Classic 1785 Hardware Programmable Installation Manualtasks you must perform as you install the PLC-5 processor system. The flowcharts guide you with questions about your system. Notice

Hardware

Installation

Manual

Classic 1785PLC5 FamilyProgrammableControllers

(Cat. No. 1785 series)

AllenBradley

efesotomasyon.com - Allen Bradley,Rockwell,plc,servo,drive

Because of the variety of uses for the products described in thispublication, those responsible for the application and use of this controlequipment must satisfy themselves that all necessary steps have been takento assure that each application and use meets all performance and safetyrequirements, including any applicable laws, regulations, codes andstandards.

The illustrations, charts, sample programs and layout examples shown inthis guide are intended solely for purposes of example. Since there aremany variables and requirements associated with any particularinstallation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon theexamples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,Installation, and Maintenance of Solid State Control (available from yourlocal Allen-Bradley office), describes some important differences betweensolid-state equipment and electromechanical devices that should be takeninto consideration when applying products such as those described in thispublication.

Reproduction of the contents of this copyrighted publication, in whole orin part, without written permission of Allen-Bradley Company, Inc., isprohibited.

Throughout this manual we use notes to make you aware of safetyconsiderations:

ATTENTION: Identifies information about practices orcircumstances that can lead to personal injury or death, propertydamage or economic loss.

Attention statements help you to:

identify a hazard avoid the hazard recognize the consequences

Important: Identifies information that is critical for successful applicationand understanding of the product.

Important User Information


Summary of Changes

Summary of Changes

This release of the publication contains new and corrected information.

New and Corrected Information

For this new information Refer to:

modified system connection diagram chapter 1

added specifications for vibration, shock, and processor weight appendix A

corrections to connection drawing for 1784PCMK appendix B

removed all information about enhanced PLC5 processors

instead, see the Enhanced and Ethernet PLC5 ProgrammableControllers User Manual, 17856.5.12

throughout

To help you find new and corrected information, we included change barsas shown to the left of this paragraph.

Summary of Changes


Summary of Changes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using this Manual i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Use this Manual ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For More Information ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reporting Corrections and Suggestions ii. . . . . . . . . . . . . . . . . . . .

Getting Started 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Objectives 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How the System Connects Together 11. . . . . . . . . . . . . . . . . . . . . .

Processor Front Panel and Switch Assembly Overview 13. . . . . . . . .

Understanding the Keyswitch 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Installation Site 21. . . . . . . . . . . . . . . . . . . . . . . .


Provide the Proper Environment for the Processor 21. . . . . . . . . . . .

Layout the Cable Raceway 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the 1771 I/O Chassis 31. . . . . . . . . . . . . . . . . . . . . . . .


Mount the Chassis 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ground the Chassis 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the I/O Chassis Switches 310. . . . . . . . . . . . . . . . . . . . . . . . .

Setting the I/O Chassis Configuration Plug 313. . . . . . . . . . . . . . . . . .

What to Do Next 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install and Remove Processor Batteries and Memory Modules 41. . . . . . . . . . . . . . . . . . . . . . . . . . . .


Installing the Battery 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Battery 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposing of a Battery 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the 1785MJ and 1785MK EEPROM Module 45. . . . . . . . . . .

Install the 1785MR and MS CMOS RAM Module (PLC5/15, 5/25 processors) 46. . . . . . . . . . . . . . . . . . . . . . . . .

Remove the EEPROM or CMOS RAM Modules(PLC5/10, 5/12, 5/15, 5/25 processors) 47. . . . . . . . . . . . . . .

What to Do Next 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents


Table of Contentsii

Install or Remove a PLC5/10, 5/12, 5/15, and 5/25 Processor 51. . . . . . . . . . . . . . . . . . . . . . . . . .


Configuring PLC5/10, 5/12, 5/15 and 5/25 Processor Communication 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuring Adapter Mode Communication 53. . . . . . . . . . . . . . . . . .

Connecting Termination Resistors 59. . . . . . . . . . . . . . . . . . . . . . . .

Installing the Keying Bands 510. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inserting the Processor into the Chassis 510. . . . . . . . . . . . . . . . . . . .

Removing the Processor from the Chassis 511. . . . . . . . . . . . . . . . . .

What to Do Next 511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the Remote I/O Link 61. . . . . . . . . . . . . . . . . . . . . . . . .


Set Remote I/O Adapter Switches 61. . . . . . . . . . . . . . . . . . . . . . . .

Install the Adapter Module 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect Remote I/O Link 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install I/O Modules 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Install Modules 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Wiring Arms 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire I/O to Wiring Arms 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect Power 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


About the Power Supplies You Can Use 81. . . . . . . . . . . . . . . . . . .

Distributing Power 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using a Second Transformer 85. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Determining the Rating of the Transformer 86. . . . . . . . . . . . . . . . . .

Grounding the Power Supply 87. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting Against EMI 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install the Power Supplies 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to Do Next 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect Processors to a DH+ Link 91. . . . . . . . . . . . . . . . . .


Determine the Needed Cable 91. . . . . . . . . . . . . . . . . . . . . . . . . . .

Connect the Processor to the DH+ Link 92. . . . . . . . . . . . . . . . . . . .

Terminate the Link 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to do Next 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Table of Contents iii

Connect a Programming Terminal to the Processor 101. . . . . .


Determine How You Want to Connect a Programming Terminal 101. . .

Connecting through a Local DH+ Link 101. . . . . . . . . . . . . . . . . . . . .

Connecting to a Remote DH+ Link 104. . . . . . . . . . . . . . . . . . . . . . . .

Connecting to a DH+ Link through an Interface to the Terminal's Serial Port 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What To Do Next 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Troubleshooting PLC5/10, 5/12, 5/15, and 5/25 Processors 112. . . .

Troubleshooting Information for 1771ASB Module 115. . . . . . . . . . . .

Processor Specifications A1. . . . . . . . . . . . . . . . . . . . . . . . . .

General A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Processor Specific A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Addressing Concept Summary A3. . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Specifications A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compatible Remote I/O Link Devices A4. . . . . . . . . . . . . . . . . . . . . .

Programming and Instruction Capabilities A4. . . . . . . . . . . . . . . . . . .

Programming Software A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O Chassis Mounting Dimensions (series A) A6. . . . . . . . . . . . . . . .

Cable Connections B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Connections for Communication Boards B1. . . . . . . . . . . . . . .

Cable Connections for Serial Port Communications B1. . . . . . . . . . . .

Cable Pin Assignments B3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Specifications B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Preface

i

Using this Manual

Your 1785 PLC-5 Programmable Controllers documentation is organizedinto manuals according to the tasks you perform. This organization lets youeasily find the information you want without reading through informationthat is not related to your current task. The arrow points to the book youare currently in.

Figure 1.1PLC5 Programmable Controllers Documentation Library

Programming

62006.4.7

Installing the software

Software Configuration

and Maintenance

62006.4.6

I/O Configuration

62006.4.12

Software

62006.4.11

ReferenceInstruction Set

1785 PLC5Programmable Controllers

Quick Reference

17857.1


Design Worksheets

17855.2


Design Manual

17856.6.1


Hardware Installation

17856.2.1

Explanation of processorfunctionality, system design,and programmingconsiderations

Worksheets help thedesigner plan thesystem and help theinstaller install thesystem

Ho to install and setswitches for chassis andPLC5 processors, howto wire and groundthe system

Defining data table filesConfiguring processorsProcessor/channel statusClearing faultsPrinting reports

Creating/managing filesSaving/restoring filesImporting/exportingCreating/editing SFCsCreating/editing ladderDocumenting ladder

Configuring intelligentI/O modules

Instruction execution,parameters, status bits,and examples

Quick access to switches,status bits, indicators,instructions, software screens

For more information on 1785 PLC-5 programmable controllers or theabove publications, contact your local sales office, distributor or system integrator.

How to Use YourDocumentation


Preface

ii

At the beginning of each chapter, you will find a flowchart that maps thetasks you must perform as you install the PLC-5 processor system. Theflowcharts guide you with questions about your system. Notice thatunderneath each chapter box is a checklist of the tasks contained withineach chapter.

In addition to the 10 chapters shown in the flowchart, the manual containsthese chapters and appendices:

For this information: See:

LED indicator troubleshooting for the PLC5processor and adapter modules

chapter 11 Troubleshooting

Processor specifications, battery specifications,additional quick reference information

appendix A Processor Specifications

Cables for available programming terminals andcable pin assignments

appendix B Cable Connections

Also refer to these manuals:


Designing DH , DH+ , DHII , DH485 cable networks 17706.2.2

DH and DH+ protocol, commands, and network timing 17706.5.16

I/O modules and power supply installation installation instructions for theindividual component

For a list of publications with information about Allen-Bradley PLC-5programmable controller products and other Allen-Bradley products,consult the Automation Group Publication Index, publication SD499.

Use the Allen-Bradley Publication Problem Report, publication ICCG-5.21to submit any corrections to or suggestions about this publication. Thisdocument is available through NEWlit and on the AB-POST system. Youcan help us improve the quality of customer documentation.

How to Use this Manual

For More Information

Reporting Corrections andSuggestions


Prepare Installation Site

Layout cable raceway

Install 1771 I/O Chassis

Mount chassis

Ground chassis

Set backplane switches

Set chassis configuration plug

Install Processor Battery and Memory Modules

Install processor battery

Install CMOS RAM module

Install EEPROM module

Install PLC5/10, 5/12, 5/15, 5/25 processor

Install the remote I/O link Install I/O modules Connect power

Connect programmingterminal to the processor

Processor front panel andswitch assembly overview

Define processor communication (SW1)

Configure adapter mode communication

Terminate DH+ and remote I/O links (SW3)

Install keying bands

Set adapter switches

Make remote I/O connections

Install modules

Install wiring arms

Wire I/O to wiring arms

Consider power distribution

Determine needed transformers and surge suppression

Install power supplies

Determine needed cable

Connect processor

Terminate the link

Determine proper cable

Connect terminal

chapter 1 chapter 2 chapter 3 chapter 4

How the system connects together

Getting Started

chapter 6 chapter 7 chapter 8

chapter 9

Provide a proper environment

Terminate the link

Determine how to connect to the processor

Insert processor into chassis

Connect processorto the DH+ link

chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5





Mount chassis

Ground chassis

















Install modules

Install wiring arms






Connect processor

Terminate the link


Connect terminal



Getting Started


chapter 9


Terminate the link




chapter 10

chapter 5


Chapter

1

1-1

Getting Started

Use this chapter to help you become acquainted with the PLC-5 systemand the PLC-5 processor.

chapter 1



Getting Started

Use the chart on the left-hand page to help guide you through theinstallation procedures.

A PLC-5 system consists of the following major components:

PLC-5 processor

Processor: Catalog Number:

PLC5/10 1785LT4

PLC5/12 1785LT3

PLC5/15 1785LT

PLC5/25 1785LT2

adapter modules (remote I/O and extended-local I/O)

I/O modules

chassis

power supplies

programming terminals

Chapter Objectives

How the System ConnectsTogether


Getting StartedChapter 1

1-2

Figure 1.1System Interconnection Overview

Data Highway Plus link

Cable: Belden 9463Terminal

terminal cable

remote I/Olink cable:Belden 9463

NEMA enclosure properly ventilated and grounded

Clear

Shield

Blue

Clear

Shield

Blue

1770SC station connector

19312

PLC5/25

1771ASB

PLC5/15

1



1-3

Clear

Blue

Shield

Cable: Belden 9463

remote I/Olink cable:Belden 9463

NEMA enclosure properly ventilated and grounded

serial cable

PLC5/25

1771ASB

PLC5/15

modem

terminal


19312a




Use Figure 1.2 and Figure 1.3 to help identify and understand theprocessor’s front panel components and the processor’s switch assemblies.

Processor Front Panel andSwitch Assembly Overview



1-4

Figure 1.2PLC5/10, 5/12, 5/15, and 5/25 Processor Front Panels

PROG

PLC5/10 Processor PLC5/12, 5/15, 5/25 Processor

Communication indicatorACTIVE/FAULT(green/red)

Keyswitch

Connectprogrammingterminal here

Connect DH+link here

Communication indicatorACTIVE/FAULT(green/red)

REM I/O indicatorACTIVE/FAULT(green/red)

Adapterindicator(green)

Connect remoteI/O link here

Battery indicator (red)

Processor RUN/FAULTindicator (green/red)

FORCEindicator(amber)

Battery holder

Write the DH+network stationnumber on this label

PLC5 family memberdesignation

Connector Name ConnectorType

Description

programming terminal 9pin, Dshell Use this connector to directly connect a programmingterminal to the processor. This connector has aparallel connection with the 3pin DH+ communicationslink connector.

DH+ communications link 3pin Use this connector to connect to DH+ communications link.

remote I/O 3pin Use this connector for the remote I/O link. (This connectoris not available on a PLC5/10 processor.)



1-5

Figure 1.3PLC5/10, 5/12, 5/15, and 5/25 Processor Module Switch Assemblies

Use this SwitchAssembly:

To:

SW1 • set the station number of the processor on theDH+ link

• select the mode of operation (scanner or adapter) ofthe processor

PLC5/10 resident I/O scanner only; PLC5/12 adapter only

SW2 • determine the number of data table words reservedfor communication between a host processor and thePLC5 processor when the PLC5 processor is inadapter mode

• determine the beginning I/O group number assignedto the PLC5 processor when it is in adapter mode

• determine the I/O rack number assigned to thePLC5 processor when it is in adapter mode

SW3 • connect a termination resistor across the line at theprocessor when the processor is an end device onthe DH+ or remote I/O link.

For more information about setting these switches, seechapter 6.

Top view of PLC5/10, 5/12, 5/15, 5/25 processor

Switch Assembly SW1

Bottom view of PLC5/10, 5/12, 5/15, 5/25 processor

Switch Assembly SW2Switch Assembly SW3

13348



1-6

Use the keyswitch to change the mode in which a processor is operating.You receive keys for the keyswitch in the processor package. Refer toTable 1.A for information about the processor modes.

Table 1.AProcessor Operation Modes

To: Turn the keyswitch to:

• Run your program, force I/O and save your programs to adisk drive. Outputs are enabled. (Equipment beingcontrolled by the I/O addressed in the ladder program begin operation.)

• Enable outputs.

Note: You cannot create or delete a ladder file; create or delete data files; or change the modes of operation through the programming terminal or software while in RUN mode.

RUN

• Disable outputs

• Create, modify and delete ladder files or data files,download to an EEPROM module, and save/restore ladderprograms.

Notes:

• The processor does not scan the program.

• You cannot change the mode of operation throughthe programming terminal or software while inPROGram mode.

PROG (program)

Change between remote program, remote test, and remote runmodes through the programming terminal software.

Remote run

• Enable outputs

• You can save and restore files as well as perform onlineediting.

Remote program

See program mode description above

Remote test

• Execute your ladder programs with outputs disabled.

• You cannot create or delete ladder programs or data files.

REM (remote)


Layout cable racewayProcessor front panel andswitch assembly overview

How the system connects together Provide a proper environment√√

chapter 1Getting Started

chapter 2

Understanding theKeyswitch

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG

What to Do Next


Chapter

2

2-1

Prepare the Installation Site

A well-planned layout and a well-prepared installation site are essential forthe proper installation of your PLC-5 processor system. Use this chapter tohelp you prepare the installation site.




chapter 2

When installing your processor, consider the environment in which theprocessor will be operating. To operate properly and effectively, theprocessor should be in an environment with conditions that fall within thefollowing guidelines (Table 2.A):

Table 2.AProper Environmental Conditions for Your Processor

Environmental condition: Acceptable range:

operating temperature 0 to 60° C (32 to 140° F)

storage temperature 40 to 85° C (40 to 185° F)

relative humidity 5 to 95% (without condensation)

To achieve this environment, do the following:

install the processor system in an enclosure provide convection cooling to the processor system

Chapter Objectives

Provide the ProperEnvironment for theProcessor


Prepare the Installation SiteChapter 2

2-2

Use an Enclosure

You provide the enclosure for your processor system. This enclosureprotects your processor system from atmospheric contaminants such as oil,moisture, dust, corrosive vapors, or other harmful airborne substances. Tohelp guard against EMI/RFI interference, we recommend a steel enclosure.

Mount the enclosure in a position that lets you open the doors fully. Youneed easy access to the processor, related components, and wiring so thattroubleshooting is convenient.

When you choose the enclosure size, allow extra space for isolationtransformers, fusing, disconnect switch, master control relay, andterminal strips.

Provide Convection Cooling

Separate your processor system from other equipment and plant walls toallow for convection cooling. Convection cooling draws a vertical columnof air upward over the processor. This cooling air must not exceed 60° C(140° F) at any point immediately below the processor. If the airtemperature exceeds 60° C, install fans (which circulate filtered air orrecirculate internal air) inside the enclosure or air conditioning/heatexchanger units.

To allow for proper convection cooling in enclosures containing aprocessor-resident chassis, extended-local I/O and remote I/O chassis,follow the guidelines described by Figure 2.1.



2-3

Figure 2.1Ensure Proper Convection Cooling By Following These MinimumComponent Spacing Guidelines

Area reserved for disconnecttransformer, control relays, motorstarters, or other devices.

Minimum spacing requirements for aprocessorresident chassis:

• Mount the I/O chassis horizontally.

• Allow 153 mm (6 in.) above and below the chassis.

• Allow 102 mm (4 in.) on the sides of each chassis.

• Allow 51 mm (2 in.) vertically and horizontally betweenany chassis and the wiring duct or terminal strips.

• Leave any excess space at the top of the enclosurewhere the temperature is the highest.

102mm(4")

153mm(6")

51mm(2")

102mm(4")

Wiring Duct153mm(6")

51mm(2")

13081

(4") (6 " )

Minimum spacing requirements for extendedlocaland remote I/O chassis:

• Mount the I/O chassis horizontally.

• Allow 153 mm (6 in.) above and below allchassis. When you use more than onechassis in the same area, allow 152.4 mm(6 in) between each chassis.

• Allow 102 mm (4 in.) on the sides of eachchassis. When you use more than onechassis in the same area, allow 101.6 mm(4 in) between each chassis.

• Allow 51 mm (2 in.) vertically andhorizontally between any chassis and thewiring duct or terminal strips.

• Leave any excess space at the top of theenclosure where the temperature isthe highest.

102mm 153mm

51mm (2")

51mm (2")

153mm (6")

(4")102mm

(4")102mm

153mm (6")

Area reserved for disconnecttransformer, control relays, motorstarters, or other devices.

18749

Wiring Duct

Wiring Duct



2-4

The raceway layout of your processor system is related to where you placethe different types of I/O modules in the I/O chassis. Before designingyour raceway layout, refer to your system’s chassis layout plans todetermine the position of your I/O modules in their respective chassis.

To plan a raceway layout, do the following:

categorize conductor cables route conductor cables

Categorize Conductors

Segregate all wires and cables into the following three categories(Table 2.B):

Table 2.BFollow These Guidelines for Grouping Conductors

Group conductor cables fitting this description: Into thiscategory:

Examples:

highpower conductors that are more tolerant ofelectrical noise than category2 conductors andmay also generate more noise

Category 1 • ac power lines

• highpower ac I/O lines - to connect ac I/O modules rated for high powerand high noise immunity

• highpower dc I/O lines - to connect dc I/O modules rated for high poweror with input circuits with long timeconstant filters for high noise rejection.They typically connect devices such as hardcontact switches, relays,and solenoids

lowpower conductors that are less tolerant ofelectrical noise than category1 conductors andshould also generate less noise

Category 2 • serial communication cables - to connect between processors or toremote I/O adapter modules, programming terminals, computers, ordata terminals

• parallel communication cables - to connect extended local I/O chassis inmultiple enclosures

• lowpower ac/dc I/O lines - to connect to I/O modules that are rated for lowpower such as lowpower contactoutput modules

• lowpower dc I/O lines - to connect to dc I/O modules that are rated for lowpower and have input circuits with short timeconstant filters to detect shortpulses. They typically connect to devices such as proximity switches,photo electric sensors, TTL devices, and encoders

interconnect the processorsystem componentswithin an enclosure

Category 3 • processorsystem power cables - provide backplane power to theprocessorsystem components

• parallel communication cables - to connect to extendedlocal I/O chassiswithin the same enclosure

• Processorperipheral cables - connect processors to their communicationinterface modules

Refer to the installation instructions for each I/O module you are using forinformation about its classification.

Layout the Cable Raceway



2-5

Route Conductors

To guard against coupling noise from one conductor to another, followthese general guidelines (Table 2.C) when routing wires and cables (bothinside and outside of an enclosure):

Table 2.CFollow These Guidelines for Routing Cables

Route this category of conductor cables: According to these guidelines:

Category 1 These conductors can be routed with machine power conductors of up to 600V ac(feeding up to 100 hp devices) if this does not violate local codes.

Article 3003 of the National Electrical Code requires that all conductors (ac and/or dc) inthe same raceway must be insulated for the highest voltage applied to any one of theconductors in the raceway.

Category 2 • Properly shield (where applicable) and route conductors in a separate raceway.

• Cross power feed lines at right angles (if necessary).

• Route at least 0.305m (1 ft) from 120V ac power lines; .610m (2 ft) from 240V acpower lines; 0.915m (3 ft) from 480V ac power lines.

• Route at least 0.915m (3 ft) from any electric motors, transformers, rectifiers,generators, arc welders, induction furnaces, or sources of microwave radiation.

If the conductor is in a metal raceway or conduit, that raceway or conduit must be wellgrounded along its entire length.

Category 3 Route conductors external to all raceways or in a raceway separate from any category1or category2 conductors.




Mount chassis

Ground chassis



Provide a proper environment√√

chapter 2 chapter 3What to Do Next


Chapter

3

3-1

Install the 1771 I/O Chassis

Use this chapter to help you install a 1771 I/O chassis.


Mount chassis

Ground chassis



chapter 3

For more information, refer to the installation instructions for the I/Ochassis you are mounting.

You can mount a chassis two ways:

mount to a panel (chassis cat. no. 1771-A1B, -A2B, -A3B1, -A4B) mount to a rack or panel (chassis cat. no. 1771-A3B only)

To mount a chassis, do the following:

Ensure that you have sufficient space to mount the chassis. Use thechassis mounting dimensions as a guide.

Attach the chassis to the rack or panel

Ensure Sufficient Mounting Space

For component spacing and dimensions for series B chassis:

For this information Refer to:

I/O chassis (series B) mounting dimensions Figure 3.1 (page 32)

I/O chassis (series B) with 1771P2 power supply mounting dimensions Figure 3.2 (page 33)

See Appendix A for series A chassis spacing and dimensions.

Chapter Objectives

Mount the Chassis


Install the 1771 I/O ChassisChapter 3

3-2

Figure 3.1Chassis Dimensions (Series B)

315mm(12.41")

PowerConnector

254mm(10")

Side

193mm1

(7.60")

591mm(23.25") 464mm

(18.25")337mm(13.25") 210mm

(8.25")

171mm(6.75")

610mm(24.01")

483mm(19.01")

356mm(14.01")

229mm(9.01")

16slot 1771-A4B

12slot 1771A3B1

8slot 1771A2B

4slot 1771A1B

16slot 1771

12slot

8slot

4slot

1771A1B1771A2B1771A3B11771A4B

Front

12450I

217mm1

(8.54")

339mm(13.53")

465mm(18.31")

484mm(19")

9mm(.34")

26mm(1.02")

178mm(7")

130mm(5.10")

1Total maximum depth dimension per installation depends on module wiring and connectors.

1771A3B

Side



3-3

You can mount a 1771-P1, -P2, -P7, or -PS7 power supply on the left sideplate of the I/O chassis, or up to 5 cable-feet from the I/O chassis.

Figure 3.21771A1B, A2B, A3B1 and A4B Mounting Dimensions with aPower Supply (Series B)

315mm(12.41")

610mm(24.01")483mm

(19.01")356mm(14.01")229mm

(9.01")

254mm(10")

1771P11771P21771P71771PS7Power Supply

Use .25" diamounting bolts

(4 places)

12451I

91mm(3.6")

591mm(23.25") 464mm

(18.25")337mm(13.25") 210mm

(8.25")

16slot 1771-A4B

12slot 1771A3B1

8slot 1771A2B

4slot 1771A1B

16slot 1771

12slot

8slot

4slot

Attach the Chassis to a Panel or Rack

Now that you have established and verified all layouts, begin mounting thechassis to a panel or rack. Use either bolts or welded studs to mount thechassis. If you are mounting a chassis to the back panel of an enclosure,use 6.35 mm (0.25 in) mounting bolts.

Refer to Figure 3.3 for the following mounting assembly details:

stud mounting of a back-panel to the back wall of an enclosure bolt mounting of a chassis or ground bus to a back-panel stud mounting of a chassis or ground bus to a back-panel



3-4

Figure 3.3Use these Assembly Details to Mount and Ground a Chassis and/orGround Busses

17666

Backpanel

Back wall of enclosure

Weldedstud

Use a wire brush to removepaint from threads to allow a ground connection.

Scrape paint on panel anduse a star washer

Nut

Ground bus ormounting bracket

BackpanelTappedhole

Bolt

Scrape painton paneland use a star washer.Flat

washerFlatwasher

Starwasher

17665

Nut

GroundLug

17664

Mounting bracketor ground bus

Back wall of enclosure

Weldedstud

Scrapepaint

Flatwasher

Scrapepaint

FlatwasherStar

washer

Nut

Groundlug

Stud mounting of the backpanel to the back wallof the enclousure.

Bolt mounting of a ground bus or chassis to the backpanel.

Stud mounting of a ground bus or chassis to the backpanel.

ATTENTION: If the mounting brackets of a chassis do not layflat before the nuts are tightened, use additional washers asshims so that the chassis will not be warped by tightening thenuts. Warping a chassis could damage the backplane and causepoor connections.



3-5

Make sure you have good electrical connections between each chassis,back-panel, and enclosure through each mounting bolt or stud. Whereveryou make electrical contact, remove paint or other non-conductive finishfrom studs or tapped holes.

To properly ground a chassis you must:

verify that your system-design plans are using the correct systemgrounding configuration

install a ground bus

connect equipment grounding conductors

connect a ground bus to the grounding electrode system

ground shielded cables

Verify Grounding Configuration

For this grounding configuration: Refer to:

remote I/O system grounding Figure 3.4 (page 36)

extendedlocal I/O grounding Figure 3.5 (page 36)

Ground the Chassis



3-6

Figure 3.4Follow this Recommended Grounding Configuration forRemote I/O Systems

EnclosureGrounding electrode conductor

To groundingelectrodesystem

Groundbus

I/O chassis wall

Groundlug

Nut

Starwasher

Ground lug

15561

Figure 3.5Follow this Required Grounding Configuration for ExtendedLocal I/O Systems

Extendedlocal I/O cables

I/O chassisground stud

Enclosure Enclosure

Groundbus Ground

bus

To grounding electrodesystem (single point only)

I/O chassis wall

Groundlug

Nut

Starwasher

Ground lug

18585



3-7

ATTENTION: Use single-point grounding for extended-localI/O systems. The systems must be grounded properly to ensureproper performance.

Install Ground Bus

Each enclosure must contain a central ground bus. The ground bus is thecommon connection for each chassis within the enclosure and theenclosure itself. Mount a ground bus using either bolts or studs. Figure 3.3(page 3-4) illustrates these mounting methods.

Connect Equipment Grounding Conductor

Use either 2.54cm (1-in.) copper braid or 8 AWG copper wire to connecteach chassis, the enclosure, and a central ground bus mounted on theback-panel. Use a steel enclosure to guard against EMI. If the enclosuredoor has a viewing window, it should be a laminated screen or aconductive optical substrate to block EMI. Do not rely on the hinge forelectrical contact between the door and the enclosure; install a bonding wire.

For information about connecting the equipmentground conductor to:

Refer to:

a ground bus Figure 3.6 (page 38)

an enclosure wall Figure 3.7 (page 38)



3-8

Figure 3.6Connecting Equipment Ground Connector to a Ground Bus

Equipmentgroundingconductors Ground

lug

Bolt

Starwasher

Grounding electrode conductorto grounding electrode system

Tapped hole

Ground bus

Ground busmounting

13271

Figure 3.7Connecting Equipment Ground Connector to an Enclosure Wall

10020

Enclosurewall Scrape

paintBolt

Groundlug

Nut

Starwasher

Equipmentgroundingconductor

Scrape paint onenclosure wall and usea star washer



3-9

Connect an equipment grounding conductor directly from each chassis toan individual bolt on the ground bus.

For chassis with: Connect the equipment groundingconductor using:

a ground stud the ground stud

no ground stud a mounting bolt

If the power supply has its own groundable chassis, do not connect theGND terminal of the power supply. However, when you connect power toa power supply without a groundable chassis (such as an ac inputpower-supply module), you must also use 14 AWG copper wire to connectits GND terminal to the ground stud or mounting bolt connected to theground bus.

Do not lay one ground lug directly on top of the other; this type ofconnection can become loose due to compression of the metal lugs. Placethe first lug between a star washer and a nut with a captured star washer.After tightening the nut, place the second lug between the first nut and asecond nut with a captive star washer (Figure 3.4 or Figure 3.5).

Connect Ground Bus to GroundingElectrode System

The grounding-electrode system is at earth-ground potential and is thecentral ground for all electrical equipment and ac power within any facility.Use a grounding-electrode conductor to connect the ground bus to thegrounding-electrode system. Use a minimum of 8 AWG copper wirefor the grounding-electrode conductor to guard against EMI. TheNational Electrical Code specifies safety requirements for thegrounding-electrode conductor.

Ground Shielded Cables

Certain connections require shielded cables to help reduce the effects ofelectrical noise coupling. Ground each shield at one end only. A shieldgrounded at both ends forms a ground loop which could cause faultyPLC-5 processor operation.

Ground each shield at the end specified in the appropriate publication forthe product.



3-10

Avoid breaking shields at junction boxes. Many types of connectors forshielded conductors are available from various manufacturers. If you dobreak a shield at a junction box:

connect only category-2 conductors in the junction box do not strip the shield back any further than necessary to make a

connection connect the shields of the two cable segments to ensure continuity along

the entire length of the cable

For more information about grounding the chassis, see ProgrammableController Wiring and Grounding Guidelines, publication 1770-4.1.

Set the I/O chassis backplane switches. Use a ball-point pen to set eachswitch. (Do not use a pencil because the tip can break off and short the switch.)

Use this table to find the switch settings you need:

When installing this component in an I/Ochassis:

Use this figure to set the chassisbackplane switches:

PLC5 processor Figure 3.8 (page 311)

1771AS, ASB, or ALX adapter module Figure 3.9 (page 312)

For information about addressing concepts, see the 1785 PLC-5Programmable Controller Design Manual, publication 1785-6.2.1.

Setting the I/O ChassisSwitches



3-11

Figure 3.8Set the I/O Chassis Backplane Switches Like This When Installing aPLC5 Processor in an I/O Chassis

4 5

2 - slot

1 - slot

1/2 - slot

1

AlwaysOff

19309

6 7

Outputs of this I/O chassis remain in their last state whena hardware failure occurs. 1

Outputs of this I/O chassis are turned off when ahardware failure occurs. 1

Pressed in at top ON (closed)

Pressed in at bottom OFF (open)

1. Regardless of this switch setting, outputs are reset when either of the following occurs:

• processor detects a runtime error

• an I/O chassis backplane fault occurs

• you select program or test mode

• you set a status file bit to reset a local rack

2. If an EEPROM module is not installed and processor memory is valid, the processor's PROC LED indicator blinks, and the processor sets S:11/9, bit 9 in the major fault status word.

3. A processor fault occurs if processor memory (solid red PROC LED) is not valid.

4. You cannot clear processor memory when this switch is on

EEPROM memory transfer to processor memory at powerup. 2

EEPROM memory transfers to processor memory if processor memorynot valid.

EEPROM memory does not transfer to processor memory. 3

RAM memory protection disabled.

RAM memory protection enabled. 4

Not allowed

RAM memory protectionSwitch

8

OFF

ON

EEPROM transfer

Addressing

Last StateSwitch

ON

OFF

Switches

Switches

OFF OFF

OFF ON

ON OFF

ON ON

OFF OFF

ON ON

ON OFF



3-12

Figure 3.9Set the I/O Chassis Backplane Switches Like This When Installing a1771AS, ASB Remote I/O Adapter Module or 1771ALX ExtendedLocalI/O Adapter Module in the I/O Chassis

ON

Switch

5

OFF

ON

OFF

ON

6

OFF

OFF

ON

ON

Switches

1

OFF

Last State

ON

Switch

2

OFF

Processor Restart Lockout

Addressing

Outputs of this I/O chassis remain in their last state when a communicationfault is detected by this I/O adapter.

ATTENTION: We recommend that you set switch 1 to the OFF position todeenergize outputs wired to this chassis when a fault is detected.

Also, if outputs are controlled by inputs in a different rack and a remote I/Orack fault occurs (in the inputs rack), the inputs are left in their last non-faultedstate. The outputs may not be properly controlled and potential personneland machine damage may result. If you want your inputs to be anything otherthan their last nonfaulted state, then you need to program a fault routine.

Outputs of this I/O chassis are turned off when acommunication fault is detected by this I/O adapter.

Processor can restart the I/O chassis after a communication fault. Set this switch to ON ifyou plan to use I/O rack autoconfiguration.

You must manually restart the I/O chassiswith a switch wired to the 1771AS or ASB,or with the pushbutton mounted in the 1771ALX.

Pressed inat top ON (closed)

Pressed inat top OFF (open)

1. The 1771AS adapter does not support 1slot or 1/2slot addressing. When you usethis adapter, set switches 5 and 6 to the OFF position.

2. The 1771ASB series A adapter does not support 1/2slot addressing.

19308

Always Off

Always Off

2slot

1slot 1

1/2 slot 1,2

Not allowed



3-13

Set the I/O chassis configuration plug according to whether you are using apower supply installed in the processor-resident chassis or an externalpower supply. To do this:

NY

NYNY

USING POWER SUPPLYMODULE IN THE CHASSIS?

Set Y when youinstall a powersupply module inthe chassis.

Set N when youuse an externalpower supply.

IMPORTANT: You cannot power a single I/O chassis with both apower supply module and an external power supply.

17075

1. Locate the chassis configuration plug (between the first two left most slotsof the chassis).

2. Set the I/O chassis configuration plug.

The default setting is N (not using a power supply module inthe chassis).


Mount chassis

Ground chassis






Install EEPROM modules

√√√√

chapter 3 chapter 4

Setting the I/O ChassisConfiguration Plug

What to Do Next


Chapter

4

4-1

Install and Remove Processor Batteries andMemory Modules

Use this chapter to help you install batteries and memory modules.





chapter 4

Also, refer to this chapter when you must remove the processor’s battery ormemory module.

Chapter Objectives


Install and Remove Processor Batteriesand Memory Modules

Chapter 4

4-2

The PLC-5/10, -5/12, -5/15, and -5/25 use the 1770-XY battery. Thisbattery contains less than 1/2 gram of lithium. Refer to Allen-BradleyGuidelines for Lithium Battery Handling and Disposal, publicationAG-5.4.

ATTENTION: Installing the battery requires handling theprocessor, which can cause electrostatic discharge. Electrostaticdischarge can damage integrated circuits or semiconductors inthe processor. Avoid damage from electrostatic discharge byusing a grounding strap and observe these guidelines:

Touch a grounded object to discharge yourself beforehandling the processor.

Do not touch the backplane connector or connector pins.

Keep the processor in its static-shield bag when not in use.

To install the battery, follow these steps:

1. Remove the processor from its static-shield bag.

2. Locate the processor’s battery connector.

3. Install the battery according to Figure 4.1.

Installing the Battery



Chapter 4

4-3

Figure 4.1Installing a Processor Battery

+

-

19333

a. Place the new battery in the holder.

b. Make sure that the positive (+) end of the battery contacts thepositive (+) end of the battery holder and that the negative (-)end of the battery contacts the negative (-) end of the battery holder.

Installing a 1770XY battery into a PLC5/10,5/12, 5/15, or 525 processor

4. Place the battery cover over the installed battery; secure the batterycover with the thumb screw.

5. Write the date you installed the battery on the battery cover.

We recommend that you replace the internal lithium battery every year orwhen the BATT status indicator is red. For estimated battery lifetimes, seeAppendix A.

ATTENTION: The 1770-XY can be replaced by a 3.6V, “AA”size, Tadiran TL5104 type AEL/S lithium battery with pressurecontact terminals.

If you replace the 1770-XY, the replacement battery must havethe same specifications as the 1770-XY.

Replacing the Battery



Chapter 4

4-4

Important: You can insert or remove the battery without powering downthe processor. However, if you do not want to lose your program, makesure the processor is powered when replacing the battery.

Important: Memory in the CMOS RAM module is volatile memory.When you replace the battery in the processor during regular maintenance,make sure the processor is powered up; otherwise you will lose memory.

To replace a battery:

1. Loosen the thumb screw that secures the battery cover.

2. Remove the battery.

3. Follow the installation procedure.

Refer to Allen-Bradley Guidelines for Lithium Battery Handling andDisposal, publication AG-5.4.

Do not dispose lithium batteries in a general trash collection when theircombined weight is greater than or equal to 1/2 gram. Check your state andlocal regulations that deal with the disposal of lithium batteries.

ATTENTION: Follow these precautions:

Do not incinerate or expose the battery to high temperatures.

Do not solder the battery or leads; the battery could explode.

Do not open, puncture, or crush the battery. The battery couldexplode and toxic, corrosive, and flammable chemicals could beexposed.

Do not charge the battery. An explosion might result or the cellmight overheat and cause burns.

Do not short positive or negative terminals together. The batterywill heat up.

Disposing of a Battery



Chapter 4

4-5

This table describes the EEPROM module you can use for the PLC-5/10,-5/12, -5/15, -5/25 processor:

For this processor: Use this EEPROM module: Size (words):

PLC5/10, 5/12, 5/15 1785MJ 8K

PLC5/25 1785MJ

1785MK

8K

16K

The EEPROM module has two plastic tracks on the bottom that correspondto grooves in the processor memory-module slot. To install the EEPROMmodule in a PLC-5/10, -5/12, -5/15, -5/25 processors, observe anti-staticprecautions and do the following:

1. Label the memory module to indicate the programs or processor youare backing-up.

2. Turn off power to the I/O chassis and processor.

ATTENTION: Do not insert or remove the EEPROM underpower. Insertion or removal under power can result in loss ofprogram memory and a processor fault.

3. Lift the latch of the I/O chassis that holds your processor; remove theprocessor from the chassis.

4. Place the processor on a clean flat surface with the bottom of themodule facing you and the front of the processor to your right.

5. Position the memory module in the memory-module slot with itslabel facing upward. Insert and press firmly (Figure 4.2).

Install the 1785MJ and

1785MK EEPROM Module



Chapter 4

4-6

Figure 4.2Inserting a Memory Module

12077

6. Slide the processor into the I/O chassis and secure the I/O chassis latches.

7. Turn on system power.

This table describes the CMOS RAM modules you can use for yourPLC-5/15 or -5/25 processor.

CMOS RAM module: Size (words):

1785MR 4K

1785MS 8K

To install a CMOS RAM module, do the following:

1. Back-up your processor memory on a disk.

2. Turn off the incoming power source.

3. Lift the latch of the I/O chassis that holds your processor; remove theprocessor from the chassis.

4. Remove the battery from the processor.

5. Place the processor on a clean flat surface with the bottom of themodule facing you and the front of the processor to your right.

6. Position the memory module in the memory-module slot with itslabel facing upward. Insert and press firmly (Figure 4.2).

Install the 1785MR and MSCMOS RAM Module(PLC5/15, 5/25 processors)



Chapter 4

4-7

7. Replace the battery.

8. Slide the processor into the I/O chassis and secure the I/O chassislatches.

9. Turn on system power.

10. Clear memory.

11. Reload processor memory.

Processor memory is invalid when you initially insert a CMOS RAMmodule. Make sure you clear memory after inserting the CMOS RAMmodule for the first time.

To remove the EEPROM modules and/or the CMOS RAM modules fromthe PLC-5/10, -5/12, -5/15, -or 5/25 processors, do the following:

1. Follow the steps listed in this table:

For this memory module: Do the following:

1785MJ, MK (EEPROM) 1. Turn off power to the I/O chassis andprocessor.

2. Lift the latch of the I/O chassis that holdsyour processor and remove the processorfrom the chassis.

3. Place the processor on a clean flat surfacewith the bottom of the module facing youand the front of the processor to your right(refer to Figure 4.2 on previous page).

1785MR, MS (CMOS RAM) 1. Back up your processor memory on a disk.

2. Turn off the incoming power source.

3. Lift the latch of the I/O chassis that holdsyour processor and remove the processorfrom the chassis.

4. Remove the battery from the processor.

5. Place the processor on a clean flat surfacewith the bottom of the module facing youand the front of the processor to your right(refer to Figure 4.2 on the previous page).

2. Insert a coin into the memory-module slot so that it engages the lip onthe memory module.

3. Carefully rotate the coin upward to remove the memory module fromits slot.

4. Grasp and remove the memory module.

Remove the EEPROM orCMOS RAM Modules(PLC5/10, 5/12, 5/15,5/25 processors)



Chapter 4

4-8

What to Do Next



Install CMOS RAM modulePLC5/10, 5/12, 5/15, 5/25 only

Install EEPROM modules

√√√







chapter 4 chapter 5


Chapter

5

5-1

Install or Remove a PLC5/10, 5/12, 5/15, and 5/25 Processor

Use this chapter to help you install and remove a PLC-5/10, -5/12, -5/15,or -5/25 processor.







chapter 5

Define the communication modes of a PLC-5/10, -5/12, -5/15, -5/25processor by specifying DH+ station address, scanner mode or adaptermode. To do this, set the switches on switch assembly SW1 by followingthese steps:

1. Locate Switch Assembly SW1.

Figure 5.1Switch Assembly SW1 on a PLC5/10, 5/12, 5/15, 5/25 Processor

Top view of PLC5/10, 5/12, 5/15, 5/25 processor

Switch Assembly SW1

Chapter Objectives

Configuring PLC5/10, 5/12,5/15 and 5/25 ProcessorCommunication



Chapter 5

5-2

2. Set the switches according to Table 5.A and Table 5.B.

Table 5.ASW1 Settings

To select: Set switch: To:

DH+ station number 1 through 6 (see Table 5.B )

Switch 7 not used 7 off

scanner mode

PLC5/10 processors function in scannermode only.

8 off

adapter mode

PLC5/12 processors function in adaptermode only.

Switch 8 not used for PLC5/10 processors.

8 on

Table 5.B lists the available station numbers that you can select and thecorresponding settings for switches 1 through 6.

Table 5.BStation Number Selections for SW1

StationNumber

01234567

1011121314151617202122232425262730313233343536

374041

1

onoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffon

offonoff

2

ononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoff

offonon

3

ononononoffoffoffoffononononoffoffoffoffononononoffoffoffoffononononoffoffoff

offonon

4

ononononononononoffoffoffoffoffoffoffoffononononononononoffoffoffoffoffoffoff

offonon

5

ononononononononononononononononoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

offonon

6

ononononononononononononononononononononononononononononononon

onoffoff

StationNumber

424344454647505152535455565760616263646566677071727374757677

1

onoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoff

2

offoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoff

3

ononoffoffoffoffononononoffoffoffoffononononoffoffoffoffononononoffoffoffoff

4

ononononononoffoffoffoffoffoffoffoffononononononononoffoffoffoffoffoffoffoff

5

ononononononononononononononoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

6

offoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

SwitchSwitch

14095

toggle pushed

on

toggle pushed

off

Side view

toward bottom

toward top


Install or Remove a PLC5/10, 5/12, Chapter 5

5/15 and 5/25 Processor

5-3

Configure adapter mode communication by defining:

I/O rack number of the processor operating in adapter mode

beginning I/O group assigned to the processor operating inadapter mode

number of words exchanged between the supervisory processor and theprocessor operating in adapter mode

Use switch assembly SW2 to define adapter mode communicationfollowing these steps:

1. Locate switch assembly SW2.

Figure 5.2Switch Assembly SW2


Switch Assembly SW2

Configuring Adapter ModeCommunication



Chapter 5

5-4

2. Set SW2 according to your use of the processor as an adapter in oneof these systems:

For switch settings for a PLC5 processor as an adapter in a: See page:

PLC5 processor acting as a scanner, Qbus I/O scanner module,IBM PC I/O scanner module, VMEbus I/O scanner module, orVME/PLC5 controller remote I/O system

54

PLC2/20, PLC2/30, or Sub I/O Scanner Module remoteI/O system

55

PLC3 or PLC5/250 remote I/O system, 8word groups 56

PLC3 or PLC5/250 remote I/O system, 4word groups 57

PLC5 Processor as an Adapter in a PLC5 Processor, ScannerModule, or VME System

Set SW2 according to Table 5.C and Table 5.D.

Table 5.CSW2 Settings for a PLC5 Processor as an Adapter in a PLC5 Processor,Scanner Module, or VME System

If You Want: Set switch: To:

Switch 1 is always unused. 1 off

the host processor to use 8 words tocommunicate with the adapter PLC5processor

2 off

the host processor to use 4 words tocommunicate with the adapter PLC5processor(8 or 4 words are being transferred)

2 on

first I/O group to be 0 (8 words are being transferred)

3 on

first I/O group to be 4 3 off

select the I/O rack number of the adapterPLC5 processor

4 through 8 see Table 5.D

Table 5.D lists the available rack numbers you can use and thecorresponding switch settings. Note that the processor-resident rack israck 0 by default.

toggle pushed

on

toggle pushed

off

Side view

toward bottom

toward top




5-5

Table 5.DI/O Rack Number Selections for a PLC5 Remote I/O System

Set switch:

To select rack: 4 5 6 7 8

01 on on on on off

02 on on on off on

03 on on on off off

04 on on off on on

05 on on off on off

06 on on off off on

07 on on off off off

PLC5/11 processors can scan remote I/O rack 03

PLC5/15 processors can scan remote I/O racks 0103


PLC5 Processor as an Adapter in a PLC2 /20, 2/30 , or Sub I/OScanner Module Remote I/O System

Set SW2 according to Table 5.E and Table 5.F:

Table 5.ESW2 Settings for a PLC5 Processor as an Adapter in a PLC2/20, 2/30,or Sub I/O Scanner Module Remote I/O System




2 off


2 on

first I/O group to be 0 3 on



4 through 8 see Table 5.F

Table 5.F lists the I/O rack numbers and corresponding switch settings forSW2 in a PLC-2 system.

toggle pushed

on

toggle pushed

off

Side view

toward bottom

toward top



Chapter 5

5-6

Table 5.FI/O Rack Number Selections for a PLC2 System

Set switch:

To select rack: 4 5 6 7 8

01 on on on on on

02 on on on on off

03 on on on off on

04 on on on off off

05 on on off on on

06 on on off on off

07 on on off off on

PLC5 Processor as an Adapter in a PLC3 or PLC5/250 System(8word groups)

Set SW2 according to Table 5.G and Table 5.H:

Table 5.GSW2 Settings for a PLC5 Processor as an Adapter in a PLC3 orPLC5/250 System (8word groups)


Switch 1 is always unused. 1 off (open)


2 off (open)


3 through 8 see Table 5.H

Table 5.H lists the I/O rack numbers and corresponding switch settings forSW2 in a PLC-3 or PLC-5/250 system (8 words).

toggle pushed

on (closed)

toggle pushed

off (open)

Side view

toward bottom

toward top




5-7

Table 5.HI/O Rack Number Selections for a PLC3 or PLC5/250 System (8 words)

StationNumber

01234567

1011121314151617202122232425262730313233343536

3

ononononononononononononononononononononononononononononononon

4

ononononononononononononononononoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

5

ononononononononoffoffoffoffoffoffoffoffononononononononoffoffoffoffoffoffoff

6

ononononoffoffoffoffononononoffoffoffoffononononoffoffoffoffononononoffoffoff

7

ononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoff

8

onoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffon

StationNumber

4243444546475051525354555657606162636465666770717273747576

3

offoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

4

ononononononononononononononoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

5

ononononononoffoffoffoffoffoffoffoffononononononononoffoffoffoffoffoffoff

6

ononoffoffoffoffononononoffoffoffoffononononoffoffoffoffononononoffoffoff

7

offoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoff

8

onoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffon

SwitchSwitch

14098

374041

oonoffoff

ooffonon

ooffonon

ooffonon

offonon

offonoff

PLC5 Processor as an Adapter in a PLC3 or PLC5/250 System(4word groups)

Set SW2 according to Table 5.I and Table 5.J:

Table 5.ISW2 Settings for a PLC5 Processor as an Adapter in a PLC3 orPLC5/250 System (4word groups)




2 on

first I/O group to be 0 3 on



4 through 8 see Table 5.J

toggle pushed

on

toggle pushed

off

Side view

toward bottom

toward top



Chapter 5

5-8

Table 5.J lists the I/O rack numbers and corresponding switch settings forSW2 in a PLC-3 or PLC-5/250 system (4 words).

Table 5.JI/O Rack Number Selections for a PLC3 or PLC5/250 System (4 words)

I/O RackNumber

01234567

101112131415161720212223242526273031323334353637

4

ononononononononononononononononoffoffoffoffoffoffoffoffoffoffoffoffoffoffoffoff

6

ononononoffoffoffoffononononoffoffoffoffononononoffoffoffoffononononoffoffoffoff

5

ononononononononoffoffoffoffoffoffoffoffononononononononoffoffoffoffoffoffoffoff

7

ononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoffononoffoff

8

onoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoffonoff

Switch

14099




5-9

If a PLC-5/10, -5/12, -5/15, or -5/25 processor is an end device on either aDH+ or remote I/O network, terminate the link by setting switch assemblySW3, which connects a terminator across the line. Follow these steps:

1. Locate switch assembly SW3.

Figure 5.3PLC5/10, 5/12, 5/15, 5/25 Processor Switch Assembly SW3


Switch Assembly SW3

2. Set SW3 according to Table 5.K:

Table 5.KPLC5/10, 5/12, 5/15, 5/25 Processor Switch Assembly SW3 Settings

If the processor is: Set switch: To:

an end device on the remote I/O link 1 on

not an end device on the remote I/O link 1 off

an end device on the DH+ link 2 on

not an end device on the DH+ link 2 off

switch 3 unused 3 off

switch 4 unused 4 off

For more information about terminating links, refer to chapter 7 andchapter 11.

Connecting TerminationResistors

toggle pushed

on

toggle pushed

off

Side view

toward bottom

toward top



Chapter 5

5-10

You receive plastic keying bands with each I/O chassis. Insert two keyingbands in the top backplane sockets of the I/O chassis. Place a keying bandin the left-most slot between the following pins (see Figure 5.4):

40 and 42 54 and 56

Figure 5.4PLC5 Processor Keying Band Positions

2468101214161820222426283032343638404244464850525456

12062

I/O Chassisbackplaneconnector

Keying bands(1771RK)

Use thesenumbersas a guide

Use the numbers to the right of the backplane socket as a guide whenpositioning the keying bands.

ATTENTION: A module inserted into a wrong slot could bedamaged by improper voltages connected through the wiringarm. Use keying bands to prevent damage to the module.

To insert the processor into the chassis, do the following:

1. Slide your processor into the left-most slot of the I/O chassis.

2. Snap the module-locking latch over the processor.

Installing the Keying Bands

Inserting the Processor intothe Chassis




5-11

To remove the processor from the chassis, do the following:

1. Back-up processor memory

2. Remove power to the processor-resident chassis.

3. Disconnect all cables from the processor’s ports.

4. Lift the locking latch and slide the processor from the chassis.

The system component you install next depends upon your system design.

To do the following: See:

Install a remote I/O link chapter 6

Install I/O modules chapter 7

Removing the Processorfrom the Chassis







√√√√√

chapter 5

What to Do Next


Chapter

6

6-1

Install the Remote I/O Link

Use this chapter to help you install a remote I/O link. We recommend thatyou perform the listed tasks in the order they are shown.

Install remote I/O link



Terminate the link

chapter 6

Set the switches on the 1771-AS or 1771-ASB (series B, C, and D) remoteI/O adapter module according to your use of chassis-to-chassiscomplementary I/O. Use the table below to find the appropriate switchsetting information and information about how to set the adapter switches.

For this switch setting information: Refer to: Page:

Adapter not in a complementary I/O system

Adapter switches settings when not used in a complementary I/O system

Available I/O rack numbers

Available starting I/O group numbers

Figure 6.1

Table 6.A

Table 6.B

62

63

64

Adapter in a complementary I/O system

Adapter switches when used in a complementary I/O system

Available I/O rack numbers

Available starting I/O group numbers

Figure 6.2

Table 6.C

Table 6.D

65

66

66

Chapter Objectives

Set Remote I/O AdapterSwitches


Install Remote I/O LinkChapter 6

6-2

Figure 6.1Switch Settings for a 1771ASB Remote I/O Adapter Module Not in aComplementary I/O System

1 2 3 4 5 6 7 8ON

OFF

1 2 3 4ON

OFF

16470

For 57.6 kbps transmission rate, set ON

For 115.2 kbps transmission rate, set OFF

1771AS or 1771ASB series A or B

Starting I/OGroup Number

I/O Rack Number

SW1 SW2

Pressed inat top ON (closed)


Always OFF

19306



Address Switch Assembly(S1)

Switch Assembly(S2)

Always OFF

StartingI/O group

I/O rack numbers

Link Response -ON for series B emulationOFF for unrestricted

Scan -ON for all but last 4 slotsOFF for all slots

Always OFF

Switch Position1 2

ON OFFOFF OFFOFF ONON ON

Maximum I/Ochassis distance

57.6 kbps 10,000ft115.2 kbps 5,000ft230.4 kbps 2,500ftnot used

1771ASB series C or D



6-3

Table 6.AAvailable Remote I/O Rack Numbers for Adapter Modules Not in aComplementary I/O System

Set switch:

To select rack: 1 2 3 4 5 6

01 on on on on on off

02 on on on on off on

03 on on on on off off

04 on on on off on on

05 on on on off on off

06 on on on off off on

07 on on on off off off

PLC5/11 processors can scan remote I/O rack 03

PLC5/15 and 5/20 processors can scan remote I/O racks 0103

PLC5/25, 5/30 processors can scan remote I/O racks 0107

10 on on off on on on

11 on on off on on off

12 on on off on off on

13 on on off on off off

14 on on off off on on

15 on on off off on off

16 on on off off off on

17 on on off off off off

20 on off on on on on

21 on off on on on off

22 on off on on off on

23 on off on on off off

24 on off on off on on

25 on off on off on off

26 on off on off off on

27 on off on off off off


PLC5/60 and PLC5/80 processors can scan remote I/O racks 0127



6-4

Table 6.BAvailable Starting I/O Group Numbers for Adapter Modules Not in aComplementary I/O System

Set switch

For Starting I/OGroup Number:

7 8

0 on on

2 on off

4 off on

6 off off



6-5

Figure 6.2Switch Settings for a Remote I/O Adapter Module in a Complementary I/O System

1 2 3 4 5 6 7 8ON

OFF

1 2 3 4ON

OFF

16471

For 57.6 kbps transmission rate, set ON

For 115.2 kbps transmission rate, set OFF

1771AS or 1771ASB series A and B



Always OFFAlways ON

ON - Primary ChassisOFF - Complementary Chassis

I/O Rack Number

Starting I/OGroup Number


SW1 SW2

19307

1771ASB series C or D

Address Switch Assembly(S1)

Starting I/Ogroup number

I/O rack numbersAlways ON


Always OFF



Link Response -ON for series B emulationOFF for unrestricted

Scan -ON for all but last 4 slotsOFF for all slots

Switch Position1 2

ON OFFOFF OFFOFF ONON ON

Maximum I/Ochassis distance

57.6 kbps 10,000ft115.2 kbps 5,000ft230.4 kbps 2,500ftnot used

ON - Primary chassisOFF - Complementary chassis

Switch Assembly(S2)



6-6

Important: Only racks 1-7 can be complemented in a PLC-5 system.

You can complement seven (1-7) racks and use the remaining racks fornon-complementary I/O when you are using a PLC-5/40, -5/40L, -5/60, or-5/60L series B (or later) processor or a PLC-5/80 series C (or later)processor as a remote I/O scanner. You can complement only racks 1-7.These complemented I/O racks can be split among scanner channels aslong as each selected scanner channel is configured for complementaryI/O. A channel configured for complementary I/O cannot scan racks 10-17or 20-27. You can scan these racks on a remote I/O scanner channel that isnot configured for complementary I/O.

Table 6.CAvailable Remote I/O Rack Numbers in a Complementary I/O System

Set switch:

To select rack: 4 5 6

1 1 on on off

2 1 on off on

3 1,2 on off off

4 off on on

5 off on off

6 off off on

7 off off off

1 PLC5/15 and 5/20 processors can access only racks 1, 2, and 3.

2 PLC5/11 processors can only access one remote rack (rack 3)

Table 6.DAvailable Starting I/O Group Numbers for Adapter Modules in aComplementary I/O System

Set switch

For starting I/O group number: 7 8

0 on on

2 on off

4 off on

6 off off



6-7

Install the adapter module in the first slot of the remote I/O chassisaccording to the installation procedure in the Remote I/O Adapter ModuleInstallation Manual, publication 1771-6.5.8. Follow all electrostaticdischarge prevention recommendations.

Use Belden 9463 twin-axial cable, cat. no.1770-CD, to connect devices toa remote I/O link. To connect a remote I/O link, do the following:

ensure the cables are the correct length prepare the cable make the remote I/O connections

Ensure Correct Cable Lengths

Verify that your system’s design plans specify remote I/O cable lengthswithin allowable measurements.

Important: The maximum cable length for remote I/O depends on thetransmission rate.

A remote I/O link using thiscommunication rate:

Cannot exceed thiscable length:

57.6 kbps 3,048 m (10,000 ft)

115.2 kbps 1,524 m (5,000 ft)

230.4 kbps 762 m (2,500 ft)

Install the Adapter Module

Connect Remote I/O Link



6-8

Important: The following products (Table 6.E) cannot be on a link using82Ω termination resistors:

Table 6.EI/O Link Devices that Do Not Support 82Ω Termination Resistors

Device Type Cat. No. Series

Scanners 1771SN all

1772SD, SD2

1775SR

1775S4A, S4B

6008SQH1, SQH2

Adapters 1771AS

1771ASB A

1771DCM all

Miscellaneous 1771AF

Prepare the Cable

Cut the cable according to the lengths you need. Route the cable tothe devices.

Make Remote I/O Connections

Use Figure 6.3 when connecting the remote I/O cable to PLC-5 processorsand remote I/O adapter modules.



6-9

Figure 6.3Remote I/O Terminal Connectors

Connect a 1771ASB to a PLC5/15 or 5/25 processor like this:

To connect remote I/O cable, do the following:

1. Run the cable (1770CD) from theprocessor to each remote I/O adaptermodule or processor in the remote I/Osystem.

2. Connect the signal conductor with blueinsulation to the 3pin connector terminallabeled 1 on the processor and to eachremote I/O adapter module (or PLC5adapter) in the remote I/O system.

3. Connect the signal conductor with clearinsulation to the 3pin connector terminallabeled 2.

4. Connect the shield drain wire to the 3pinterminal labeled SH.

5. Tie wrap the remote I/O network cable tothe chassis to relieve strain on the cable.

13 0 9

DH+

DH+

0

Terminal identificationof remote I/O connectionto a PLC5/15 or 5/25 processor

Terminal identificationof 1771ASB remote I/Oadapter module

Remote I/Oterminalconnectors

BlueShieldClear

BlueShieldClear

1 Line 12 Shield3 Line 24 No connection5 No connection6 No connection7 No connection8 No connection9 No connection10 No connection11 In12 Ret

Cable

Reset

Terminate the Link

You must terminate both ends of a remote I/O link to ensure properoperation. Use Table 6.F to determine how to terminate the link.

Table 6.FTerminating the Remote I/O Link

If this device is an enddevice of a remote I/O link:

Terminate the link by:

PLC5/15 or 5/25 processor setting switch 1 of switch assembly SW3 to ON. Refer tochapter 6 for more information on setting this switch

remote I/O adapter module connecting a terminator resistor between the remote I/Oterminals labeled 1 and 2. Refer to Figure 6.4.

Use either a 150Ohm or 82Ohm terminator. However, youcan only use an 82Ohm resistor when either of the followingconditions are met:

• The remote I/O link is operating at 230.4 kbps (terminatormust be connected at both the scanner and adapter.)

• The remote I/O link is operating at 57.6 kbps or 115.2 kbpsand none of the devices on the link are listed in Table 6.E.



6-10

Figure 6.4Terminating a Remote I/O Link Using a Resistor

1

2

19334

PLC5/11, 5/20, 5/30, 5/40, 5/40L, 5/60, 5/60L, or5/80 processor or remote I/O adapter module as thelast device on an remote I/O link.

Another I/O link deviceTo

I/O adapter

Blue

Shield

Clear

Blue

Shield

Clear

Blue

Shield

Clear

150Ωor82Ω

Beldon9463

Beldon9463

The system component you install next depends upon your system design.What to Do Next

Install remote I/O link



Terminate the link

√√√

Install I/O modules

Install modules

Install wiring arms


chapter 6 chapter 7


Chapter

7

7-1

Install I/O Modules

Use this chapter to help you install I/O modules.

Install I/O modules

Install modules

Install wiring arms


chapter 7

Before installing I/O modules, remove power from the I/O chassisbackplane and wiring arm.

ATTENTION: Remove power from the 1771 I/O chassisbackplane and wiring arm before installing or removing anI/O module.

Failure to remove power from the backplane or wiring armcould cause module damage, degradation of performance, orpersonal injury.

Failure to remove power from the backplane couldcause injury or equipment damage due to possibleunexpected operation.

Insert each I/O module into its corresponding keyed slot by sliding it ontothe plastic tracks of the I/O chassis. Snap the module locking latch over theI/O module.

ATTENTION : Do not force an I/O module into a backplaneconnector. Forcing an I/O module can damage the backplaneconnector and/or the I/O module.

Because power-supply modules have a controlled “soft start” feature toenhance power supply reliability, some output modules can momentarilychange operating state during power-up or power-down of thepower-supply modules. Table 7.A lists these output modules.

Chapter Objectives

Install Modules


Installing I/OChapter 7

7-2

Table 7.AOutput Modules Affected by the Power Supply SoftStart Feature

Catalog Number Module Series

1771OD Isolated ac (120V) Output Module A or B 1

1771OY Contact Output Module A or B 1

1771OZ Contact Output Module A or B 1

1771OR Isolated ac (220V) Output Module A 1

1 later series output modules are not affected

If you are using these modules in your plant, observe the followingwarning when powering-up or powering-down the chassis that containsthese modules.

ATTENTION: Disconnect all power from devices controlledby these I/O modules that can cause damage to equipment orinjure people during power-up and power-down of thepower-supply modules.

For more information on these power supplies, refer to the appropriatepublication, as listed in the Allen-Bradley Publications Index,publication SD499.

Snap each wiring arm onto the horizontal bar of the I/O chassis(Figure 7.1). When I/O modules are in place, the wiring arm connects tothe module.

Install Wiring Arms



7-3

Figure 7.1Installing Wiring Arms

Wiring arm

Horizontal BarRemove

Install17643

Your I/O devices (sensors, actuators, etc.) connect to the I/O module’swiring arm. Before wiring your I/O devices, choose the proper cable forthe I/O modules you are using. Refer to the specific I/O moduleinstallation instructions for this information and for connection diagrams.

Choose the Proper Cable

You can wire your I/O devices using:

single-conductor cable

A single-conductor cable has one wire strand enclosed in a casing orouter jacket. We recommend using copper wire.

multi-conductor cable

A multi-conductor cable has many single-conductor wires enclosed in acasing or outer jacket.

multi-conductor shielded cable

Multi-conductor shielded cable can be Belden type 9463. It consists oftwisted pairs of conductor wires wrapped in a foil shield. The number ofI/O terminals determines the number of conductor wires that you needwithin the cable. Figure 7.2 shows each component of this cable:

Wire I/O to Wiring Arms



7-4

Figure 7.2Components of a Multiconductor Shielded Cable

13087

Foil shield InsulationConductor

Drain wire

Outer jacket

These I/O modules: Require this cable:

intelligent I/O multiconductor shielded cable

low voltage dc (discrete) I/O

analog I/O either single or multiconductor cable

remaining discrete I/O



7-5

Connect I/O to Wiring Arm

To wire your I/O devices, do the following:

3

4

Multiconductor nonsheilded

Outer jacket Foil shieldConductor

2"

Insulation

.38"

Drain wire

Multiconductor shielded

If you are using this type of cable: Then do the following:

1. Remove the wiring arm's terminal cover using a

flathead screwdriver.

2. Prepare cable.

a. Measure the wire distance from your I/O devices to the wiring arm terminals.This distance plus 3 ft is the amount of wire you need.

b. Cut the wire.

c. Refer to the table below.

3. Loosen a terminal screw and place the wire under the pressure plate

of the terminal screw.

4. Secure the terminal screw.

5. Repeat steps 2 through 4 for all I/O devices.

d. Strip about 3/8 inch insulation to expose the end of the wire.

Expose the individual wires by strippingsome casing from the end of the cablethat connects to the wiring arm

1. Strip insulation from the end of the cable thatconnects to the wiring arm and expose the foil.

You may need to insulate the bare drain wirewith tape or shrink tubing along areas whereit might otherwise come in contact with wiringarm terminals.

2. Bend the drain wire back to separate it from the conductor wiring.

3. Trim the insulated wires to 5.08cm (2in) lengths.



7-6

19313

6. Connect the drain wire to ground at the I/O chassis only.

7. Gather all similar wires and bundle them using tie wraps.

8. Label all of your wires at each wire connection at the wiring arm.

9. Make sure that the wiring arm pivots freely.

10. Replace the wiring arm's terminal cover.

11. Write terminal numbers on the labels next to the terminal's

status indicator and on the terminal cover.

Refer to chapter 3 for more information about grounding shielded cablesand connecting drain wires to the chassis grounding system.

Install I/O modules Connect power




√ Install modules

Install wiring arms


√√

chapter 7 chapter 8What to Do Next


Chapter

8

8-1

Connect Power

Use this chapter to help you connect the proper power system to yourprocessor system.

Connect power




chapter 8

For more information, see Programmable Controller Wiring andGrounding Guidelines, publication 1770-4.1.

You can use two types of power supplies:

power-supply modules — located in the same chassis with the processor power supplies — located external to the chassis

Powering a Chassis Containing a PLC5 Processor

Table 8.A lists the power-supply modules you can use in a chassis with aPLC-5 processor and the power supplies you can use external to a chassis.

Table 8.APower Supply Modules in a Chassis (containing a PLC5 processor)

Output Current (in amps) When Parallel With:

Power Supply

Input Power

Output Current(in Amps)

P3 P4 P4S P4S1 P5 P6S P6S1 Power SupplyLocation

1771P3 120V ac 3 6 11 11 slot

1771P4 120V ac 8 11 16 16 slot

1771P4S 120V ac 8 11 16 16 slot

1771P4S1 100V ac 8 16 slot

1771P4R 120V ac 8/16/24 2 slot

1771P5 24V dc 8 16 slot

1771P6S 220V ac 8 16 slot

1771P6S1 200V ac 8 16 slot

1771P6R 220V ac 8/16/24 2 slot

1771P7 120/220V ac 16 external 1

1771PS7 120/220V ac 16 external 1

1 You cannot use an external power supply and a power supply module to power the same chassis; they are not compatible.

2 See publication 17712.136 for more information.

Chapter Objectives

About the Power SuppliesYou Can Use


Connect PowerChapter 8

8-2

Powering a Remote I/O Chassis Containing a 1771AS or 1771ASB oran ExtendedLocal I/O Chassis Containing a 1771ALX.

Table 8.B lists the power-supply modules you can use:

in a remote I/O chassis with a 1771-AS or -ASB in an extended local I/O chassis with a 1771-ALX external to a remote I/O chassis. external to an extended local I/O chassis.

Table 8.BPower Supplies in a Remote Chassis (containing a 1771AS or ASB) oran Extended Local I/O Chassis (containing a 1771ALX)

Output Current (in amps) When Parallel With:

Power Supply

Input Power

Output Current(in Amps)

P3 P4 P4S P4S1 P5 P6S P6S1 Power SupplyLocation

1771P3 120V ac 3 6 11 11 slot

1771P4 120V ac 8 11 16 16 slot

1771P4S 120V ac 8 11 16 16 slot

1771P4S1 100V ac 8 16 slot

1771P4R 120V ac 8/16/24 2 slot

1771P5 24V dc 8 16 slot

1771P6S 220V ac 8 16 slot

1771P6S1 200V ac 8 16 slot

1771P6R 220V ac 8/16/24 2 slot

1771P1 120/220V ac 6.5 external 1

1771P2 120/220V ac 6.5 external 1

1771P7 120/220V ac 16 external 1

1771PS7 120/220V ac 16 external 1

1777P2 120/220V ac 9 external 1

1777P4 24V dc 9 external 1

1 You cannot use an external power supply and a power supply module to power the same chassis; they are not compatible.

2 See publication 17712.136 for more information.

Connect a separate transformer between the ac power source and theprocessor power supply to provide dc isolation from other equipment. Toconnect a transformer, do the following:

1. Connect the transformer primary to the ac source.

2. Connect the high side of the transformer secondary to the L1 terminalof the power supply.

Distributing Power



8-3

3. Connect the low side of the transformer secondary to the neutral(common) terminal of the power supply.

Figure 8.1 and Figure 8.2 illustrates the proper power distribution.

Figure 8.1Grounded ac Power Distribution System with Master Control Relay

1

+ -

Notes:

1. To minimize EMI generation, you should connect a suppression network: for 120V AC, useAllenBradley cat. no. 700-N24; for 220/240V AC, use cat. no. 599-KA04.

2. To minimize EMI generation, you should connect a suppression network: for 120V AC, useAllenBradley cat. no. 599-K04; for 220/240V AC, use cat. no. 599-KA04.

3. For a power supply with a groundable power supply chassis, this represents connection to thepower supply chassis only. For a power supply without a groundable power supply chassis,this represents connection to the GND terminal.

4. In many applications, a second transformer provides power to the input circuits and powersupplies for isolation from the output circuits.

Incoming ac

L1

L2

L3

Disc1FU

2FU

3FU

L1

L2

L3

To motorstarters

Stepdown4

transformer Enclosure wallBack panel

ground bus

Grounding electrodeconductor togrounding electrodesystem

Connectwhen applicable

To dc I/Odevices

User DCSupply

CRM

Equipmentgroundingconductors

CRM

Start

CRM

Use any numberof Estep switchesin series

FUSE

CRM

GND3PLC

power supply

L1 N

Outputdevice

2

Inputmodulewiring arm

Inputdevice

Output modulewiring arm

H1

H2H3

H4

X1 X2

12203



8-4

Figure 8.2Ungrounded ac Power Distribution System with Master Control Relay

+ -

Notes:

1. To minimize EMI generation, you should connect a suppression network: for 120V AC, useAllenBradley cat. no. 700-N24; for 220/240V AC, use cat. no. 599-KA04.

2. To minimize EMI generation, you should connect a suppression network: for 120V AC, useAllenBradley cat. no. 599-K04; for 220/240V AC, use cat. no. 599-KA04.

3. For a power supply with a groundable power supply chassis, this represents connection to thepower supply chassis only. For a power supply without a groundable power supply chassis,this represents connection to the GND terminal.

4. In many applications, a second transformer provides power to the input circuits and powersupplies for isolation from the output circuits.

Disc

Incoming ac

L1

L2

L3

1FU

2FU

3FU

L1

L2

L3

To motorstarters

Stepdown4

transformer Enclosure wall

Back panelground bus

Connectwhen applicable

Equipmentgroundingconductors

H1

H2H3

H4

To dc I/Odevices

User DCSupply

CRM

GND3PLC

power supply

L1 N

Outputdevice

Output modulewiring arm

2

CRM

Input device

Inputmodulewiringarm

Use any numberof Estop switchesin series Start

CRM

CRM

1

X1 X2FUSE FUSE

12204

Grounding electrodeconductor togrounding electrodesystem



8-5

To guard against output transients from being induced into inputs andpower supplies, isolate output circuits from power supplies and inputcircuits. Use a separate transformer to provide power to the input circuitsand power supplies. Refer to Figure 8.3.

Figure 8.3Power Supplies and Input Circuits Receiving Power through aSeparate Transformer

Disc

Incoming ac

L1

L2

L3

1FU

2FU

3FU

L1

L2

L3

To motorstarters

Stepdowntransformer

H1

H2H3

H4

X1 X2

Isolation/constantvoltagetransformer

I/O output circuitsTo power suppliesand input circuits

X1 X2

H1 H4

H3 H2

15318

Depending upon your application, you may choose to use a secondtransformer, such as the following:

isolation transformer constant voltage transformer

The following sections describe the uses of these transformers.

Using a Second Transformer



8-6

Using an Isolation Transformer

Allen-Bradley power supplies have circuits that suppress electromagneticinterference from other equipment. However, for installations nearparticularly excessive electrical noise generators, using an isolationtransformer provides further suppression of electromagnetic interferencefrom other equipment. The output devices being controlled should drawpower from the same ac source as the isolation transformer, but not fromthe secondary of the isolation transformer (Figure 8.3).

Using a Constant Voltage Transformer

In applications where the ac power source is especially “soft” and subjectto unusual variations, a constant-voltage transformer can stabilize the acpower source to the processor, thereby minimizing shutdowns. However,the constant-voltage transformer must provide a sinusoidal output.

If you use a constant-voltage transformer to provide power to theprocessor-resident chassis, then the input devices connected to the I/Ochassis must also receive their ac power through the same constant-voltagetransformer. If the inputs receive their ac power through anothertransformer, the ac source voltage could go low enough that incorrect inputdata enters memory while the constant-voltage transformer prevents thepower supply from shutting down the processor.

The output devices being controlled should draw power from the same acsource as the constant-voltage transformer, but not from the secondary ofthe constant-voltage transformer (Figure 8.3).

To determine the required rating of the transformer, add theexternal-transformer rating for the power supply and all other powerrequirements (input circuits, output circuits). The power requirements musttake into consideration the surge currents of devices controlled by thecontroller. Choose a transformer with the closest standard transformerrating above the calculated requirements.

For example, the external-transformer rating of a 1771-P4S power-supplymodule at maximum back-plane load is 140 VA. A 140 VA transformercould be used if a 1771-P4S power-supply module were the only load. A500 VA transformer should be used if there were 360 VA of load inaddition to that of the 1771-P4S power-supply module.

Determining the Rating ofthe Transformer



8-7

Each power supply is designed to generate a shutdown signal whenever theac line voltage drops below its lower voltage limit, and to allow theprocessor to resume operation when the line voltage reaches the lowervoltage limit again. A shutdown is necessary in that situation to ensurethat only valid data is stored in memory.

Choosing properly sized transformers is important because:

If the transformer is too small, it will clip the peak of the sine wave.When the voltage is still above the lower voltage limit, the powersupply will sense this as a low voltage and shut down theprocessor prematurely.

If the transformer is too large, it will not provide as much isolation as atransformer of proper size.

Important: Note that the external-transformer rating (in VA) is 2.5 timesthe power supply input power requirement (in Watts). This is necessarybecause of the design feature that lets the power supply maintain its outputduring loss of input power for up to a half cycle.

When bringing ac power into the enclosure, do not connect its racewaythrough an equipment-grounding conductor to the ground bus on theback-panel. The raceway should be grounded elsewhere. Connecting theraceway to the ground bus will cause a ground loop.

Ground loops may introduce objectionable ground currents causing faultyoperation of the processor. Refer to Article 250-21 of the NationalElectrical Code for recommended methods of reducing the objectionableground current.

When ac power is supplied as a separately derived system through anisolation/step-down transformer, you can connect it as a grounded acsystem or an ungrounded ac system.

For this type of ac system: Connect:

grounded one side of the transformer secondary to the groundbus. Refer to Figure 8.1 (page 83).

ungrounded one side of each test switch for thegroundfaultdetector lights to the ground bus. Refer toFigure 8.2 (page 84).

Grounding the PowerSupply



8-8

Electromagnetic interference (EMI) can be generated whenever inductiveloads such as relays, solenoids, motor starters, or motors are operated by“hard contacts” such as pushbuttons or selector switches. Following theproper wiring and grounding practices guards the processor system againstthe effects of EMI. However, in some cases you can use suppressionnetworks to suppress EMI at its source.

Inductive loads controlled only by solid-state output devices alone do notcause comparable EMI generation. However, inductive loads of ac outputmodules that are in series or parallel with hard contacts require suppressionnetworks to protect the module output circuits as well as to suppress EMI.

Connect suppression networks at the inductive loads. If you connect themat the switching devices, the wires connecting the switching devices to theinductive loads will act as antennas to radiate EMI. Figure 8.4 showstypical suppression circuitry for different types of loads.

Figure 8.4Typical Suppression Networks

V dc

+ –

120V ac 120/230V ac

Cat No. 599K04

Suppressor for large apparatus(contacts up to size 5)

Cat No. 700N24

For small apparatus (relays,solenoids and motor starters up to size 1)

Freewheeling diode

For dc relays12057

Allen-Bradley bulletin 700 relays and bulletin 509, 709 motor starters havesurge suppressors available as an option. Table 8.C lists theseAllen-Bradley products and their suppressors.

Protecting Against EMI



8-9

Table 8.CAllenBradley Suppressors

AllenBradley Equipment: Suppressor Catalog Number:

Motor Starter Bulletin 509 599K04 1

599KA04

Motor Starter Bulletin 709 1401N10 1

Relay Bulletin 700 Type N or P 700N24 2

Miscellaneous 700N24 3

1 For starters with 120V ac coils

2 M i il l 1 0V d2 Maximum coil voltage 150V ac or dc

3 The 700N24 is a universal surge suppressor You can use it on electromagnetic devices3 The 700N24 is a universal surge suppressor. You can use it on electromagnetic devices with the limitations of 35 sealed VA, 150V.

Install the power supplies according to the instructions contained in thepower supply’s installation data.

Connect power Connect processorto the DH+ link




Connect processor

Terminate the link

√√Install power supplies√

chapter 8 chapter 9

Install the Power Supplies

What to Do Next


Chapter

9

9-1

Connect Processors to a DH+ Link

Use this chapter to help you connect a processor to a DH+ link.



Connect processor

Terminate the link

chapter 9

For additional DH+ link wiring information, refer to the Data Highway/Data Highway Plus/Data Highway II/Data Highway-485 Cable InstallationManual, publication 1770-6.2.2.

Consult the system diagram for your plant. Determine the following:

Is your processor connecting to the DH+ link using a daisychain ortrunkline/dropline configuration?

If you are installing a trunkline/dropline, what station connectors doyou need?

Use Belden 9463 twinaxial cable (cat. no.1770-CD) cable to connect tothe DH+ link. What cable lengths do you need?

Follow these guidelines while installing DH+ communication links:

at a DH+ communication rate of 57.6 kbps, do not exceed thesecable lengths:

- trunkline cable length — 3,044 m (10,000 cable-ft)- drop cable length — 30.4 m (100 cable-ft)

no more than 64 stations can be on a single DH+ link

Chapter Objectives

Determine the Needed Cable


Connect Processors to a DH+ LinkChapter 9

9-2

Use the 3-pin connector on the processor to connect a DH+ link. Theconnector’s port must be configured to support a DH+ communication link. To connect a processor to a DH+ link, refer to Figure 9.1 andTable 9.A.

Figure 9.1Connecting Processors to a DH+ Link

Terminate DH+ link by setting switch 2 of SW3 to ON.

PLC5/10, 5/12, 5/15, 5/25 processors

Clear

Shield

Blue

Connect the Processor tothe DH+ Link


Connect Processors to a DH+ LinkChapter 9

9-3

Table 9.AConnecting a PLC5 Processor to a DH+ Link

If you are installing this DH+link configuration:

Connect the 1770CD cable: By doing the following:

trunkline/dropline from the dropline to the connector screw terminalson the DH+ connectors of the processor

1. Connect the signal conductor with CLEAR insulation to the3pin connector terminal 1 at each end of each cablesegment.

2. Connect the SHIELD drain wire to the 3pin connector SHterminal at both ends of each cable segment.

3. Connect the signal conductor with BLUE insulation to the3pin connector terminal 2 at each end of each cablesegment.

daisychain to the connector screw terminals on the DH+connectors of the processor

You must terminate the DH+ link on both ends. On PLC-5/10, -5/12,-5/15, and -5/25 processors, set switch 2 of Assembly SW3 on (closed).

Connect processor

Terminate the link


Connect terminal

Determine how to connect to the processor√√√



chapter 9Connect programmingterminal to the processor

chapter 10

For information about: See:

programming data transfer betweenPLC5 processors.

1785 PLC5 Programmable Controllers DesignManual (17856.2.1)

PLC5 Programming Software Instruction Set(62006.4.11)

Enhanced and Ethernet PLC5 ProgrammableControllers User Manual (17856.5.12)

Terminate the Link

What to do Next


Chapter

10

10-1

Connect a Programming Terminal to the Processor

Use this chapter to help you connect a programming terminal to a PLC-5 processor.


Connect terminal



chapter 10

You can connect a programming terminal to a processor in several ways.

Connect a programming terminal to the processor using: See:

remote link connection (DH+ to DH to DH+) 104

remote connection to DH+ through an interface to theterminal's serial port

104

The processor has electrically-parallel DH+ connectors. They areelectrically identical, and connecting to either one provides access to thesame communication link. The PLC-5/10,-5/12, -5/15, -5/25processors have one of each:

9-pin D-shell DH+ connector 3-pin DH+ connector

Once you connect the programming device through a local DH+ link toone processor, the device can communicate with each PLC-5 processor onthe link. You can also communicate with PLC-2, PLC-3 and PLC-5/250processors connected to the link provided you have the appropriateprogramming software installed.

To connect a programming terminal to a processor using a local DH+ link,do the following:

determine the communication board used in your programming terminal determine the correct cable connect the programming terminal to the processor

Chapter Objectives

Determine How You Want toConnect a ProgrammingTerminal

Connecting through a LocalDH+ Link



Chapter 10

10-2

Determine the Communication Board Used in Your Programming Terminal

Use Table 10.A to help you determine the communication board that yourprogramming terminal uses.

Table 10.AProgramming Terminals and Their Communication Boards

This programming terminal: Uses this communication card toaccess a DH+ link:

1784T50

IBM or compatible

1784KT, KT2 or 1784KTK1

6160T53

6160T60

6160T70

1784KT

1784T45 1784KL

1784T47 1784KL/B

Determine the Correct Cable

Choose the correct cable to use to connect to the processor based upon thecommunication board Table 10.B.

Table 10.BProcessor to Communication Board Interconnect Cables

If You Have ThisCommunication Board:

Use This Cable:

1784KT, KT2 1784CP

1784KL, KL/B

1784KTK1 1784CP5

1784PCMK 1784PCM5

For information about connecting a processor and a programming device,refer to Appendix B.


Connect a Programming Terminalto the Processor

Chapter 10

10-3

Connect the Programming Terminal

Using the correct interconnect cable, connect the programming terminal.Refer to Figure 10.1.

Figure 10.1Connecting the Programming Terminal

19314

9pinDShell

Programming Terminal

PLC5/25 processor



Chapter 10

10-4

The remote programming configurations available with the 1784-KT,1784-KL, and 1784-KL series B boards let you communicate withprocessors on other DH+ links to expand the range of processors you canuse for program development (Figure 10.2).

Figure 10.2Example DH+ to DH to DH+ Network Configuration

17195

Data Highway link

LocalData Highway Plus link

RemoteData Highway Plus link

DH+ link

DH+ link

1770CD

1784T60

1784CP6

1785KA 1785KA

PLC5processor

PLC5processor

1770SC station connectors

1770SCstation

connector

1770SCstation

connector

To connect a DH+ link through a terminal’s serial port (COM1 or COM2)use one of the following communications modules:

1785-KE series A or series B Communication Interface Module(residing in a 1771 I/O rack)

1770-KF2, series B Communication Interface Module (desktop unit)

Important: The serial port communication driver of 6200 PLC-5Programming Software is interrupt-driven; the serial port must supporthardware interrupts. On most DOS-based machines, COM1 and COM2support these interrupts.

Hardware configurations for each of the computers that PLC-5 processorssupport are listed in Appendix B.

Connecting to a RemoteDH+ Link

Connecting to a DH+ Linkthrough an Interface to theTerminal's Serial Port



Chapter 10

10-5

Using the 1785KE Communication Interface Module

If you have a series A 1785-KE module, see Figure 10.3 for connectioninformation through a serial port. If you have a series B 1785-KE module,see Figure 10.5 for connection information.

Figure 10.31785KE (Series A) Connection through a Serial Port

17815

1784T50 Serial Port(COM1 or COM2)

1785KE(series A)

PLC5processor

Data Highway Plus



Refer to Figure 10.4 (on page 10-5) for an explanation of the switchassemblies and an example switch setting.

Figure 10.41785KE (series A) Switch Assemblies

Switch Assembly: Function:

SW1 Asynchronous linkfeatures

SW2, SW3, SW4 Station address

SW5 Data Highwaycommunication rate

SW6 Asynchronous linkcommunication rate

17813

SW1Full DuplexBCCNone(Parity)

SW2Must be off

SW3Address

SW4Address

SW557600bps

SW69600bps

Pressed inat topon (closed)orPushed up

Pressed inat topoff (open)orPushed down



Chapter 10

10-6

Figure 10.51785KE (Series B) Connection through a Serial Port

178911784T50 serial port


(COM1 or COM2)

1785KE(series B)

PLC5processor



Refer to Figure 10.6 (on page 10-6) for an explanation of the switchassemblies and an example switch setting.

Figure 10.6Example of a 1785KE (series B) Switch Setting


SW1 Asynchronous link features

SW2 Station address

SW3 Data Highway communication rate,RS232C communication rate,Local/Remote addressing

SW4 Reserved

For more information on series A or series B modules, refer to the1785-KE Communication Interface Module User Manual,publication 1785-6.5.2.

17892

SW1Full Duplex BCCNone (Parity)

SW2Station Address

SW5DH+ RateRS232 Ratelocal/remAddress

SW4Reserved

Togglepushedtowardbottomon (closed)

Togglepushedtowardtopoff (open)



Chapter 10

10-7

Using a 1770KF2B Communication Interface Module

See Figure 10.7 for a 1770-KF2 series B connection through a serial port.

Figure 10.71770KF2B Connection through a Serial Port

17814

1784T50 serial portPLC5 processor

1770KF2B


(COM1 or COM2)



Refer to Figure 10.8 an explanation of the switch assemblies and anexample switch setting.

Figure 10.8Example of a 1770KF2series B Switch Setting


SW1 Asynchronous link features

SW2, SW3, SW4 Station address

SW5 Data Highway communicationrate

SW6 Asynchronous linkcommunication rate

SW7 DH or DH+ selection

SW8 RS232C or RS422A compatibleselection

For more information, refer to the 1770-KF2B Communication InterfaceModule User Manual, publication 1770-6.5.13.


Processor and adaptertroubleshooting

chapter 11

Specifications appendix A

Cable diagrams and pinouts appendix B

17091

SW8RS232C

SW1Full DuplexBCCNone(Parity)

SW2Address

SW3Address

SW4Address

SW557600bps

SW69600bps

SW7DataHighwayPlus

Pressed inat topon (closed)

Pressed inat bottomoff (open)

What To Do Next


Connect terminal

Determine how to connect to the processor√√√


chapter 10


Chapter

11

11-1

Troubleshooting

Use this chapter to help you troubleshoot your PLC-5 system using theprocessor and adapter modules LED indicators (Table 11.A).

Table 11.ALED Status Indicator Troubleshooting Guide

Type of Problem: Table Number: On Page:

PLC5/10, 5/12, 5/15, 5/25 processors

• general

• in adapter mode

• in scanner mode

• DH+ link

Table 11.B

Table 11.C

Table 11.D

Table 11.E

112

113

113

114

1771ASB module

• series B

• series C and D

Table 11.G

Table 11.F

117

115

Chapter Objectives


TroubleshootingChapter 11

11-2

Use Table 11.B, Table 11.C, Table 11.D, and Table 11.E to troubleshootyour PLC-5/10, -5/12, -5/15, and -5/25 processor.

Table 11.BPLC5/10, 5/12, 5/15, 5/25 General Problems

Indicator Color Description Probable Cause Recommended Action

PROC green(steady)

processor in RUN mode andfully operational

normal operation no action required

green(blinking)

Processor memory beingtransferred to EEPROM


red(blinking)

major fault runtime error Check major fault bit in status file (S:11)for error definition. Clear fault bit, correctproblem, and return to RUN mode.

red(steady)

major fault • user RAM haschecksum error

• memory moduleerror

• Clear memory and reload program.

• Check backplane switch settingsand/or insert correct memory module.

off processor in program load orTEST mode or is not receivingpower

Check power supply and connections.

PROCREM I/O

all red(steady)

internaldiagnostics havefailed

Power down, reseat processor andpower up. Then, clear memory andreload your program. Replace EEPROMwith new program. Then, if necessary,replace the processor.

FORCE amber(steady)

forces enabled normal operation no action required

amber(blinking)

forces present, but notenabled


off no forces present normal operation no action required

BATT red(steady)

battery low Replace battery within 12 days (typical).

off battery is good normal operation no action required

ADPT green(steady)

processor is in adapter mode normal operation no action required

off processor is in scanner mode normal operation no action required

Troubleshooting PLC5/10,5/12, 5/15, and 5/25Processors

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG



11-3

Table 11.CPLC5/12, 5/15, 5/25 Processor in Adapter Mode


REM I/O green(steady)

active remote I/O link normal operation no action required

green(blinking)

remote I/O active and hostprocessor is in program loador TEST mode


red(steady)

no communication with hostprocessor

duplicate stationaddress selected

Correct station address.

green(sporadic)

bad communication with hostprocessor

Check connections.

off no communication with hostprocessor

no action required

Table 11.DPLC5/15, 5/25 Processor in Scanner Mode


REM I/O green(steady)

active remote I/O link normal operation no action required

red(steady)

remote I/O link fault wiring, adaptermodule(s)

• Check all connections, check adaptermodule(s).

• If you have 6200 programmingsoftware, put the processor in PROGmode and do an autoconfigure forremote racks (see the 6200 PLC5Programming Software ConfigurationManual, 62006.4.6).

green/red(blinking)

partial remote I/O link fault one or moreremote I/O chassisfaulted

• Check status bits in status file(element #7) to identify faulted chassisnumber; check wiring, adaptermodule(s), power supplies.

• If you have 6200 programmingsoftware, put the processor in PROGmode and do an auto configure forremote racks (see 6200 PLC5Programming Software ConfigurationManual, 62006.4.6).

off no remote I/O selected no action required

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG



11-4

Table 11.EPLC5/10, 5/12, 5/15, 5/25 DH+ Link


COMM green(blinking rapidlyor slowly)

processor is transmitting orreceiving on DH+ link


red(steady)

watchdog timeout hardware error Turn power off, then on. Checkthat the software configurationsmatch the hardware setup.Replace the processor.

red(sporadic)

bad communication on DH+link

duplicate stationaddress selected

Correct station address.

off • If directly connected toprocessor, nocommunication on DH+ link

• If last processor on DH+link, no communication onDH+ link

• no action required

• Check DH+ wiringconnections.

COMM BATT

REM I/O

ADPT

PROC

FORCE

FAULT

ACTIVERUN

REM

RUN

PROG



11-5

Use Table 11.F and Table 11.G to help you troubleshoot your remoteI/O system.

Table 11.FRemote I/O System Troubleshooting Guide for the1771ASB series C or D Adapter Module

Indicators

Active AdapterFault

I/ORack

Description Probable Cause Recommended Action

On Off Off Normal indication; remote adapter is fullyoperational

Off On Off RAM memory faultwatchdog timeout

Replace module.

On Blink Off Module placement error I/O module in incorrect slot Place module in correct slot inchassis.

Blink in unison Off Incorrect starting I/O group number Error in starting I/O group numberor I/O rack address

Check switch settings.

On On On Module not communicating Incorrect transmission rate setting Check switch setting.

Off On On Module not communicating Scan switch set for all but last fourslots" in 1/4 rack

Reset scan switch setting.

Blink Off Off Remote adapter not actively controllingI/O (scanner to adapter communicationlink is normal)4

Processor is in program or testmodeScanner is holding adapter modulein fault mode

Fault should be cleared by I/Oscanner.

LEDs sequence on/off from top tobottom

Module not communicating Another remote I/O adapter withthe same address is on the link

Correct the address.

Blink alternately Off Adapter module not actively controllingI/O2

Adapter module in processor restartlockout mode (adapter to scanner link isnormal)

Processor restart lockout switch onchassis backplane switchassembly1

Press reset button to clear lockoutfeature or cycle power; if afterrepeated attempts indicators arestill blinking, check:

• pushbutton not wired properly tofield wiring arm.

• wiring arm not connected toadapter module.

• adapter module was reset byprocessor/scanner, thenimmediately faulted.

1 You must select the operating mode of the remote I/O adapter module as outlined in the publication furnished with the remote I/O scanner/distributionpanel, remote I/O scannerprogram interface module, or I/O scannermessage handling module. Pay close attention to the disable search mode in the1771SD, SD2.

2 The I/O chassis is in faulted mode as selected by the last state switch on the chassis backplane.3 Cycling power clears the blocktransfer request queue. All pending block transfers are lost. Your program must repeat the request for block transfer

from the chassis.4 If a fault occurs and the processor is in the run mode but is actually operating in the dependent mode, the chassis fault response mode is selected by

the last state switch on the chassis backplane.

Troubleshooting Informationfor 1771ASB Module

ACTIVE

ADAPTER FAULT

I/O RACKFAULT



11-6

Indicators

Active AdapterFault

I/ORack


Off Off On I/O chassis fault.2 No communication onlink.

Problem exists between:

• adapter and module in chassis;the module will stay in faultmode until fault is corrected

• shorted printed circuit boardruns on backplane or I/O module

Cycle power to the chassis to cleara problem resulting from highnoise.3

• remove and replace all I/Omodules one at a time.

• if problem does not clear,something is wrong in chassis orI/O module.

Blink Off On Communication on link. Possible shortedbackplane

• noise on backplane

• shorted circuit board runs

• faulty card in chassis

• Eliminate noise.

• Isolate noise.

• Add surge suppression.

• Replace chassis.

• Replace defective card inchassis.

Blink On Off Module identification line fault Excessive noise on backplane Verify power supply and chassisgrounding.

Off Off Off Module not communicating Power supply fault

Wiring from scanner to adaptermodule disrupted

Scanner not configured properly

One faulted chassis within a rackgroup address causingscanner/distribution panel to faultall chassis in rack group address(when in disable search mode)

Check power supply, cableconnections, and make sureadapter module is fully seated inchassis.

Correct cable and wiring defects.

Refer to publication 17722.18 forscanner configuration.

Check sequentially from the firstmodule to the last module topinpoint fault; correct any faults andproceed to the next chassis.

1 You must select the operating mode of the remote I/O adapter module as outlined in the publication furnished with the remote I/O scanner/distributionpanel, remote I/O scannerprogram interface module, or I/O scannermessage handling module. Pay close attention to the disable search mode in the1771SD, SD2.

2 The I/O chassis is in faulted mode as selected by the last state switch on the chassis backplane.

3 Cycling power clears the blocktransfer request queue. All pending block transfers are lost. Your program must repeat the request for block transfersfrom the chassis.

4 If a fault occurs and the processor is in the run mode but is actually operating in the dependent mode, the chassis fault response mode is selected bythe last state switch on the chassis backplane.



11-7

Table 11.GRemote I/O System Troubleshooting Guide For the1771ASB Series B Module

Indicators

Active AdapterFault

I/ORack


On Off Off Normal indication; adapter is fullyoperational

On orOff

On On orOff

Remote adapter fault2 Remote adapter not operating; itwill stay in fault mode until fault iscorrected

Cycle power to the chassis to clearthe adapter fault..3 Replaceadapter if fault does not clear.

On orOff

Off On I/O chassis fault2 Problem exists between:

• adapter and module in chassis;the module will stay in faultmode until fault is corrected

• shorted printed circuit boardruns on backplane or I/O module

Cycle power to the chassis to cleara problem resulting from highnoise.3

• Remove and replace all I/Omodules one at a time.

• Replace adapter.

• If problem does not clear,something is wrong in chassis orI/O module.

Blinking Off Off Remote adapter not actively controllingI/O (scanner to adapter communicationlink is normal)4

Processor is in program or testmodeScanner is holding adapter modulein fault mode

none

Fault should be cleared by I/Oscanner.

Blinking alternately Off Adapter module not actively controllingI/O2

Adapter module inprocessorrestartlockout mode (adapterto scanner link is normal)

Processorrestartlockout switch onchassis backplane switchassembly1

Press reset button to clear lockoutfeature or cycle power; if afterrepeated attempts indicators arestill blinking, check:

• pushbutton not wired properly tofield wiring arm.

• wiring arm not connected toadapter module.

• adapter module was reset byprocessor/scanner, thenimmediately faulted.

1 You must select the operating mode of the remote I/O adapter module as outlined in the publication furnished with the remote I/Oscanner/distribution panel, remote I/O scannerprogram interface module, or I/O scannermessage handling module. Pay close attention to thedisable search mode in the 1772SD, SD2.


3 Cycling power clears the blocktransfer request queue. All pending block transfers are lost. Your program must repeat the request for blocktransfers from the chassis.

4 If a fault occurs and the processor is in the run mode but is actually operating in the dependent mode, the chassis fault response mode is selectedby the last state switch on the chassis backplane.

ACTIVE

ADAPTER FAULT

I/O RACKFAULT



11-8

Indicators

Active AdapterFault

I/ORack


Off Off Off If remote I/O scanner/distribution panel(1772SD, SD2) is in disable searchmode, then response is normal2

Power supply fault

Wiring from scanner to adaptermodule disrupted

Scanner not configured properly

One faulted chassis within a rackgroup address causingscanner/distribution panel to faultall chassis in rack group address(when in disable search mode)

Check power supply, cableconnections, and make sureadapter module is fully seated inchassis.

Correct cable and wiring defects.

Refer to publication 17722.18 forscanner configuration.

Check sequentially from the firstmodule to the last module topinpoint fault; correct any faults andproceed to the next chassis.

Blinking On On Module identification line fault Excessive noise on backplane Verify power supply and chassisgrounding.

On Blinking Off Module placement error in remote I/Ochassis

Incorrect placement of highdensitymodules

Verify addressing modes andswitch settings.

Flashing in unison Off Incorrect starting I/O group number forchassis size

Error in starting I/O group numberor I/O rack address

Check switch settings.

1 You must select the operating mode of the remote I/O adapter module as outlined in the publication furnished with the remote I/Oscanner/distribution panel, remote I/O scannerprogram interface module, or I/O scannermessage handling module. Pay close attention to thedisable search mode in the 1772SD, SD2.


3 Cycling power clears the blocktransfer request queue. All pending block transfers are lost. Your program must repeat the request for blocktransfers from the chassis.

4 If a fault occurs and the processor is in the run mode but is actually operating in the dependent mode, the chassis fault response mode is selectedby the last state switch on the chassis backplane.


Appendix

A

A-1

Processor Specifications

This table lists general specifications of the PLC-5/10, -5/12, -5/15, and-5/25 processors.

Weight PLC5/10 (1785LT4) 1336 g (47.12 oz.)

PLC5/12 (1785LT3) 1337 g (42.15 oz.)

PLC5/15 (1785LT) 1339 g (47.23 oz.)

PLC5/25 (1785LT2) 1337 g (42.15 oz.)

Backplane Current 2.5A

Environmental Conditions:

operating temperature 0° to 60° C (32° to 140° F)

storage temperature 40° to 85° C (40° to 185° F)

relative humidity 5 to 95% (without condensation)

Vibration(operating and nonoperating)

1 g @ 10 to 500 Hz0.012 inches peaktopeak displacement

Shock

operating 30 g peak acceleration for 11±1 ms duration

nonoperating 50 g peak acceleration for 11±1 ms duration

Timeof Day Clock and Calender

maximum variations at

60° C± 3 min per month

typical variations at 20° C ± 20 s per month

timing accuracy one program scan

Typical Discrete I/O Scan • 1ms/local I/O rack

• 10 ms/remote I/O adapter communication at 57.6 kbps

I/O Modules Bulletin 1771 I/O including 8, 16, 32pt., and intelligent modules

Hardware Addressing:

2slot • any mix of 8pt modules

• 16pt modules must be I/O pairs

• no 32pt modules

1slot • any mix of 8 or 16pt modules

• 32pt modules must be I/O pairs

1/2slot any mix of 8,16, or 32pt modules

Communication • DH+ 3,048 cablem (or 10,000 cableft) max

• DH using 1785KA

Location 1771I/O chassis, leftmost slot

Keying • between 40 and 42

• between 54 and 56

Agency Certification

(when product is marked)

• CSA certified

• CSA Class I, Division 2, Groups A, B, C, D

• UL listed

General


Processor SpecificationsAppendix A

A-2

This table lists specifications of each PLC-5 family processor.

Processor MaximumLocal RacksSupported

MaximumRemote Racks

Supported

I/O Capacity Memory(Words)

Program ScanTime

Communication MemoryModules(optional)

Battery

PLC5/10 4(1 residentchassis)

none • 128 I/O with 8ptmodules 1

• 256 I/O with16pt modules 1


6 K 2 ms/K words(bit logic)

8 ms/K words(typical)

standalone

DH+

8K EEPROM(1785MJ)

1770XY


none • 128 I/O with 8ptmodules 1



standalone,adapter

DH+

8K EEPROM(1785MJ)


3 (up to 12physicaldevices)

• 512 I/O 1

• 512 inputs and512 outputsusing 16 or32pt modules 2

6K(expand

s to14K)

standalone

scanner (local andremote I/O)

adapter

DH+

• 4K RAMexpansion,1785MR

• 8 K RAMexpansion,1785MS

• 8KEEPROM(1785MJ)


7(up to 28physicaldevices)

• 1024 I/O 1

• 1024 inputs and1024 outputsusing 16 or32pt modules 2

13 K(expand

s to21K)

2 ms/K words(bit logic)

8 ms/K words(typical)

standalone

scanner (local andremote I/O)

adapter

DH+

• 4K RAMexpansion(1785MR)

• 8 K RAMexpansion(1785MS)

• 8KEEPROM(1785MJ)

• 16KEEPROMbackup,1785MK

1 Any mix of I/O.2 Maximum I/O possible using 16pt modules with 2slot addressing or 32pt modules with 1slot addressing. Modules must alternate IOIOIO in the chassis slots.

Processor Specific



A-3

This table summarizes the relationship among chassis size, addressingmode and the I/O module density.

If You are Using thisChassis Size:

And 2slot addressing Or 1slot addressing Or 1/2slot addressing

4slot 1/4 rack 1/2 rack 1 rack

8slot 1/2 rack 1 rack 2 racks

12slot 3/4 rack 11/2 racks 3 racks

16slot 1 rack 2 racks 4 racks

For more information, see the 1785 PLC-5 Family ProgrammableControllers Design Manual, publication 1785-6.2.1.

Battery Type

This processor: Uses this battery:

PLC5/10, 5/12, 5/15, 5/25 1770XY , contains less than 1/2gram of lithium

3.6V, AA" size, Tadiran TL5104 type AEL/Slithium battery with pressure contact terminals.

Average Battery Lifetime Specifications

Battery used in this processor: At this temperature: Power off 100%: Power off 50%:

PLC5/10, 5/12, 5/15, 5/25 60°C 329 days 1.4 yrs

25°C 2 yrs 3.3 yrs

Addressing ConceptSummary

Battery Specifications



A-4

This table lists devices compatible with a PLC-5 processor.

Supervisory Processors • PLC2/30 processor

• PLC3, 3/10 processor

• PLC5/15, 5/25 processor

• PLC5/250 processor

• PLC5/11, 5/20, 5/30, 5/40, 5/60, and 5/80 processor

• PLC5/40L and 5/60L processor

I/O Adapters • Remote I/O Adapter Module (1771ASB)

• ExtendedLocal I/O Adapter Module (1771ALX), usedwith PLC5/40L and 5/60L processors

• Any PLC5 processor in adapter mode

• PLC5/250 Remote Scanner (5150RS2) inadapter mode

• Direct Communication Module (1771DCM)

• PLC Interface Module (3500-NA1) for digital ac anddc drives

• Remote I/O Adapter for Bulletin 1336 drives(1336MODG2)

• Serial Port Connector (MODS1)

• RediPANEL Pushbutton and Keypad Modules(bulletin 2705)

• Option Module (1784F30D) for the T30PlantFloor Terminal

• 8600 CNC with remote I/O adapter option (86002058K)

• CVIM set for adapter mode (5370CVIM)

• ProSpec 6000 Fastening System with the remote I/Oadapter option (1860CPUC)

This table lists the type of programming and instructions supported by thePLC-5 processor.

Programming • ladder diagram (all)

• sequential function chart (all)

• I/O configuration (all)

• selectable timed interrupt (all)

Instruction Set • relaytype through advanced (all)

• PID control (all)

• machine diagnostics (all)

Compatible Remote I/O LinkDevices

Programming andInstruction Capabilities



A-5

Available Packages

Operating system/media: Catalog number: Description:

DOS andWIndows

3.5"1 4 Mbyte disks

9321PLC5 PLC5 programming software on line onlyWIndows 1.4 Mbyte disks

9323PLC5 PLC5 programming software on line and off line

9321ST5P PLC5 programming software on line only and PLC5 structured text

9323ST5P PLC5 programming software on line and off line and PLC5 structured text

3.5"720 Kbyte disks

9313ST5 PLC5 structured text option(requires 9321PLC5 or 9323PLC5)

Software Release Needed for Your Processor

If You Have This Processor: You Must Use ThisSoftware Release:

PLC5/10 3.21 or later

PLC5/12, 5/15, 5/25 any release

Programming Software



A-6

System Requirements

DOS environment: Windows environment:

Computer hardware • 13 Mbytes hard disk space for 6200 software

• optional 600 Kbytes hard disk space for block transfer

programming examples

• optional 800 Kbytes hard disk space for Remote

Software Support

• 551 Kbytes (564,000 bytes) free RAM

• recommended additional 384 Kbytes extended or

expanded memory to program off line

• highdensity, 1.44 M disk drive (3 1/2")

• monochrome or color monitor

same as DOS environment, plus

• 384 Kbytes expanded memory

• 551 Kbytes (564,000 bytes) free RAM after loading

INTERCHANGE

Programming terminal Minimum

• AllenBradley DOSbased

• IBM XT, AT, 80386 or compatible

Recommended

• IBM 80486 or compatible

Minimum

• IBM 80386SX, 16MHz or compatible

Recommended

• IBM 80486, 33MHz or better or compatible

Operating system • DOS 3.2, 3.3, 4.x, 5.0,

6.0, or 6.2

• DOS 4.01 (1784T47)

same as DOS environment, plus

• Windows 3.1 or later

Printer interface • parallel or serial

• 80, 132, or 255 columns

same as DOS environment

Communication • 1784KL/B (DH+)

• 1784KT (DH+)

• 1784KT2 (DH+)

• 1784KTK1 (DH+)

• 1784PCMK (DH+)

• 1784KTX, KTXD (DH+)

• 1770KF2/B (serial to DH+)

• 1785KE (serial to DH+, serial to DH)

• 1771KE (serial to DH)

Requires INTERCHANGE multisession drivers to beloaded before starting Windows

• 1784KL/B (DH+)

• 1784KT (DH+)

• 1784KT2 (DH+)

• 1784PCMK (DH+)

• 1784KTX, KTXD (DH+)

For component spacing and dimensions for series A chassis:

For this information Refer to:

I/O chassis (series A) mounting dimensions Figure A.1 (page A7)

I/O chassis (series A) with 1771P2 power supply mounting dimensions Figure A.2. (page A8)

I/O Chassis MountingDimensions (series A)



A-7

Figure A.1Follow These Guidelines When Mounting a 1771 I/O Chassis (Series A)

16468

Panel Mount Chassis 594mm(23.4") 467mm

(18.4")340mm(13.4") 213mm

(8.4")

315mm(12.41")

PowerConnector

With extendedlocal I/O cables

172mm(6.75")

229mm(9.00")

16slot

12slot

8slot

4slot

254mm(10")

GroundStud

610mm(24.01")

483mm(19.01")

356mm(14.01")

229mm(9.00")

16slot 1771A4B

12slot 1771A3B1

8slot 1771A2B

4slot 1771A1B

Cat No. 1771A1B, A2B, A3B1, A4B I/O Chassis

13408

Rack or PanelMount Chassis 221mm

(8.70")

214.4mm(8.44")

482.6mm(19")

465.1mm(18.31")

8.6mm(.34")

37.6mm(1.48")

177.8mm(7")

139.2mm(5.48")

354.6mm(13.96")

12slot I/O Chassis (Cat. No. 1771A3B)



A-8

Figure A.2Follow These Guidelines When Mounting a 1771 I/O Chassis with1771P2 Power Supply (Series A)

16189

Panel Mount ChassisUse .25" dia

mounting bolts(4 places)

594mm(23.4")

467mm(18.4")

340mm(13.4")

213mm(8.4")

16slot

12slot

8slot

4slot

16slot 1771A4B

12slot 1771A3B1

8slot 1771A2B

4slot 1771A1B

GroundStud

254mm(10")

610mm(24.01")483mm

(19.01")356mm(14.01")247mm

(9")

92mm(3.6")

315mm(12.41") 1771P2 or

1771P7Power Supply

16190

Rack or Panel Mount Chassis

12slot I/O Chassis (Cat. No. 1771A3B)Clearance depth is 8.7" (221mm)

92mm(3.6")

354.6mm(13.96")

1771P2 or1771P7

Power Supply

465.1mm(18.31")

482.6mm(19")

Ground Stud 8.6mm(.34")

37.6mm(1.48")

177.8mm(7")

Use .25" dia.mounting bolts

(4 places)


Appendix

B

B-1

Cable Connections

Table B.A lists the cables you use if you have an Allen-Bradleycommunication board in your programming terminal.

Table B.AAllenBradley Communication Board Cables

If You Have This Processor: And You Have ThisCommunication Board:

Use This Cable:

PLC5/10, 5/12, 5/15, 5/25 1784KT, KT2 1784CP

1784KL, KL/B

1784KTK1 1784CP5

1784PCMK 1784PCM5

For pinouts for these A-B cables, see pages B-7 and B-8.

The diagrams in this section show the cable connections for serial portcommunications.

For these wiring diagrams: See page:

cables 1 through 6 B3

AllenBradley cables B4

Cable Connections forCommunication Boards

Cable Connections for SerialPort Communications


Cable ConnectionsAppendix B

B-2

PLC5/10, 5/12, 5/15, 5/25

PLC5

1770KF2 modem

modem

1770KF2

1785KE

1784CP5

1770CD

phone line

cable #6

cable #1

1784CAK

cable #4

Terminal

Terminal

Terminal

Series B

PLC5/10, 5/12, 5/15, 5/251784CP5

11942I

11943I

11945I

1785KE series A uses 1784CP5 with PLC5/10, 5/12, 5/15, 5/25 processors.

PLC5

PLC5 1770KF2 modem

modem

1785KE 1770CD

1784CP5

phone line

cable #6

1784CXK

cable #6

Terminal

Terminal

Series B

1770KF2cable #2

Terminal

11947I

11948I

11940I

PLC5/10, 5/12, 5/15, 5/251784CP5

1785KE series A uses 1784CP5 with PLC5/10, 5/12, 5/15, 5/25 processors.

9Pin Serial Port

1784T351784T506160T536160T606160T70IBM AT

Compaq Portable 2Compaq Portable 286Compaq Deskpro 286Compaq Deskpro 386

25Pin Serial Port

1784T451784T47IBM XT

IBM PS/2 Model 30IBM PS/2 Model 60



B-3

The following diagrams show the pin assignments for the cables you needfor serial port communications.

Cable #1

25pin SKT1770KF2

RXD 2GND 5

TXD 3

DCD 1DTR 4DSR 6

RTS 7CTS 8

27

3

4 RTS5 CTS

6 DSR8 DCD20 DTR

9pin SKTIBM AT

Cable #2

25pin SKT1770KF2

TXD 2GND 7

RXD 3

RTS 4CTS 5

DSR 6DCD 8

DTR 20

37

2

4 RTS5 CTS

6 DSR8 DCD20 DTR

25pin SKTIBM XT

Cable #3

25pin SKT1770KF2

TXD 2GND 7

RXD 3

RTS 4CTS 5

DSR 6DCD 8DTR 9

37

2

4 RTS5 CTS

6 DSR8 DCD20 DTR

9pin SKTComputer

Cable #4

9pin SKTIBM AT

25pinModem

DCD 1RXD 2TXD 3DTR 4GND 5DSR 6RTS 7CTS 8RNG 9CASE

832207645221

9pin SKTComputer

25pinModem

RNG 1TXD 2RXD 3RTS 4CTS 5DSR 6GND 7DCD 8DTR 9

22234567820

Cable #5

25pin SKTComputer

25pinModem

CHS 1TXD 2RXD 3RTS 4CTS 5DSR 6GND 7DCD 8

DTR 20

1234567820

Cable #6

11955I 11957I 11958I

11959I 11960I 11961I

(female) (female) (female) (female) (female) (female)

(female) (female) (female) (female) (female) (female)

Cable Pin Assignments



B-4

The specifications for each Allen-Bradley cable used for communicationsare shown on the following pages. See Table B.B.

Table B.BCable Specifications

For: To: Use This Cable: See Page:

1784T506160T601784T356160T536160T70IBM PC ATCompaq

1785KE 1784CAK B5

1784T45IBM PC XT

1785KE 1784CXK B6

PLC5/10, 5/12, 5/15,5/25 Processor

Terminal (using a 1784KTK1)

1784CP5 B7

Terminal (using a 1784KT,KT2, or KL, KL/B)

1784CP B8

Terminal (using 1784PCMK)

1784PCM5 B9

Cable Specifications



B-5

Figure B.1Interconnect Cable - 1784CAK1784T50, T35, 6121, IBM AT, Compaq to 1785KE

1

2

7

3

13

4

5

6

8

11

1

4

6

2

5

3

7

8

14936

5

1

9

6

9

15

1

8 2.9 m(9.50 ft.)

15pin DshellConnectorPin male

1785KE

9pin DshellConnectorPin Female

Dsub 15pin(1785KE)

Dsub 9pin(IBMPC/AT)

IBMPC/AT



B-6

Figure B.2Interconnect Cable - 1784CXK1784T45, IBM XT to 1785KE

9

15

1

8 1

13

14

25

1

3

7

2

13

4

5

6

8

11

2

7

3

5

4

6

8

12727

20

289.6 cm(114 in.)

15pin DshellConnectorPin male

1785KE

Shielded Cable24 AWG

25pinConnectorPin Female

RED

BLK

WHT

BLK

Dsub 15pin(1785KE)

25 pin(PCXT)

PCXT



B-7

Figure B.3Interconnect Cable - 1784CP5Processor to Terminal (using a 1784KTK1)

1

2

3

4

5

6

7

8

9

1

2

6

4

5

6

8

9

5

1

9

69

15

1

8

10

11

12

13

14

15

7

14938

3.2 m(10.50 ft.)

9pin DshellConnectorPin Male

TerminalProcessor

15pin DshellConnectorPin Female

Terminal(15Skt connector)

Processor(9pin Connector)

Clear

BLUE

Clear

BLUE



B-8

Figure B.4Interconnect Cable - 1784CP Processor to Terminal(using a 1784KT, 1784KL, 1784KL/B, or 1784KT2)

43

21

1

621

5

6

9

22

2

3

4

5

6

7

8

9

1

16860a

Clear Clear

Blue Blue

3.2 m(10.50 ft.)

10.2 cm(4 in.)

10.2 cm(4 in.)

IndustrialTerminal End

PLC5 End

PLC5 EndIndustrialTerminal End

62

61

37

36

35

34

33

3

2

1

60



B-9

Figure B.5Interconnect Cable - 1784PCM5Processor to Terminal (using a 1784PCMK)

PLC5 DH+9pin

KT/PCMCIA

1

5

7

1

2

124.25 in

3

SHELLSHIELD

DRAIN

LINE 2 CLR

LINE 1 CLRCLR

BLUE

DRAIN

SHIELDSHELL

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

1

2

33

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

10

11

12


Numbers

1slot addressing, 311

1/2slot addressing, 311

1770-CD, 69, 93

1770-KF2, 104, 107, B1

1770-XY, 42, A3

1771A1B, 31

1771AF, 68

1771AS, 68installing, 67switch settings

complementary I/O, 65noncomplementary I/O, 62

1771ASB, troubleshooting, 111

1771CD, 91

1771DCM, 68

1771OD, 72

1771OR, 72

1771OY, 72

1771OZ, 72

1771SN, 68

1771A2B, 31

1771A3B1, 31

1771A4B, 31

1771ALX, chassis backplane switchsettings, 312

1771ALX adapter module, 12

1771ASB, 12, 68chassis backplane switch settings, 312installing, 67switch settings


1772SD, SD2, 68

1775S4A, S4B, 68

1775SR, 68

1784, 102

1784CP10, B3

1784KTK1, 102

1784-CAK, B4, B5

1784-CP, 102, B1, B4, B8

1784-CP5, 102, B1, B4, B7

1784-CPM5, B9

1784-CXK, B4, B6

1784-KL, 102, 104, B1

1784-KT, 102, 104, B1

1784-KTK1, 102, B1, B4

1784-T45, -T47, -T50, T53, T60, T70, 101

1784CP11, B3

1785KL, 102

1785KL/B, 102

1785MJ, 45

1785MK, 45

1785MR, 46

1785MS, 46

1785-KE, 104, 105, B1, B4

1785KT, 102

2slot addressing, 311

25pin serial port, B2

6008SQH1, SQH2, 68

9pin serial port, B2

A

ACTIVE, 115118

Adapter configurationPLC5/12, 5/15, 5/25, 52PLC-5/12, 5/15, 5/25

as an adapter to PLC2, 55as an adapter to PLC5, 54as an adapter to PLC3 or 5/250

4 words, 57

8 words, 56

remote I/O, 61switch settings, 1771AS, ASB, 62,

65

ADAPTER FAULT, 115118

Adapter modeconfiguring, PLC5/12, 5/15, 5/25, 15troubleshooting, 111

Adapter module1771ASB, 121771ALX, 12installation, ASB, 67

Addressing1slot, A31/2slot, A32slot, A3

Index


IndexI–2

selecting mode, 311

ADPT, 113

B

Backplaneswitch settings, 311, 312switches, 310

Backplane current, A1

BATT, 113

Battery, 41, A2disposal, 44lifetime specifications, A3replacement, 44

C

Cable, specifications, B4

Cables, B1Belden 9463, 12connections for communication boards,

B1connections for serial communications,

B1DH+ lengths, 91extendedlocal I/O, 12I/O, 73pin assignments, B3programming terminal, 102raceway layout, 24remote I/O, 67routing conductors, 25shielded, 39specifications, B4

Certification, A1

Chassisattaching to rack or panel, 33dimensions, 23grounding, 33, 35installing, 31mounting hardware, 33setting configuration plug, 313setting switches. See Switch Assembliessize and relation to addressing, A3switch assemblies, 310

Clock, processor, A1

CMOS RAMSee also Memoryinstalling, 46removing, 47

COMM, 114

Communication modes, defining,PLC-5/12, -5/15, -5/25, 51

Component spacing, 23

Computer. See programming terminal

Configuration, adapter communication,PLC-5/12, -5/15, -5/25, 53

Configuration plug, 313

Connectionsdaisy-chain, 91trunkline/dropline, 91

ConnectorsDH+, 92for shielded cables, 310remote I/O, 69

constantvoltage transformer. See

Transformer

D

Daisychain connection, 69

Daisy chain connection, 91, 92

DH+cable lengths, 91communication rates, 91connections, 92daisy-chain connection, 92define station number, PLC5/10, 5/12,

5/15, 5/25, 15installing link, 91remote connect, 101terminating the link, 59, 93trunkline/dropline connection, 92

DH+ link, defining address, PLC5/10,5/12, 5/15, 5/25, 52

Dimensionschassis, 23chassis with external power supply, A8chassis with external power supply

(series B), 33

Disposal, lithium batteries, 44

DOS, A5

Dropline connection. See Trunkline/DroplineConnection

E

EEPROM, 16, A21785-MJ, MK. See Memoryinstalling, 45removing, 1785MJ, MK, 47transfer, 311

Electromagnetic interference, 22, 86protection, 37, 88


Index I–3

Electromagnetic interference protection, 39

Electrostatic discharge. See ESD

EMI. See Electromagnetic interference;Electromagnetic interference protection

EMI protection. See Electromagneticinterference

Enclosures, 12

Environmentoperating temperature, 21relative humidity, 21storage temperature, 21

Environment specifications, A1

Environmental conditions, 21

ESD, 42

Extendedlocal I/O, grounding, 36

F

Fans, 22

Faults, 112

FORCE, 112

Frontpanel, PLC5/10, 5/12, 5/15, 5/25, 14

G

Ground bus installation, 37

Grounding, 88attaching ground bus, 33conductor, 37electrode system, 39extendedlocal I/O system, 35ground bus connections, 38grounded system, 87power supply, 87processorresident chassis, 35remote I/O system, 35shielded cables, 39ungrounded system, 87

Grounding strap, 42

I

I/O addressing, A1

I/O chassis. See Chassis; chassis

I/O group, assigning, 53

I/O modulecable categories, 24grounding shielded cables, 39installing, 71

removing module, 71

I/O rack addressing, A3

I/O RACK FAULT, 115118

I/O rack number, 53

I/O scan, discrete, A1

IBM or compatible, 102

Indicators, PLC5/10, 5/12, 5/15, 5/25, 14

Indicators, troubleshooting, 111

Installingbattery, 41chassis, 31I/O modules, 71keying bands, 510memory modules, CMOS RAM, 46power supplies, 81processor, PLC5/10, ,5/12, 5/15, 5/25,

510programming terminal, 101wiring arms, 72

Instruction set, A4

Isolation transformer. See Transformers

J

Jumper, chassis. See Configuration plug

K

Keying bands, 510

Keyswitchlocation of, PLC5/10, 5/12, 5/15, 5/25,

14operation, 16

L

Last state, 312

Last state switch, 311

LED. See Indicators

Link termination, 59

Lithium, 43

M

Maintenance1785MJ, MK EEPROM module, 471785MR, MS CMOS RAM module, 47removing processor, PLC5/10, 5/12,

5/15, 5/25, 511


IndexI–4

Master control relay, 83

Memory ModulesCMOS RAM, 41EEPROM, 41

Modem, B1See also Programming Terminal

Mountingassembly details, 34I/O chassis dimensions, A7I/O chassis dimensions (series B), 32

N

Noise protection, 25

P

Panel, mounting a chassis to, 31

Power distribution requirements, 82grounded, 83rating of transformer, 86ungrounded, 84

Power supplies, 71distribution requirements, 82installing, 81installing externally to chassis, A8installing externally to chassis (series B),

33processorresident chassis, 81remote chassis, 81

Power supply, setting chassis configurationplug, 313

PROC, 112

Processorcables to communication interfaces, B4connecting DH+ link, 92connecting programming terminal, 101connecting remote I/O link, 67defining communication modes,

PLC-5/12, -5/15, - 5/25, 51front panel, PLC5/10, 5/12, 5/15, 5/25,

14installing, PLC5/10, 5/12, 5/15, 5/25,

510installing battery, 41instruction set, A4keying bands, installing, 510keyswitch operation, 16operating temperature, 21PLC5/10, 5/12, 5/15, 5/25

configure adapter communication, 15configure for scanner or adapter, 15define beginning I/O group, 15define data table words, 15

define DH+ station number, 15define I/O rack number, 15installing, 51

programming software, 93protecting, 22protecting from ESD, 42raceway layout, 24relative humidity, 21removing, PLC5/10, 5/12, 5/15, 5/25,

511software releases used to program, A5specifications, A1status indicators, 111storage temperature, 21switch assemblies

PLC5/10, 5/12, 5/15, 5/25, 15PLC5/10, 5/12, 5/15, 5/25, 52,

53, 59system interconnection, 12

Processor memory, A2

Processor module, programming terminal,cable connections, B4

Processor restart lockout, 312

PROG. See Keyswitch operation

Program execution, 16

Programming instructions, A4

Programming software, 93, A5

Programming software requirements, A6

Programming Terminal, cable connections, B4

Programming terminal, 101cables, 104communication boards, 102modem, B1remote connection, 101, 104serial connection, 104

R

Rack, mounting a chassis to, 31

Rack addressing capability, A2

RAM protection, 311

Random Access Memory. See RAM

REM. See Keyswitch operation

REM I/O, 112

Remote I/Ocable lengths, 67connecting link to PLC5 processors,

67installing link, 61list of compatible link devices, A4making connections, 68


Index I–5

rack numbers for a PLC-5 as an adapterto a PLC-5, 55

rack numbers for a PLC-5 as an adapterto PLC-2, 56

rack numbers for a PLC-5 as an adapterto PLC-3, 57, 58

selecting communication rate, 62terminating the link, 59, 68, 69troubleshooting, 115118

Remote I/O system, groundingconfiguration, 36

Removingmemory modules

CMOS RAM, 47EEPROM, 47

processor, PLC5/10, 5/12, 5/15, 5/25, 511

Replacing, memory modules, CMOS RAM, 47

Routing guidelines, 25

RUN. See Keyswitch operation

S

Scanner configuration, PLC5/10, 5/15,5/25, 52

Scanner mode, troubleshooting, 111

Serial port, cables, B3

Setting switchesSW1, PLC5/10, 5/12, 5/15, 5/25, 52SW2, PLC5/10, 5/12, 5/15, 5/25, 53SW3, PLC5/10, 5/12, 5/15, 5/25, 59

Shock specifications, A1

Site preparation, 21conductor categories, 24environment, 21providing convection cooling, 22raceway layout, 24routing conductors, 25using an enclosure, 22

Software, compatible releases, A5

Software system requirements, A6

Specification, battery, A3

Specifications, A1

Station address1770KF2 series B, 1071785KE, 1051785KE series B, 106defining, PLC5/10, 5/12, 5/15, 5/25,

52

Station addresses, 91

Suppressors, listing of, 89

Surge suppression, 88

SW1. See switch assemblies

SW2. See switch assemblies; Switchassemblies

SW3See also Switch assemblies; switch

assembliessettings, 59

Switch assemblieschassis, 310remote I/O adapter module, 62SW1, PLC5/10, 5/12, 5/15, 5/25, 15,

52SW2, PLC5/10, 5/12, 5/15, 5/25, 15,

53SW3, PLC5/10, 5/12, 5/15, 5/25, 15,

59

Switch Settingschassis backplane for adapter modules.

See Switch Assemblieschassis backplane for PLC-5 processor.

See Switch Assemblies

Switch settings1770KF2 series B, 1071771AS, ASB


1785KE series B, 1061785KE series A, 105SW1

PLC5/10, 5/12, 5/15, 52remote I/O adapter module, 62

SW2PLC5/10, 5/12, 5/15, 53remote I/O adapter module, 62

SW3, 93PLC5/10, 5/12, 5/15, 59

Switches. See Switch assemblies

T

Terminating linkDH+, 93remote I/O, 68, 69

Termination resistors, 15, 59, 69using 150Ohm resistors, 69using 82Ohm resistors, 68, 69

Transformer, 85constant voltage, 86isolation, 86rating, 86

Troubleshooting, 111

Trunkline/Dropline connection, 91, 92


IndexI–6

V

VAX/VMS, A5

Vibration specifications, A1

W

Wiring Arminstalling, 72

multi-conductor cable, 73single-conductor wire, 73wiring I/O to, 73


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Documents

Classic 1785 Hardware Programmable Installation Manualtasks you must perform as you install the PLC-5 processor system. The flowcharts guide you with questions about your system. Notice