AEG Modicon 884 User manual

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Modicon
884 Programmable Controller
Maintenance Manual
PI-884A-006 Rev C
AEG
MODlCON
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PI-884A-006 Rev. C
Modicon
884 Maintenance Manual
SUBJECT: Contains the instructions required to perform maintenance on an 884 Programmable
Control System.
c
January, 1990
ModiconInc.
IndustrialAutomationSystems
One High Street
NorthAndover, MA 01845
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PREFACE
This guide contains information on the maintenance of the 884 Programmable
Controller.
Use the followingdocumentsin conjunctionwiththis guide:
PI-884A-001 PC ProgrammableGuide
PI-884A-002 PC System Planningand InstallationGuide
PI-884A-003 PC ProgrammingReference Card
PI-884A-005 PC Tape Loader User’s Guide
The information in this document is subject to change withiut notice and should
not be construed as a commitment by Modicon Inc., Industrial Automation Systems.
Modicon Inc. assumes no responsibility for any errors that may appear in this
document. No part of this document may be reproduced in any form without the
express written permission of Modicon Inc., Industrial Automation Systems. All
rightsreserved.
The followingare trademarksof Modicon Inc.:
Modicon 184
Micro84 384
Modbus 484
Modvue 584
Modway 584M
584L
884
P180
Pi90
0 Copyright 1983, ModiconInc.
Printedin U.S.A.
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TABLE OF CONTENTS
PAGE
SECTION 1 - GENERAL INFORMATION
1.1 SYSTEM DESCRIPTION .................................................. l-l
1.1.1 Optional Equipment
..................................................
l-l
1.1.2 Major System Features.
..............................................
l-l
1.1.3 Major Diagnostics Features ........................................... 1-l
1.2 OVERVIEW...........................................................~ . 1-2
1.3 POWER SUPPLY..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1.4 MODULE HOUSING
. . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . , . . . . . .
1-2
1.5 CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 I/O MODULES
. . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1.7 8841P190 TAPES AND CABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
SECTION 2 - FUNCTIONAL DESCRIPTION
2.1 CONTROLLER MODULE DIAGNOSTIC INDICATORS..
. . . . . . . . . . . . . . . . . . . . . . .
2-1
2.2 CONTROLLER MODULE CONTROLS
......................................
2-1
2.2.1 Memory Protect Key Switch
...........................................
2-1
2.2.2 Communication Interface Switch
......................................
2-1
2.3 MODBUS CONNECTOR PORT
. . . , . . . . , . . . . . . . . . . . . . . . , . . . , . . . . . . . . . . , , . . .
2-2
2.4 POWER SUPPLY DESCRIPTION
...........................................
2-2
2.4.1 P800 Power Supply Module
...........................................
2-2
2.4.2 Power Supply Module Indicators
......................................
2-2
2.4.3 Power Supply Module Controls
........................................
2-3
2.4.4 Power Supply Module Output Connections
.............................
2-3
2.5 I/O DESCRIPTION..
. . . . . . . . . a.. . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . .
2-3
SECTION 3 - INSTALLATION
3.1 MOUNTING ............................................................ 3-1
3.1.1 Wall Mount Procedure
...............................................
3-1
3.1.2 Rack Mounting Procedure
............................................
3-3
3.1.3 Sample Configuration
................................................
3-5
3.2 FIELD WIRING . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . , . . . . . .
3-5
3.3 MODULE INSERTION
....................................................
3-6
3.3.1 Power Supply Module Insertion
.......................................
3-6
3.3.2 Controller Module Insertion
...........................................
3-6
3.3.3 l/O Module Insertion
.................................................
3-6
...
III
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3.4 CONFIGURATION ....................................................... 3-6
3.4.1 Configuration Procedure
..............................................
3-6
3.4.2 I/O Slot Configuration Procedure
......................................
3-7
3.4.3 Writing the Configuration ............................................. 3-9
3.4.4 MODBUS Port Configuration (RS-232-C) ................................ 3-9
SECTION 4 - OPERATION
4.1 P190OPERATlON ....................................................... 4-1
4.1.1 Connecting the P190 Programmer
.....................................
4-1
4.1.2 8841P190Tapes ...................................................... 4-1
4.1.3 Loading a Tape into the P190
.........................................
4-2
4.1.4 Monitor or Programming an 884 with the P190
..........................
4-2
4.15 Loading an 884 with a User Program Tape.
.............................
4-2
4.1.6 Recording and Comparing an 884 User Program.
........................
4-3
4.2 MODBUS OPERATION
...................................................
4-4
4.2.1 Interface to MODBUS Master
.........................................
4-4
4.2.2 MODBUS Communication Interface Switch
.............................
4-4
4.2.3 Communication Parameters
...........................................
4-4
4.2.4 MODBUS Port Pin Assignments
.......................................
4-4
4.2.5 MODBUS Active LED
.................................................
4-5
SECTION 5 - TROUBLESHOOTING AND REPAIR
5.1 ERROR CLASSIFICATION
................................................
5-l
51.1 Panel Errors ........................................................ 5-l
5.1.2 PCLErrors .......................................................... 5-2
5.1.3 PCC Errors ......................................................... 5-2
5.2 TROUBLESHOOTING FLOW CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
iv
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LIST OF ILLUSTRATIONS
FIGURE
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
4-1
TITLE PAGE
Controller Module.
......................................................
2-2
Power Supply Module
...................................................
Power Supply Terminal Block.
............................................ t-g
-
H819 and H827 Housing Dimensions
......................................
3-2
Connecting Side Plates
..................................................
3-3
Rack Mounting Housing
.................................................
System Configuration
................................................... z-
Location of Modules
....................................................
3-6
884A l/O CHANNEL TRAFFIC COP screen
.................................
3-8
Rearview of P190 ...................................................... 4-1
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LIST OF TABLES
TABLE
l-l
1-2
l-3
l-4
3-1
3-2
4-1
5-l
5-2
5-3
TITLE PAGE
Module Housing Assemblies
.............................................
1-2
Interconnecting Cables
..................................................
1-3
l/O Modules ............................................................ 1-3
P190 Tapes and Cables.
.................................................
1-3
Recommended Equipment and Tools for Rack Mounting
..................... 3-3
N-232-C Pin Assignments ............................................... 3-9
Modbus Port pin Assignments
............................................
4-4
Panel Error Codes ...................................................... 5-l
PCL Error Codes.
.......................................................
5-2
PCC Error Codes ........................................................ 5-2
vi
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SECTION 1
GENERAL INFORMATION
1.l SYSTEM DESCRIPTION
The 884 system consists of customer configured modules (field replaceable units)
which are the building blocks of the system. The system building blocks consist of:
l Module Housing, 19 inch or 27 inch, with backplane.
l P800 Power supply module
l 884A Controller module with one Modbus@ port
l User selected 800 series set of l/O modules
l P190@ Programmer
l P190/884 tapes
1.l .l Optional Equipment
The system optional equipment consists of:
l Extended power cables
l Extended data cables
l Additional Modbus port
l Redundant power supply
l Secondary module housing, 19 inch or 27 inch
1.1.2 Major System Features
The major system features are:
.
.
.
2K user logic plus 1K registers
256 discrete l/O points, plus additional analog/register capacity
Advance instructions (sequencer/drum, I/O diagnostic, signed double precision
math)
Integral Modbus port (second port optional)
Rack or panel mountable
Simplified self-prompting P190 interface with powerful editing tools
Remote l/O (optional)
Report generation capability (optional)
Complete configuration flexibility (input vs. output, analog vs. register vs.
discrete, 8 vs. 16 point discrete)
High security bus protocol
Front-accessible fuses
Integral carrying handles
Rigid field wiring
1.1.3 Major Diagnostics Features
The major diagnostics features are:
l Internal power up test
l Internal communications test
l P190 Load/Dump/Compare
l l/O data
l Real time confidence test
l Power supply test
l-l
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