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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GENERAL INFORMATION
1.2 OVERVIEW The Modicon@ 884 Programmable Controller has three processors in one
enclosure. The enclosure is called the 884A Controller. The controller slides into
a module housing with backplane which it shares with a power supply, 800 series
l/O modules and up to four option cards.
The 884 Controller has one main processor that executes the main body of
software in the system and two front-end processors which handle the low-level
logic required to drive the Modbus and l/O ports. The main processor is an 8086,
and the front ends are each 8051s. The front ends communicate with the main CPU
via 1K byte switch RAMS. The switches are controlled by handshake logic.
1.3 POWER SUPPLYThe P800 Power Supply is capable of providing all system DC power to the 884A
Controller and up to 256 l/O points.
The P800 Power Supply prime power requirement is 115 or 230 VAC, 50160Hz. There
are six outputs from the power supply which connect to the housing backplane.
All outputs are tightly regulated and can be short circuited without damage to the
power supply.
The output connector is the card edge and plugs the power supply into the
backplane of the module housing. The power supply module
slot.
1.4 MODULE HOUSING
Table l-l lists the various module housing assemblies that
Table 1-l Module Housing Assemblies
seats in the leftmost
are available.
Part number Description
AS-H819-000
AS-H819-003
19 inch housing capable of housing onty 110 modules.
19 inch housing capable of housing power supply, controller, and l/O
modules.
AS-H819-007 19 inch housing capable of housing power supply, controller, l/O
modules, and Options.
AS-H827-000
AS-H827-003
27 inch housing capable of housing only l/O modules.
27 inch housing capable of housing power supply, controller, and l/O
modules.
AS-H827-007 27 inch housing capable of housing power supply, controller, l/O
modules, and Options.
1-2
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GENERAL INFORMATION
‘LJ
1.5 CABLES Table 1-2 lists the cables that are available
for interconnecting modules housings.
Table 1-2 Interconnecting Cables
Part number
AS-W801-001
AS-W801-006
AS-W801-012
AS-W802-001
AS-W802-006
AS-W802-012
Description
1 foot signal cable
6 foot signal cable
12 foot signal cable
1 foot power cable
6 foot power cable
12 foot power cable
1.6 l/O MODULES Table 1-3 lists some of the l/O modules presently available.
Table l-3 I/O Modules
Part number Description
AS-B802-008
AS-B803-008
AS-B804-016
AS-B80501 6
AS-B808-016
AS-B809-016
AS-B820-008
AS-B821-008
115 VAC 8 point output module.
115 VAC 8 point input module.
115 VAC 16 point output module.
115 VAC 16 point input module.
220 VAC 16 point output module.
220 VAC 16 point input module.
10 - 60 VDC 8 point output module.
10 - 60 VDC 8 point input module.
1.7 8841P190 TAPES AND CABLES
Table 1-4 lists the tapes and cables used with the P190.
Table l-4 P190 Tapes and Cables
Part number
AS-T884-001
AS-T884-003
AS-W806-012
AS-W806-025
AS-W806-050
Description
ProgrammerlConfigurator tape.
Tape Loader tape.
12 foot 8841P190 connecting cable.
25 foot 884lP190 connecting cable.
50 foot 8841P190 connecting cable.
1-3
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SECTION 2
FUNCTIONAL DESCRIPTION
2.1 CONTROLLER MODULE DIAGNOSTIC INDICATORS
The 884A Controller module performs several confidence tests to verify the
system’s integrity. If it fails any confidence test, it will stop running and extinguish
the run LED. The four LED indicators on the front panel of the controller signal the
system’s status. When the indicators are on, they signal the following:
READY - the Controller’s components (processors and CPU) are functioning
properly.
RUN - the Controller is running and is solving user logic.
BATTERY OK - the battery voltage is within specification.
MODBUS ACTIVE - the Modbus port has received a valid address. The Modbus
active indicator is off at the end of every message transmission.
2.2 CONTROLLER MODULE CONTROLS
Two control switches are located on the controller module: the memory protection
key switch and the communication interface switch.
2.2.1 Memory Protect Key Switch
The memory protect switch protects the user memory from unauthorized changes.
The memory protect switch is operated with a key. Only personnel with the key can
gain access to the user memory. When the memory protection key switch is in the
OFF position, the memory can be altered. When the memory protection key switch
is in the ON position, the memory cannot be altered, but may be monitored.
2.2.2 Communication Interface Switch
The communication interface switch is located behind the access panel. It is used
to select the 884 communication parameters. Two separate sets of port
parameters (baud rate, ASCII or RTU mode, parity option, number of stop bits, and
slave address number) can be stored in the Controller. The first set is controlled
by the DIP switches located inside the Controller module. These DIP switches are
arranged at the factory to correspond to the default settings of the P190
Programmer. The second set can be entered by way of the P190 or another Modbus
host device, and is stored in the Controller’s battery protected RAM memory. When
the communication interface switch is positioned to DIP, the default
communication parameters are selected, otherwise the parameters are those
stored in RAM.
2-1
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FUNCTIONAL DESCRIPTION
2.3 MODBUS CONNECTOR PORT
The Modbus port is a standard RS-232-C port. It is located on the controller front
panel (see Figure 2-l). The P190 Programmer or the Modbus Industrial
Communications Network connects at this port.
Figure 2-l 884A Controller Module
2.4 POWER SUPPLY DESCRIPTION
2.4.1 P800 Power Supply Module
The P800 Power Supply module installs to the left of the controller, and connects
to the backplane. The power supply provides power to the controller module, l/O
modules, and controller option modules. Figure 2-2 shows the power supply
module.
Figure 2-2 Power Supply Module
2.4.2 Power Supply Module Indicators
The LED indicator lights are located on the front panel of the power supply are
PWR and OVERLOAD.
2-2
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FUNCTIONAL DESCRIPTION
POWEROK - indicates that the power supply is functioning properly.
2.4.3 Power Supply Module Controls
The power key switch on the power supply’s front panel, turns the power supply
ON and OFF.
The power switch must be OFF when installing or removing
the power supply.
2.4.4 Power Supply Module Connections
The AC power connects
(Figure 2-3). The terminal
OVERLOAD - indicates that the configured power output has exceeded the
specified limits and that the fuse must be replaced. The P800 power supply
requires an 8A 250 volt type fuse.
CAUTION
to the screw terminals on the module terminal block
block has a shield to protect against accidental shock.
230 VAC
OPERATION
ONLY
GND AC NEUT
IN
115VAC
OPERATION ONLY
Figure 2-3 Power Supply Terminal Block
Jumpers are used to set the power supply for an input voltage of either 115 or 230
VAC. When jumpers are installed between pins 1 and 2, 3 and 4, and 5, the 884 PC
is set for an input voltage of 115 VAC. When a jumper is installed between pins 2
and 3, the 884 PC is set for an input voltage of 230 VAC. The P800 power supply
is shipped with jumpers in place for 115 VAC operation.
The power supply output connections are achieved by an edgeboard connector
which mates with a connector on the backplane of the module housing.
2.5 l/O DESCRIPTION
User connections are made to terminal strips attached to the front of the housing.
These are standard screw-type terminal strips that are mounted vertically on the
2-3
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FUNCTIONAL DESCRIPTION
wire trough of the module housing. Terminals are numbered from one at the top
to twenty at the bottom. The front accessible terminals can each accept two AWG
14 wires or one AWG 12 wire per point. The l/O module is plugged into the module
housing and is secured by two screws. This configuration allows quick
replacement of the modules without disturbing field wiring.
The databus connections are made via the standard interface connectors to a
shielded backplane at the rear of the housing. The module may be placed in any
location in the l/O structure without interfering with any other module operation.
When the module is inserted into the housing, it picks up a shield ground by
connecting the module shield to the backplane shield ground.
2-4
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SECTION 3
INSTALLATION
3.1 MOUNTING The 884 Programmable Control system consists of plug-in modules (power supply,
controller and l/O) and module housings. The housing may be rack mounted in a
19 inch NEMA rack, panel mounted in a 10 inch (depth) NEMA panel, or wall
mounted. This section describes the procedure to rack mount, panel mount, or wall
mount the 884 system.
NOTE
When rack, panel or wall mounting the housing(s) allow four
inches of space between each pair of housings.
CAUTION
The length of each cable connecting the primary housing
and its immediate secondary housing must not exceed six
feet. The sum of the lengths for each cable type in the local
884 system must not exceed twenty feet.
3.1.1 Wall Mount Procedure
The module housings can be mounted on any surface capable of supporting its
weight.
Before beginning this procedure determine the quantity and location of the
housing(s). It is suggested that two people perform this procedure.
1. Drill holes for a ‘1’4 inch bolt in the mounting surface. Figure 3-1 shows
dimensions for the 19 inch and 27 inch housings.
2. Install housings using l/4inch bolts to secure housing to surface.
3. Connect the W801 power cable and W802 signal (bus) cable. The cables
(W801, W802) connect to the ports located on the front flange of the housing.
The female power and signal cable connectors mate with the ports on the
lower front flange of the primary housing (the primary housing contains the
Controller and Power Supply module). The male power and signal cable
connectors mate with the ports on the upper flange of the consecutive
housing. Additional housings can be connected in the same manner.
3-1
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INSTALLATION
=
2
L
0
Figure 3-l H819 and H827 Housing Dimensions
3-2
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INSTALLATION
&IV- 3.1.2 Rack Mounting Procedure
Table 3-1 contains the list of recommended equipment and tools to perform the
rack mount procedure.
Table 3-1. Recommended Equipment and Tools for Rack Mounting
Quantity Item
c
19 inch Standard (NEMA) Rack
#lo-32 Pan Head Screws
#lo-32 Flat Lock Nuts (optional)
#lo-32 Flat Head Screws
l/4 inch Screwdriver
Before beginning this procedure determine the quantity and location of the rack(s)
and housing(s). It is suggested that two people perform the mounting procedure.
1. Remove the side plates on the H819 module housing. Unscrew the connecting
screws. See Figure 3-2.
L
Figure 3-2 Connecting Side Plates
3-3
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