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Allen-Bradley PLC-5 User Manual
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Publicatio
n 1785
-UM012D
-EN-P -
July
2005
G-8
Cable Re
ference
Cable - 1784-CP11
Controller t
o Workstation
Using a Serial P
ort
Cable - 1784-PCM5
Controller t
o Work
station (using a 1784-PCMK
)
1
13
14
25
1
13
14
25
1
13
14
25
25-pin D-Shell
Workstation
Female
25-pin D-Shell
Controller
Male
3.2m
(10 ft
)
TXD
GND
RXD
RTS
CTS
DSR
DCD
DTS
RTS
CTS
DSR
DCD
DTR
2
7
3
4
5
6
8
20
3
7
2
4
6
8
20
5
19871
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
12
11
Controller DH+
9-pin
Workstation
1
5
7
1
2
124.25 in
3
SHELL
SHIELD
DRAIN
LINE 2 CLR
LINE 1 CLR
CLR
BLUE
DRAIN
SHIELD
SHELL
DTD
SY
DRD
RET
EN
TD
RET
RIO
DTR
SY
RTS
CTS
SHELL
SHELL
SHELL
SHELL
BLACK
WHITE
RED
GREEN
BROWN
BLUE
ORANGE
YELLOW
PURPLE
GRAY
PINK
TAN
DRAIN
SHIELD
19872
6
9
1
5
367
369
Table of Contents
Default Chapter
3
Summary of Changes
3
Table of Contents
5
Purpose of this Manual
15
Related PLC-5 Documentation
15
Terms Used in this Manual
16
Manual Overview
17
Chapter 1
19
Using this Chapter
19
Lay out the System
19
Identifying Controller Components
20
PLC-5/11, -5/20, and -5/26 Controller Front Panels
21
Controller Front Panel
22
PLC-5/20E Controller Front Panel
24
PLC-5/40E and -5/80E Controller Front Panels
25
PLC-5/40L and -5/60L Controller Front Panels
26
Programming Features
28
Using a Controller Channel as a Remote I/O Scanner
29
Appendix C Program Scan
29
Using a Controller Channel as a Remote I/O Adapter
30
Using a PLC-5/40L, -5/60L Programmable Controller as an Extended-Local I/O Scanner
32
Chapter 2 Using this Chapter
33
Selecting I/O Modules
33
Guidelines for Selecting I/O Modules
34
Selecting I/O Module Density
34
Placing I/O Modules in a Chassis
35
Using this Chapter
37
Chapter 3
37
Determining the Proper Environment
37
Protecting Your Controller
39
Preventing Electrostatic Discharge
39
Laying out Your Cable Raceway
40
Categorize Conductors
40
Route Conductors
40
Laying out Your Backpanel Spacing
41
Chassis Dimensions (Series B)
41
I/O Chassis and External Power Supply Dimensions
42
Grounding Your System
42
Using this Chapter
45
Chapter 4
45
I/O Addressing Concept
45
Choosing an Addressing Mode
47
Addressing Block-Transfer Modules
51
Addressing Summary
51
Assigning Racks
52
Understanding PLC-5 Controller Memory
54
Understanding Data Storage (Data-Table Files)
55
Addressing File Types
57
Understanding Program-File Storage
59
Addressing
60
Specifying I/O Image Addresses
60
Specifying Logical Addresses
61
Specifying Indirect Addresses
62
Specifying Indexed Addresses
64
Specifying Symbolic Addresses
65
And Controller Memory
66
Effectively Using I/O Memory
68
Chapter 5
69
Using this Chapter
69
Introduction to PLC-5 Controller Scanning
69
Program Scanning
70
Transferring Data to Controller-Resident I/O
71
Transferring Discrete Data to Controller-Resident I/O
71
Transferring Immediate I/O Requests
71
Transferring Block-Transfer Data to Controller-Resident I/O
72
Configuring the System for Controller-Resident I/O
72
Using this Chapter
73
Chapter 6
74
Selecting Devices that You Can Connect
74
Introduction to Remote I/O
75
Designing a Remote I/O Link
76
Configuring a Controller Channel as a Scanner
78
Define an I/O Status File
79
Specify Channel Configuration Information
79
Specify the Scan List
81
Communicating to a Remote I/O Node Adapter
83
Troubleshooting Remote I/O Communication Difficulties
84
Transferring Block Data
85
Block-Transfers of Remote I/O Data
87
Block-Transfer Sequence with Status Bits
89
Block-Transfer Programming Considerations
91
General Considerations
91
For Controller-Resident Local Racks
92
Monitoring Remote I/O Scanner Channels
93
Monitoring Transmission Retries
93
Addressing the I/O Status File
96
Chapter 7 Using this Chapter
99
Configuring Communication to a PLC-5 Adapter Channel
99
Adapter Channel Configuring Communication to a PLC-5 Adapter Channel
100
Address, and Rack Size
101
Specify an Adapter Channel's Communication Rate
101
Specify the Discrete Transfer Configuration Files
103
Programming Discrete Transfers in Adapter Mode
108
Programming Block-Transfers of Data to an Adapter Channel
108
Configure Block-Transfer Requests
109
Examples of Block-Transfer Ladder Logic
112
Effects of Programming Block-Transfers to an Adapter-Mode
113
Controller Channel on Discrete Data Transfer
113
Monitoring the Status of the Adapter Channel
115
Monitoring the Status of the Supervisory Controller
116
Monitoring Remote I/O Adapter Channels
117
Chapter 8 Using this Chapter
119
Selecting Devices that You Can Connect
119
Cabling
120
Addressing and Placing I/O
120
Transferring Data
122
Discrete Data Transfer
123
Transferring Block Data
124
Calculating Block-Transfer Completion Time
125
Considerations for Extended-Local Racks
126
Configuring the Controller as an Extended-Local I/O Scanner
127
Monitoring Extended-Local I/O Status
130
Chapter 9 Using this Chapter
133
Selecting Devices that You Can Connect
133
Link Design
134
Configuring the Channel for DH+ Communication
135
Using the Global Status Flag File
137
Monitoring DH+ Communication Channels
139
Monitoring Data Sent with Acknowledgment
140
Monitoring Data Sent Without Acknowledgment
142
Monitoring General Status
143
Estimating DH+ Link Performance
144
Nodes
145
Size and Number of Messages
145
Message Destination
146
Internal Processing Time
147
Average DH+ Link Response Time Test Results
148
Application Guidelines
149
Using this Chapter
151
Chapter 10
152
Configuring the Controller
152
Serial Port
152
Using Channel 0
152
User Mode
152
System Mode
152
Master Station to Remote Station Communication Methods
154
Polling Inactive Priority Stations
155
Changing Modes
155
Cabling
155
Configuring Channel 0
156
Configure Channel 0 for DF1 Point-To-Point
156
Configure Channel 0 as a Slave Station
159
Configure Channel 0 as a Master Station
162
Configure Channel 0 for User Mode (ASCII Protocol)
168
Configure Channel 0 for a Communication Mode Change
171
Monitoring Channel 0 Status
172
Using the System Mode Status Display
172
Using the User Mode (ASCII) Status Display
174
Using this Chapter
175
Chapter 11
175
Media and Cabling
175
Assigning Your IP Address
176
Network Addressing
176
Configuring Channel 2 for Ethernet Communication
176
Manually Configuring Channel 2
176
Using BOOTP to Enter Configuration Information
179
Editing the BOOTPTAB Configuration File
181
Using Advanced Ethernet Functions
183
Using Broadcast Addressing
183
Using Subnet Masks and Gateways
185
Manually Configuring Channel 2 for Controllers on Subnets
186
For Controllers on Subnets
187
Using Domain Name Service
189
Using the Embedded Web Server
190
Generating User Provided Web Pages
196
Importing User Page Files to the PLC-5 Controller
200
Using Multihop Messaging
203
Multihop Examples
204
Over Ethernet
206
Communicating with Controllogix Devices
206
Tcp/Ip
206
Interpreting Error Codes
207
Interpreting Ethernet Status Data
208
Monitoring General Ethernet Status
209
Monitoring Ethernet Commands
210
Monitoring Ethernet Replies
210
Ethernet PLC-5 Performance Considerations
211
Performance: Host to Ethernet PLC-5 Controller
211
Performance: Ethernet PLC-5 Controller to Ethernet
212
PLC-5 Controller
212
Using this Chapter
213
Chapter 12
214
About Passwords and Privileges
214
Defining Privilege Classes
215
Assigning a Privilege Class to a Channel or Offline File
216
Assigning a Privilege Class to a Node
216
Assigning Read/Write Privileges to a Program File
217
Assigning Read/Write Privileges to a Data File
217
Chapter 13
219
Using this Chapter
219
Forcing
219
Forcing Inputs and Outputs
219
Forcing SFC Transitions
220
Extended Forcing
220
Increased Program Scan Time
222
I/O Force Privileges
222
Using Protected Controllers
223
Using Selectable Timed Interrupts (Stis) and Controller Input Interrupts (Piis)
223
Setting up and Using Extended Forcing
223
Step 1 - Select Which Group of Data You Want to Force
224
Step 2 - Use the Programming Software to Enter or Edit the Data You Want to Force in the Extended Force Configuration Table
225
Step 3 - Use the Programming Software to Enter Force Values for the Specified Data Table Files
226
Step 4 - Enable or Disable the Forces
226
Using Extended Forcing with Time-Critical Applications
226
Using Special Programming Routines
228
Priority Scheduling for Interrupts and Mcps
229
Program Execution States
230
Influencing Priority Scheduling
232
Defining and Programming Interrupt Routines
233
Programming Considerations
219
Chapter 14
235
Using this Chapter
235
Setting Power-Up Protection
235
Allowing or Inhibiting Startup
236
Defining a Controller Power-Up Procedure
236
Using this Chapter
239
Preparing Power-Up Routines
235
Chapter 15 Understanding the Fault Routine Concept
239
Responses to a Major Fault
239
Understanding Controller-Detected Major Faults
240
Fault in a Controller-Resident or Extended-Local I/O Rack
241
Fault in a Remote I/O Chassis
241
Defining a Fault Routine
242
Defining a Watchdog Timer
243
Avoiding Multiple Watchdog Faults
244
Programming a Fault Routine
244
Setting an Alarm
245
Clearing a Major Fault
245
Changing the Fault Routine from Ladder Logic
247
Using Ladder Logic to Recover from a Fault
248
Block-Transfers in Fault Routines
249
Testing a Fault Routine
249
Monitoring Faults
249
Monitoring Major/Minor Faults and Fault Codes
250
Interpreting Major Faults
250
Interpreting Minor Faults
250
Monitoring Status Bits
251
Using this Chapter
253
Chapter 16
253
Selecting Main Control Programs
253
Understanding How the Controller Interprets Mcps
254
Configuring Mcps
255
Monitoring Mcps
257
Using this Chapter
259
Chapter 17 Using a Selectable Timed Interrupt
259
Writing STI Ladder Logic
259
STI Application Example
260
Block-Transfers in Selectable Timed Interrupts (Stis)
260
Defining a Selectable Timed Interrupt
261
Monitoring Selectable Timed Interrupts
262
Using this Chapter
263
Chapter 18 Using a Processor Input Interrupt
263
Writing PII Ladder Logic
264
PII Application Examples
264
Block-Transfers in Processor Input Interrupts (Piis)
265
Design Considerations
266
Defining a Controller Input Interrupt
267
Monitoring Controller Input Interrupts
268
Appendix A
269
Controller Specifications
269
Memory and Channel Specifications
270
Memory Backup Devices
272
EEPROM Compatibility
272
Appendix B
277
S:3-10
277
S:11
278
S:12
279
S:13-S:24
283
S:26-S:35
284
S:36-S:78
285
S:79-S:127
286
Effects of False Logic Versus True Logic on Logic Scan Time
288
Effects of Different Input States on Logic Scan Time
288
Effects of Different Instructions on Logic Scan Time
289
Effects of Using Interrupts on Logic Scan Time
289
Effects of Housekeeping Time
290
Editing While in Remote Run Mode
290
Using Global Status Flag Files
291
Calculating Throughput
291
I/O Backplane Transfer
291
Input and Output Modules Delay
291
Remote I/O Scan Time
291
Communication Rate
293
Number of Rack Entries
293
Block-Transfers
293
Calculating Worst-Case Remote I/O Scan Time
295
Optimizing Remote I/O Scan Time
295
Controller Time
297
Example Calculation
298
Performance Effects of Online Operations
298
Effect of Inserting Ladder Rungs at the 56K-Word Limit
299
Using Program Control Instructions
300
Using JMP/LBL Instructions
300
Using FOR/NXT Instructions
300
Appendix D
301
Compare Instructions
301
Compute Instructions
301
Counter Instructions
301
Relay Instructions
301
Timer Instructions
301
Relay Instructions
302
Counter Instructions
304
Compare Instructions
305
Compute Instructions
307
Logical Instructions
314
Conversion Instructions
315
Bit Modify and Move Instructions
316
File Instructions
317
Diagnostic Instructions
319
Shift Register Instructions
320
Sequencer Instructions
321
Program Control Instructions
322
Block Transfer Instructions
325
Process Control, Message Instructions
325
Publication 1785-UM012D-EN-P - July
325
ASCII Instructions
327
Bit and Word Instructions
330
File, Program Control, and ASCII Instructions
332
Appendix E Controller Switches
340
Switch 1
340
Switch 2
340
I/O Chassis Backplane
342
PLC-5 Controller in the I/O Chassis
342
Extended-Local I/O Adapter
343
I/O Chassis Configuration Plug
344
ASB Series C and D) Without Complementary I/O
345
Remote I/O Adapter Module
345
Extended-Local I/O Adapter Module
347
ALX) Configuration Plug
348
Appendix F PLC-5 Controller
349
Troubleshooting
349
General Problems
350
Controller Communication Channel Troubleshooting
352
Extended-Local I/O Troubleshooting
353
Ethernet Status Indicator
353
Ethernet Transmit LED
354
Remote I/O System
354
Adapter Module
354
Adapter Module (Continued)
356
Extended-Local I/O System
357
Troubleshooting Guide for the 1771-ALX Adapter Module
357
Unexpected Operation When Entering Run Mode
358
Instructions with Unique Prescan Operations
358
Suggested Action
359
Publication 1785-UM012D-EN-P - July
359
Appendix G
361
Channel 0 Pin Assignments
361
Connecting Diagrams
361
Programming Cable Specifications
361
Serial Cable Pin Assignments
361
Using this Chapter
361
Connecting Diagrams
363
Programming Cable
365
Specifications
365
Ethernet Cable Connections
369
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Allen-Bradley PLC-5 Specifications
General
Brand
Allen-Bradley
Model
PLC-5
Category
Controller
Language
English
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