Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication. Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley Company, Inc., is prohibited. Throughout this manual we use notes to make you aware of safety considerations:! ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss. Attention statements help you to: identify a hazard avoid the hazard recognize the consequences Identifies information that is critical for successful application and understanding of the product. ControlNet, DH+, and PLC-5/40 are trademarks; PLC and PLC-5 are registered trademarks of Allen-Bradley Company, Inc.
Table of Contents
Table of Contents
This getting started manual introduces installing and using an enhanced PLC-5 processor system. This manual shows you how to set up a system using a typical configuration. We do not cover all the enhanced PLC-5 processor features; we cover enough information to get you started. See the next page for a list of additional publications. You can also see the Allen-Bradley Publication Index, publication SD499, for a listing of all publications. The recommended switch settings in this manual help you set up a test system and get it working. Actual switch settings depend on your application. This manual uses these conventions: Pictures of keys and/or screens represent the actual keys you press or the screens you see. For example, in the procedure for online programming, you see: These symbols:,, represent steps that you perform.
P 2 Preface
The figure below helps you identify and understand the processor s front panel components.
1 2 Before You Begin! ATTENTION: Electrostatic discharge can damage integrated circuits or semiconductors in the processor module if you touch backplane connector pins. It can also damage the module when you set configuration plugs or switches inside the module. Avoid electrostatic damage by observing the following precautions. Remain in contact with an approved ground point while handling the module (by wearing a properly grounded wrist strap). Do not touch the backplane connector or connector pins. When you are ready to take the PLC-5 processor out of the box, remember to: keep the box upright remove the following things from the box:
Before You Begin 1 3 You need the following hardware and software. an enhanced PLC-5 processor a 1771 Universal I/O Chassis I/O modules a power supply (either an external power supply or a power supply module that fits within the I/O chassis) PLC-5 programming software (A.I. series) 1770-CD blue hose cable, Belden 9463 programming terminal, communication card, and cable This manual describes a PLC-5/40 processor in a 1771-A2B, 8-slot chassis. This QuickStart manual example requires the online version of A.I. Series PLC-5 programming software to program the PLC 5 via a PC-compatible 386/486/Pentium computer with a 1784-KT communication card and 1784-CP6 cable.
1 4 Before You Begin
In this chapter, make sure you have the following: I/O chassis PLC-5 processor I/O modules power supply programming terminal communication card programming terminal cable DH+ cable
2 2 Setting up the Processor System To configure the I/O chassis, do the following: Set the power supply configuration jumper on the chassis backplane.
Setting up the Processor System 2 3 Set the chassis switches on the backplane assembly by using a ball-point pen.! Do not use a pencil because the tip can break off and short the switch. ATTENTION: If you do not properly configure the backplane switch assembly, various system failures may occur.
2 4 Setting up the Processor System To install the processor, do the following: Define the DH+ station address of channel 1A to address 10 (octal) by setting switches 1 through 6 of switch assembly SW-1. Specify the serial port configuration for RS-232-C by setting switch assembly SW-2.
Setting up the Processor System 2 5 Insert the keying bands in the left-most slot between the following pins: 40 and 42 54 and 56 Insert the 1770-XYC processor battery. Insert the PLC-5 processor in the left-most slot of the I/O chassis and snap the module-locking bar over the processor.
2 6 Setting up the Processor System This manual shows a generic installation procedure for 1771 I/O modules; for details about specific I/O modules, see the installation instructions for those modules. To install the I/O modules: Make sure power to the I/O chassis is off. Set any jumpers and keying bands. Insert each I/O module into its corresponding keyed slot by sliding it onto the plastic tracks of the I/O chassis. Locate your installation instructions and do the following: a b c Snap the module-locking bar over the I/O module. Make wiring connections to the field wiring arm (or prewired terminal strip). Connect the wiring arm (or prewired terminal strip) to the module.
Setting up the Processor System 2 7 You can install either an external power supply (for example, 1771-P7) or a power supply module within the I/O chassis (for example, 1771-P4S). a b a b
2 8 Setting up the Processor System a b c c
Setting up the Processor System 2 9 To connect the programming terminal to the PLC-5 processor, do the following: Turn off the computer and disconnect the ac power cord. Remove all covers necessary to gain access to the computer s expansion slot area. The industrial terminals may have retainer brackets. See the computer s user manual for access procedures. Remove the expansion slot bracket that covers the computer I/O opening. Verify the configuration settings for your system (see Communication Interface Module installation instructions, publication 1784-2.31). If another card is already using the switch settings you chose for the 1784-KT communication card, change the card s switch settings to an unused memory location. The KT card uses a 16K memory range. This range should be excluded when you configure your system s memory manager. Page 3 2 gives an example of this exclusion. Make sure you record the 1784-KT communication card settings; you will need the memory address in the Configure the computer section in chapter 3.
2 10 Setting up the Processor System With a hand on each end of the card, slowly slide the 1784-KT communication card into the I/O expansion slot. Firmly insert the edge card connector into the I/O expansion slot connector. Place the retaining screw in the retaining bracket and tighten. Replace all brackets (if applicable) and covers removed in step 2. Connect the 1784-KT communication card to the PLC-5 processor by using the 1784-CP6 cable. NOTE: If your PLC has a 9-pin D-shell connector on the front rather than a mini-din connector, use the adapter that shipped with the PLC-5 processor.
Setting up the Processor System 2 11 Use channel 1A on the processor to connect to a DH+ link. The connector s port must be configured to support a DH+ communication link. To connect a processor to a DH+ link, use the 1770-CD cable (blue hose) and do the following: Ω,
2 12 Setting up the Processor System
Setting up the Processor System 2 13
In this chapter, make sure you have the following: the processor system you set up in chapter 2 one of these A.I Series PLC-5 programming software packages: online programming software 9325 L5140D online and offline programming software 9323 L5300D
3 2 Installing and Configuring the Software Configure the CONFIG.SYS and AUTOEXEC.BAT files. Below are example files recommended for an IBM-compatible 386/486/Pentium PC using the 1784-KT communication card, 1784-CP6 cable, and DOS 6.x and Windows 3.x. The CONFIG.SYS and AUTOEXEC.BAT files are computer dependent. If these files are not configured properly, your software may not work properly. If you are using a different programming terminal, communication card, cable, and/or version of DOS or Windows, your files will probably be different from these files. DEVICE=C:\DOS\HIMEM.SYS DEVICE=C:\DOS\EMM386.EXE NOEMS X=D400-D7FF SHELL=C:\DOS\COMMAND.COM C:\DOS /P /E:1024 STACKS=9,256 FILES=40 BUFFERS=30 DOS=HIGH,UMB @ECHO OFF PROMPT $P$G PATH=C:\;C:\DOS;C:\WINDOWS;C:\PLC5 LOADHIGH C:\DOS\SMARTDRV.EXE LOADHIGH C:\DOS\SHARE.EXE /F:8192 /L:40
Installing and Configuring the Software 3 3 To install the software, do the following: Turn on the computer. When the DOS prompt appears, insert the disk labelled Setup Disk into the disk drive. Type: You see: Press I Press
3 4 Installing and Configuring the Software Enter a Y next to the packages you want to install. Y To begin the installation, press and then press Y If the default installation path is acceptable, press If the default path is not correct, change it to the correct path, and then press
Installing and Configuring the Software 3 5 If all settings have been entered correctly, press Y and then press As the installation progresses, you will be asked to insert disks depending on which of the installation options was selected. Place the appropriate disk in the drive and press Enter. Select the appropriate video driver. Most users will enter 1. Press Once the installation program is complete, press any key to return to the DOS prompt.
3 6 Installing and Configuring the Software You start the software from any DOS prompt. To do so: Change the directory to x:\plc5, and type: where x is the drive on which you installed the programming software. Once the software is running, the following screen will appear.
Installing and Configuring the Software 3 7 To configure the software for online communication: Press Press to open the Configuration Program Parameters box. to select the Communication Hardware parameters. Use the function keys given below to set the following communications parameters. The settings below are only one possible configuration, your system may vary. Refer to the PLC-5 A. I. Series Installation Guide for specific settings for other configurations. Press to save your changes. Press to exit the configuration screen.
3 8 Installing and Configuring the Software
In this chapter, make sure you have the following: the processor system you set up in chapter 2 the A. I. Series PLC-5 programming software you installed and configured in chapter 3
4 2 Configuring the Processor Put the processor in remote program mode by turning the keyswitch to PROG and then back to REM. To program on line: From the opening screen, Press Online Programming/Doc The online programming option lets you develop, document, and monitor ladder logic when your programming terminal is connected (directly or over a DH+ link) to a processor. Cursor to your PLC-5 processor and press If you see the message: PLC Memory is bad Must be initialized. OK to initialize?, answer [F1] Yes If you are using AI5 software for the first time and you have a new PLC 5 out of the box, you will see this message: Project name must be changed from default before editing. You should enter a project name at the prompt. This name will be assigned to your PLC. If you see any additional error messages or the fault light is still lit on your processor, review the steps in Chapters 2 and 3.
Configuring the Processor 4 3 To name the processor: Do the following: Enter a project name and press Press twice to return to the top level menu.
4 4 Configuring the Processor To define an I/O status file: You must define the I/O status file if you want the software to assign your rack addresses. From the top level menu, do the following: Press until you have returned to the top level menu.
Configuring the Processor 4 5 To configure the processor channels 1A, 0, 2A, and 2B: This section shows example processor channel configurations. The actual configurations depend on your application. See Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12, for more information. Make sure the processor is in program mode. From the top level menu, do the following: Press until you have returned to the top level menu.! ATTENTION: Assign a unique diagnostic file to each channel. Do not assign a diagnostic file that is the I/O status file you assigned or any other used file. Unpredictable machine damage can result. You must define a diagnostics file for a channel configured for anything but Unused (even if you are not using the channel) if you want to get status information for that channel. Defining diagnostic files helps you to troubleshoot the system.
4 6 Configuring the Processor To configure channel 0 for DF1 point-to-point communication: While the cursor is on channel 0, do the following: Serial to PLC Diag. file 20 System mode char. S Remote mode change Mode attention char. \0x1b User mode char. Parity U Baud rate Error detect Stop bits NAK receive 3 Control line Duplicate detect DF1 ENQS 3 ACK timeout 100 Msg appl timeout 1
Configuring the Processor 4 7 To configure a channel to support a DH+ link: While the cursor is on channel 1A, do the following: Diagnostics file 14 Global Status Flags file (opt.) 16 Link ID 0
4 8 Configuring the Processor To configure channel 2A as a scanner: While the cursor is on channel 2A, do the following: Diag. file Baud rate Complementary I/O 13 Disabled
Configuring the Processor 4 9 To select channel 2B as an adapter: While the cursor is on channel 2B, do the following: Any files used for Discrete Transfer Configuration must already exist or the software displays an error. Discrete Transfer Configuration: Inputs destination: 010:000 Outputs source: 011:000 Diagnostics file 18 Baud rate Rack address: 3 Starting group 0 Rack size Last rack Input source 10 Output source 11
4 10 Configuring the Processor
In this chapter, make sure you have the following: the processor system you set up in chapter 2 and configured in chapter 4 the A. I. Series PLC-5 programming software you installed and configured in chapter 3
5 2 Programming the Processor The A. I. Series software automatically creates program file 2. To create additional program files enter the following key sequence from the top level menu: Press Press Press Press Ladder File Enter a program file number and press Press Enter a file name, up to ten characters, and a file description, up to 50 characters. Press twice to return to the top level menu.
5 3 Programming the Processor
5 4 Programming the Processor For specific instructions on entering ladder logic, see PLC-5 A. I Series Ladder Logistics Software Reference, Doc ID 9399 L5SR 04.17.95. To enter ladder logic: From the top level menu, you are automatically monitoring program file number 2. To edit the program file press Press to insert a rung. [F3] Append [F4] Insert [END][F3] Append [END] [F3] Append [F4] Insert The A. I. Series software provides two methods of entering rungs. The first way is to use the function and letter keys to add a single instruction at a time. The second, more advanced way is to use the command line programming mode to add an entire rung at one time. First, we will add a rung using the function keys. Do the following: Press XIC Press or type X. Type I:0/0 and press [F7] The Instruction Description box appears on the screen. Press until your cursor is on the Symbol field. Type SW0 and press Press to exit the description box. Type O to insert an OTE instruction. Type O:0/7 and press The Instruction Description box appears on the screen. Press until your cursor is on the Symbol field. Type LT7 and press Press to exit the description box. Press to accept the new rung.
Programming the Processor 5 5 The second way to enter a rung is to use the command line programming mode. You enter the programming mode by pressing /. After entering the programming mode, enter the rung using text string shorthand. Do the following: Place your cursor on the power bar next to rung 1, and press xic I:0/0 OTE O:000/00 O:000/00 I:000/00 N7:0 T4:0 To enter a symbol name for the instruction address, place the cursor over the instruction symbol and press and then Press to place the cursor in the SYMBOL field and type the symbol name. Press to accept the symbol name and to exit the description editor box. Choose from the following keys to build the rungs in steps a through f (on the following pages): + I I I I I I I
5 6 Programming the Processor a Enter a rung to turn on output 4 when switch 2 is closed. SW2 LT4 I:000 O:005 12 07 I:000 O:005 12 07 I:000/12
Programming the Processor 5 7 b Enter a rung to turn on output 5 when switches 1, 2, and 3 are closed and switch 4 is open. SW1 I:000 SW2 I:000 SW3 I:000 SW4 I:000 LT5 O:000 00 12 02 03 01 c Enter a rung to start MOTOR3. Use the STOP button to stop MOTOR3 and the START1 button to start MOTOR3. Provide a holding contact to keep MOTOR3 running after the START1 button is released. To enter the branch for the holding contact, press: Use the left and right arrow keys to place the branch in the correct position. When the branch is in the correct position, press: STOP START1 I:000 I:000 04 05 MOTOR3 O:000 03 MOTOR3 O:000 03 d Enter two rungs to start MOTOR2 ten seconds after MOTOR3 starts. Make MOTOR2 stop when the STOP button is pressed. MOTOR3 O:000 03 TIMER ON DELAY Timer T4:0 Time Base 1.0 Preset 10 Accum 0 STOP I:000 04 T4:0 DN MOTOR2 O:000 02 MOTOR2 O:000 02
5 8 Programming the Processor e Edit the rung from step c to add a second start button for MOTOR3. STOP START1 I:000 I:000 04 05 START2 I:000 06 MOTOR3 O:000 03 MOTOR3 O:000 03 f Enter a rung that writes the output and configuration data from words N9:11 through N9:23 to the 1771-OFE I/O module. The block transfer length is 13 words if you use scaling or 5 words if you do not use scaling. Enter scaling values in integer format or BCD format depending on which data format you selected. This sample logic segment is written for a 1771-OFE analog I/O module in slot 6 of a 1771 Universal I/O Chassis in single slot addressing mode. If you are using another analog I/O module, your logic may be different. CONFIG BTW I:000 BLOCK TRNSFR WRITE Rack 00 10 Group 5 Module 0 Control Block BT10:0 Data File N9:11 Length 13N Continuous
Programming the Processor 5 9 To save the program from the processor to a disk file from the top level menu, do the following: or type.us.ul
5 10 Programming the Processor To run the program, turn the processor keyswitch to RUN. To search for an instruction from the top level menu, do the following: Press Enter the address to search for (eg: O:0/0). Press to search for the next occurence of the address.
Programming the Processor 5 11 To monitor an address, do the following form the top level menu: To display the processor status screen, do the following from the top level menu:
5 12 Programming the Processor
5 2