuration Information
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Editing the BOOTPTAB Configuration File
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Using Advanced Ethernet Functions
Using Broadcast Addressing
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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
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Details of each counter on the General Ethernet Counters page are described in the following table.
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Generating User Provided Web Pages
HTML Pages
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Generating Custom Data Table Monitor Pages
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Importing User Page Files to the PLC-5 Controller
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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.
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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
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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
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Programming Considerations
Forcing
Forcing Inputs and Outputs
Forcing SFC Transitions
Extended Forcing
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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
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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
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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
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Preparing Power-Up Routines
Setting Power-Up Protection
Allowing or Inhibiting Startup
Defining a Controller Power-Up Procedure
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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
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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
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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.
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Monitoring MCPs
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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
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Battery Specifications
Memory Backup Devices
EEPROM Compatibility
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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.
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S:3-10
S:11
S:12
This word stores the following fault codes:
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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
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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
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Compute Instructions
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Logical Instructions
Conversion Instructions
Bit Modify and Move Instructions
File Instructions
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Diagnostic Instructions
Shift Register Instructions
Sequencer Instructions
Program Control Instructions
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Process Control, Message Instructions
Block Transfer Instructions
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ASCII Instructions
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Bit and Word Instructions
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File, Program Control, and ASCII Instructions
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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
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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
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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
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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:
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Index
Numerics
A
B
C
D
E
F
G
H
I
K
L
M
N
O
P
R
S
T
U
W
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How Are We Doing?
Other Comments
BUSINESS REPLY MAIL
FIRST-CLASS MAIL PERMIT NO. 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE
1 ALLEN-BRADLEY DR MAYFIELD HEIGHTS OH 44124-9705
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