Allen-Bradley SLC 500 User manual

SLC 500™ Modular

Hardware Style

(Cat. Nos. 1747-L511, 1747-L514,

1747-L524, 1747-L531, 1747-L532,

1747-L541, 1747-L542, 1747-L543,

1747-L551, 1747-L552, 1747-L553)

User Manual

Allen-Bradley PLCs

Important User Information

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, Rockwell International Corporation does not assume

responsibility or liability (to include intellectual property liability) for

actual use based upon the examples shown in this publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the

Application, Installation and Maintenance of Solid-State Control

(available from your local Rockwell Automation 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 part, without written permission of Rockwell Automation, is

prohibited.

Throughout this manual we use notes to make you aware of safety

considerations:

Attention statements help you to:

•identify a hazard

•avoid a hazard

•recognize the consequences

PLC-5 is a registered trademark; and MicroLogix, SLC 500, RSLogix, and RSLinx are trademarks of Rockwell Automation.

Modbus is a trademark of Schneider Automation Incorporated.

DeviceNet is a trademark of Open DeviceNet Vendor Association (ODVA).

ATTENTION

Identifies information about practices or

circumstances that can lead to personal injury or

death, property damage or economic loss

IMPORTANT Identifies information that is critical for successful

application and understanding of the product.

iii Publication 1747-UM011C-EN-P - December 2001

Summary of Changes

The information below summarizes the changes to this manual since

the last printing.

To help you find new and updated information in this release of the

manual, we have included change bars as shown to the right of this

paragraph.

The table below lists the sections that document new features and

additional or updated information on existing features.

For this information See

Updated references to related publications page P-2

1747-P6 and 1747-P7 power supplies

wiring page 1-5

heat dissipation Appendix G

Updated SLC 5/03, 5/04, and 5/05

communication parameters table

page 1-8

1784-PKTX interface card pages 1-2, 1-8, and A-4

A list of processors supporting ASCII

instructions

page 2-5

Information on DeviceNet and ControlNet

capabilities

page 2-9

Appendix D

Selecting a memory module for SLC 5/03,

5/04 and 5/05 processors - revised

page 2-21

Revised recommended surge suppressor

catalog numbers

page 2-28

Revised grounding diagram page 3-5

1746-BAS-T module page B-3

Minimizing noise when using SLC 5/04

processor

page C-5

Updated power supply loading worksheet Appendix F

Updated heat dissipation worksheet Appendix G

Allen-Bradley PLCs

Publication 1747-UM011C-EN-P - December 2001

Summary of Changes iv

vPublication 1746-UM011C-EN-P - December 2001

Table of Contents

Preface

Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-2

Common Techniques Used in this Manual . . . . . . . . . . . . . P-3

Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-3

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3

Your Questions or Comments on this Manual . . . . . . . . P-4

Chapter 1

Quick Start for Experienced Users

Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . 1-2

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 2

Selecting Your Hardware

Components

European Union Directive Compliance . . . . . . . . . . . . . . . 2-2

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Overview of Your Modular Control System . . . . . . . . . . . . 2-3

Principles of Machine Control. . . . . . . . . . . . . . . . . . . . 2-4

Selecting Modular Processors. . . . . . . . . . . . . . . . . . . . . . . 2-5

Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Processor Communication Options . . . . . . . . . . . . . . . . 2-6

SLC 500 System Test General Specifications. . . . . . . . . . 2-10

Processor General Specifications. . . . . . . . . . . . . . . . . . 2-11

Memory Backup for the 1747-L511, SLC 5/01 Processor . 2-12

Selecting Discrete I/O Modules . . . . . . . . . . . . . . . . . . . . . 2-12

Selecting Specialty I/O Modules. . . . . . . . . . . . . . . . . . . . . 2-12

Selecting Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Power Supply Specifications. . . . . . . . . . . . . . . . . . . . . 2-14

Example for Selecting Power Supplies . . . . . . . . . . . . . 2-15

Example Worksheet for Selecting a 1746 Power Supply. 2-16

Selecting Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Selecting Operator Interfaces . . . . . . . . . . . . . . . . . . . . . . . 2-18

Programming with a Hand-Held Terminal. . . . . . . . . . . 2-18

Selecting a Memory Module for the SLC 5/01 and

SLC 5/02 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Selecting a Memory Module for SLC 5/03, SLC 5/04,

and SLC 5/05 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

EEPROM Burning Options. . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Selecting Isolation Transformers. . . . . . . . . . . . . . . . . . . . . 2-24

Special Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Class I, Division 2 Applications. . . . . . . . . . . . . . . . . . . 2-25

Selecting Contact Protection . . . . . . . . . . . . . . . . . . . . . 2-28

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Table of Contents vi

Chapter 3

System Installation

Recommendations

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Spacing Your Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Grounding Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Special Grounding Considerations for DC

Applications using 1746-P3. . . . . . . . . . . . . . . . . . . . . . 3-6

Modification to the SLC 500 Series A Chassis . . . . . . . . . 3-6

Determining the Date of the SLC 500 Series A Chassis . . 3-7

Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Emergency-Stop Switches. . . . . . . . . . . . . . . . . . . . . . . 3-9

Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Common Power Source . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Grounded ac Power-Distribution System with

Master-Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Input States on Power Down . . . . . . . . . . . . . . . . . . . . 3-11

Other Types of Line Conditions . . . . . . . . . . . . . . . . . . 3-11

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 3-12

Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Periodic Tests of Master Control Relay Circuit . . . . . . . . 3-13

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Chapter 4

Mounting Your SLC 500 Control

System

Mounting Modular Hardware Style Units . . . . . . . . . . . . . . 4-1

4-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

7-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

10-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . 4-2

13-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Link Coupler (AIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Data Table Access Module (DTAM, DTAM Plus,

and DTAM Micro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

AIC+ Advanced Interface Converter (1761-NET-AIC)

DeviceNet Interface (1761-NET-DNI)

Ethernet Interface (1761-NET-ENI) . . . . . . . . . . . . . . . . 4-6

Chapter 5

Identifying the Components of

Your Processor

SLC 5/01 Processor Hardware Features . . . . . . . . . . . . . . . 5-1

SLC 5/02 Processor Hardware Features . . . . . . . . . . . . . . . 5-3

SLC 5/03 Processor Hardware Features . . . . . . . . . . . . . . . 5-6

SLC 5/04 Processor Hardware Features . . . . . . . . . . . . . . . 5-8

SLC 5/05 Processor Hardware Features . . . . . . . . . . . . . . . 5-12

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Table of Contents vii

Keyswitch for the

SLC 5/03, SLC 5/04, and SLC 5/05 Processors . . . . . . . . . . . 5-15

RUN Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

PROG Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

REM Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Chapter 6

Installing Your Hardware

Components

Compliance to European Union Directives . . . . . . . . . . . . . 6-1

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Installing Your Processor. . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Installing Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Installing Your Memory Module. . . . . . . . . . . . . . . . . . . . . 6-4

Removing the Memory Module. . . . . . . . . . . . . . . . . . . 6-5

Installing Your Power Supply . . . . . . . . . . . . . . . . . . . . . . 6-5

Installing Your Chassis Interconnect Cable . . . . . . . . . . . . . 6-8

Chapter 7

Wiring Your I/O Modules

Defining Sinking and Sourcing. . . . . . . . . . . . . . . . . . . . . . 7-1

Contact Output Circuits — AC or DC . . . . . . . . . . . . . . 7-2

Solid-State DC I/O Circuits . . . . . . . . . . . . . . . . . . . . . . 7-2

Preparing Your Wiring Layout . . . . . . . . . . . . . . . . . . . . . . 7-3

Recommendations for Wiring I/O Devices . . . . . . . . . . . . . 7-4

Features of an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Wiring Your I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Octal Label Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Applying the Octal Filter Label . . . . . . . . . . . . . . . . . . . 7-7

Applying the Octal Door Label . . . . . . . . . . . . . . . . . . . 7-7

Octal Kit and I/O Module Information . . . . . . . . . . . . . 7-8

Using the Removable Terminal Block (RTB). . . . . . . . . . . . 7-9

Removing the RTB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Installing the RTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Chapter 8

Starting Up Your Control System

Procedures for Starting the Control System. . . . . . . . . . . . . 8-1

1. Inspect Your Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-2

2. Disconnect Motion-Causing Device . . . . . . . . . . . . . . . . 8-2

3. Initialize and Test Your Processor . . . . . . . . . . . . . . . . . 8-3

4. Test Your Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Input Troubleshooting Steps. . . . . . . . . . . . . . . . . . . . . 8-6

5. Test Your Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Output Troubleshooting Steps . . . . . . . . . . . . . . . . . . . 8-8

6. Enter and Test Your Program. . . . . . . . . . . . . . . . . . . . . 8-9

7. Observe Control Motion . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8. Conduct a Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

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Table of Contents viii

Chapter 9

Maintaining Your Control System

Handling and Storing Battery, Catalog Number 1747-BA . . . 9-1

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Installing and Replacing the Battery of the SLC 5/01

or SLC 5/02 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Replacing Your SLC 5/03, SLC 5/04, or SLC 5/05 Battery. . . 9-4

Replacing Retainer Clips on an I/O Module . . . . . . . . . . . . 9-6

Removing Damaged Retainer Clips . . . . . . . . . . . . . . . . 9-6

Installing New Retainer Clips . . . . . . . . . . . . . . . . . . . . 9-7

Replacing a Fuse on the Power Supply . . . . . . . . . . . . . . . 9-7

Chapter 10

Troubleshooting

Contacting Rockwell Automation for Assistance . . . . . . . . . 10-1

Tips for Troubleshooting Your Control System . . . . . . . . . . 10-2

Removing Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Program Alteration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Troubleshooting the SLC 5/01 and SLC 5/02 Processors . . . 10-3

Identifying SLC 5/01 and SLC 5/02 Processor Errors. . . . 10-4

Identifying SLC 5/02 Processor Communication Errors. . 10-7

Troubleshooting the SLC 5/03, SLC 5/04, and

SLC 5/05 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

Clearing SLC 5/03, SLC 5/04, and SLC 5/05

Processor Faults Using the Keyswitch . . . . . . . . . . . . . . 10-9

Identifying SLC 5/03, SLC 5/04, and SLC 5/05

Processor Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Identifying SLC 5/03, SLC 5/04, and SLC 5/05

Processor Communication Errors . . . . . . . . . . . . . . . . 10-12

Identifying Processor Errors while Downloading an

Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Returning the SLC 5/03, SLC 5/04, and SLC 5/05

Processors to “Initial Factory Conditions” . . . . . . . . . . 10-17

Troubleshooting Your Input Modules. . . . . . . . . . . . . . . . 10-19

Input Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 10-19

Troubleshooting Your Input Modules . . . . . . . . . . . . . 10-20

Troubleshooting Your Output Modules . . . . . . . . . . . . . . 10-21

Output Circuit Operation . . . . . . . . . . . . . . . . . . . . . . 10-21

Troubleshooting Your Output Modules. . . . . . . . . . . . 10-22

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Chapter 11

Replacement Parts

Replacement Cables and Connectors . . . . . . . . . . . . . . . . . 11-1

Cable Connectivity Summary . . . . . . . . . . . . . . . . . . . . 11-2

Replacement Terminal Blocks. . . . . . . . . . . . . . . . . . . . 11-3

Other Replacement Hardware. . . . . . . . . . . . . . . . . . . . 11-3

Appendix A

Setting Up the DH-485 Network

DH-485 Network Description. . . . . . . . . . . . . . . . . . . . . . . A-1

DH-485 Network Protocol . . . . . . . . . . . . . . . . . . . . . . . . . A-2

DH-485 Token Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

DH-485 Network Initialization . . . . . . . . . . . . . . . . . . . . . . A-2

Devices that Use the DH-485 Network . . . . . . . . . . . . . . . . A-3

1747-AIC Isolated Link Coupler for DH-485 . . . . . . . . . . . . A-4

Example System Configuration . . . . . . . . . . . . . . . . . . . . . A-5

Configuring the SLC 5/03, SLC 5/04, and SLC 5/05

Channel 0 for DH485 . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Important Planning Considerations . . . . . . . . . . . . . . . . . . A-7

Hardware Considerations . . . . . . . . . . . . . . . . . . . . . . . A-7

Software Considerations . . . . . . . . . . . . . . . . . . . . . . . . A-9

Installing the DH-485 Network . . . . . . . . . . . . . . . . . . . . A-11

DH-485 Communication Cable and Isolated

Link Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Installing the DH-485 Communication Cable . . . . . . . . A-11

Connecting the Communication Cable to the

Isolated Link Coupler. . . . . . . . . . . . . . . . . . . . . . . . . A-12

Powering the Link Coupler. . . . . . . . . . . . . . . . . . . . . A-14

Installing and Attaching the Link Couplers . . . . . . . . . A-17

Appendix B

RS-232 Communication Interface

RS-232 and SCADA Applications . . . . . . . . . . . . . . . . . . . . B-1

RS-232 Communication Interface Overview . . . . . . . . . . . . B-1

SLC 5/03, SLC 5/04, and SLC 5/05 processors and RS-232

Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

SLC 500 Devices that Support RS-232 Communication. . . . . B-3

1770-KF3 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

1747-KE Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

1746-BAS and 1746-BAS-T Modules . . . . . . . . . . . . . . . B-3

DF1 Protocol and the SLC 5/03, SLC 5/04, and SLC 5/05

Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

DF1 Full-Duplex Protocol. . . . . . . . . . . . . . . . . . . . . . . B-4

Full-Duplex (Point-to-Point) . . . . . . . . . . . . . . . . . . . . . B-5

DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . B-5

ASCII Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

DF1 Communication Protocol Modems Overview. . . . . . . . B-7

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Wiring Connectors for RS-232 Communication . . . . . . . . . . B-8

Types of RS-232 Connectors . . . . . . . . . . . . . . . . . . . . . B-8

DTE Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

DCE Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Pin Assignments for Wiring Connectors. . . . . . . . . . . . . B-9

Applications for the RS-232 Communication Interface . . . . B-20

DF1 Full-Duplex Peer-to-Peer. . . . . . . . . . . . . . . . . . . B-20

Half-Duplex with Slave-to-Slave Routing . . . . . . . . . . . B-21

Appendix C

Setting Up the DH+ Network

Data Highway Plus Communication Protocol Overview . . . C-1

SLC 5/04 Processors and DH+ Communication. . . . . . . . . . C-2

DH+ Channel 1, 3-Pin . . . . . . . . . . . . . . . . . . . . . . . . . C-2

DH+ Channel 1, 8-Pin . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Wiring Connectors for DH+ Communication for SLC 5/04

Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Minimizing Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Typical DH+ Network Configuration . . . . . . . . . . . . . . . . . C-6

Appendix D

Control Networks

Allen-Bradley Remote I/O Network . . . . . . . . . . . . . . . . . . D-1

Remote I/O Passthru . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

DeviceNet Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

The 1747-SDN DeviceNet Scanner . . . . . . . . . . . . . . . . D-3

The 1761-NET-DNI DeviceNet Interface . . . . . . . . . . . . D-4

DeviceNet Network Length. . . . . . . . . . . . . . . . . . . . . . D-5

ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6

The 1747-SCNR ControlNet Scanner Module . . . . . . . . . D-6

The 1747-KFC15 ControlNet Messaging Module. . . . . . . D-6

Appendix E

Communicating with Devices on

an Ethernet Network

SLC 5/05 Processors and Ethernet Communication . . . . . . . E-1

SLC 5/05 Performance Considerations . . . . . . . . . . . . . . . . E-2

SLC 5/05 and PC Connections to the Ethernet Network. . . . E-3

Ethernet Network Topology . . . . . . . . . . . . . . . . . . . . . E-3

Ethernet Channel 1 8-Pin 10Base-T Connector. . . . . . . . E-3

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Configuring the Ethernet Channel on the SLC 5/05 . . . . . . . E-5

Configuration Using RSLogix 500 Programming Software . . E-6

Configuration Via BOOTP . . . . . . . . . . . . . . . . . . . . . . . . . E-6

Using DOS/Windows BOOTP . . . . . . . . . . . . . . . . . . . E-8

Run the Boot Server Utility. . . . . . . . . . . . . . . . . . . . . E-11

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