AEG Modicon Micro 84 User manual

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ML-M84A-USE Rev I
MODICON
Micro 84 Programmablp Controller
USER’S MANUAL
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ML-M84A-USE Rev I
Gould
Mrcro 84 Programmable Controller
USER’S MANUAL
L
SUBJECT: Description of the MICRO 84 Programmable Controller and the information
necessary to configure, install, and program a control system.
J
SPECIAL INSTRUCTIONS: This manual supercedes the version dated August, 1984.
April, 1987
Gould Inc.
Industrial Automation Systems Group
1 High Street
North Andover, MA 01845
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PREFACE
This manual contains instructions for installing and programming the Micro 84
Programmable Controller. Section 2 describes the system components: controller,
input/output modules, and programming devices. Installation is outlined in
Section 3. System checkout is described in Section 4. Section 5 details the theory
of operations. The P370 Programmer is described in Section 6 and programming
procedures are given in Section 7. The P371 Program Pack, a device for
transferring user programs is described, in Section 8. Four appendices, A through
D, list error codes, supply programming examples, define terms, and give
information on l/O modules.
RELATED PUBLICATIONS
ML-M84A-REF Reference Card
PI-M84A-001 Programming Guide IP190
PI-J375002 J375 Modbus Interface
PI-J378-002 J378 Modem
“The information in this document is subject to change without notice and should
not be construed as a commitment by Gould Inc., Programmable Control Division.
Gould Inc., assumes no responsibility for any errors that may appear in this
document.”
The following are trademarks of Gould Inc.:
Modicon 184
Micro 84 384
Modbus 484
Modvue 584
Modway 584M
584L
884
P180
P190
0 Copyright 1981, Gould Inc.
Printed in U.S.A.
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TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
PAGE
SECTION 2 - SYSTEM CONFIGURATION
J
J
2.1 CONTROLLER ................................................... 2-l
2.1.1 Processor .................................................... 2-l
2.1.2 User Memory ................................................. 2-1
2.1.3 PowerSupply ................................................. 2-1
2.2 INPUT/OUTPUT (l/O) MODULES .................................... 2-2
2.2.1 Module Characteristics ........................................ 2-2
2.2.2 Module Addressing ............................................
2.2.3 I/O Configuration Rules ........................................ ;!;
2.2.3.1 l/O Configuration Rules - Basic System .......................... 2-2
2.2.3.2 l/O Configuration Rules . Expanded System ...................... 2-3
2.3 PROGRAMMING DEVICES .........................................
2.3.1 P370 Programming Panel f%
-
......................................
2.3.2 P370 Program Pack ........................................... 2-4
SECTION 3 - SYSTEM INSTALLATION
3.1 SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 CONTROLLER . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . a. . . . . . 3-3
3.4 INPUT/OUTPUT MODULES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 COMPONENT MOUNTING . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 SYSTEM WIRING .................................................
3.6.1 Power Connection ............................................. i-i
-
3.6.2 l/OWiring .
3.6.3 ...........................................................................................
l/O Module Addressing
i-L
-
SECTION 4 - SYSTEM CHECKOUT
4.1 CONTROLLER OPERATION ........................................
4.1.1 Power-Up Sequence
9-i
-
...........................................
4.1.2 Power-Down Sequence. ........................................ 4-2
4.2 P370 PROGRAMMER OPERATION . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 4-2
4.3 SYSTEM CHECKOUT AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
SECTION 5 - THEORY OF OPERATION
5.1 SCAN.. ......................................................... 5-1
5.2 INPUT/OUTPUT (l/O) MODULES .................................... 5-l
5.2.1 Discrete l/O Modules ..........................................
5.2.2 Register Modules
z-i
-
.............................................
...
III
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6.1 PROGRAMMER OPERATING MODES ............................... 6-1
6.1 .l Examine Mode ................................................ 6-2
6.1.2 Enter Mode ................................................... 6-2
6.1.3 Supervisory Mode ............................................. 6-2
6.1.4 Error Mode ................................................... 6-2
6.2 DISPLAY AREA .................................................. 6-2
6.2.1 Reference Data Area .......................................... 6-3
6.2.1 .l Network Display .............................................. 6-3
6.2.1.2 Reference Display ............................................. 6-3
6.2.1.3 Data Display ................................................. 6-3
6.2.2 Node and Element Display ..................................... 6-3
6.2.3 Status indicators ............................................. 6-3
6.3 KEYBOARD ...................................................... 6-5
6.3.1
6.3.2
6.3.3
6.3.4
6.3.4.1
6.3.4.2
6.3.4.3
6.3.4.4
6.3.4.5
6.3.4.6
6.3.4.7
6.3.4.8
6.3.4.9
6.3.4.10
6.3.4.11
6.3.4.12
6.3.4.13
Numeric Keys ................................................ 6-6
Logic Element Keys ........................................... 6-6
Cursor Control Keys. .......................................... 6-6
Function Keys ................................................ 6-7
SHIFT.. ..................................................... 6-7
A-SHlFTlDEFlNEA ........................................... 6-7
B - SHIFT/DEFINE B ........................................... 6-7
SUPV ........................................................ 6-8
CLEAR ...................................................... 6-9
HOLD ....................................................... 6-9
RESET-SHIFT/RESET .......................................... 6-9
REF-SHIFT/PREVIOUS REF ..................................... 6-10
NET-SHIFT/PREVIOUS NET ..................................... 6-10
SRCH-SHIFT/CONTINUE SRCH ................................. 6-11
ENTER ...................................................... 6-11
SHIFT/ENTER VALUE .......................................... 6-13
DISABLE (SHIFT/FORCE) ...................................... 6-14
FORCE-SHIFT/DISABLE ........................................ 6-14
SECTION 6 - P370 PROGRAMMER
6.4 MEMORY PROTECT KEYLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . a.. . . . 6-14
6.5 PROGRAMMER OPERATIONS.. . . . . . . . . . . . . . . . a.. . . . . . . . . . . . . . . . . . . 6-14
SECTION 7 - PROGRAMMING THE MICRO 84
7.1
7.2
7.3
7.4
7.5
7.6
7.6.1
NETWORKS ..................................................... 7-l
SOLVING NETWORK LOGIC ....................................... 7-l
NETWORK POWER FLOW ......................................... 7-2
LADDER LOGIC PROGRAMMING PAD .............................. 7-2
REFERENCE NUMBERS ........................................... 7-3
PROGRAMMING FUNCTIONS ...................................... 7-4
Basic Programming Elements .................................. 7-5
_. .. -
7.6.1 .-I Normally Open Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6.1.2 Normally Closed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
iv
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7.6.1.3 Coil ......................................................... 7-5
7.6.1.4 Latched Coil ................................................. 7-6
7.6.1.5 Horizontal Connector .......................................... 7-6
7.6.1.6 Vertical Connector ............................................ 7-6
7.6.2 Timers ....................................................... 7-6
7.6.3 Counters ..................................................... 7-7
7.6.4 Cascading Timers and Counters ................................ 7-8
7.6.5 Arithmetic Operations ......................................... 7-8
7.6.5.1 Addition ..................................................... 7-9
7.6.5.2 Subtraction .................................................. 7-9
7.6.6 Sequencers (Drum Programmers). ............................... 7-9
SECTION 8 - USING THE P371 PROGRAM PACK
8.1 P371 PROGRAM PACK INSERTION
8.2 DUMPING (STORING) A PROGRAM
. . . . . . . . . ..*..................... 8-1
TO THE P371 PROGRAM PACK . . . . 8.2
8.3 LOADING A PROGRAM FROM THE P371 PROGRAM PACK.. . . . . . . _. . . 8-2
APPENDIX A - ERROR CODES
APPENDIX 6 - PROGRAM LOGIC EXAMPLES
APPENDIX C - GLOSSARY OF TERMS
APPENDIX D - I/O MODULE DATA SHEETS
2-1
2-2
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
4-1
5-l
6-1
6-2
6-3
6-4
6-5
FIGURES
Programmable Controller, System Basic Block Diagram ....................... 2-1
Expanded System Configuration Diagram ................................... 2-3
Typical System Installation ................................................ 3-1
MICRO 84 Mounting Dimensions ........................................... 3-1
MICRO 84 Controller ...................................................... 3-3
Bottom of MICRO 84 Controller ............................................ 3-4
Typical Discrete l/O Module ............................................... 3-5
l/O Module Interconnections ............................................... 3-6
Connection of External Power to MICRO 84 ................................. 3-6
Input Module Wiring ...................................................... 3-7
Output Module Wiring .................................................... 3-7
l/O Addressing ........................................................... 3-8
P370 Programmer With All Display Segments Lit ............................. 4-2
System Block Diagram. ................................................... 5-1
P370 Programmer ........................................................ 6-l
Reference Data Area ..................................................... 6-2
Network Display Area ..................................................... 6-4
Element Display Area. .................................................... 6-4
Status Indicators. ........................................................ 6-4
V
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6-7 Numeric Keys ........................................................... 6-6
6-8 Logic Element Keys
......................................................
6-6
6-9 Cursor Movement Keys
...................................................
6-7
6-10 Function Keys ........................................................... 6-7
7-1 Typical Multi-Node Network
...............................................
7-l
7-2 Network Solving Sequence
................................................
7-2
7-3 Coil Used as Discrete Input
...............................................
7-2
7-4 Ladder Logic Programming Pad
............................................
7-3
7-5 Interconnecting Timers
...................................................
7-8
7-6 Time-of-Day Clock
........................................................
7-8
7-7 Sequencer Example ...................................................... 7-10
8-1 Program Pack ........................................................... 8-1
.
FIGURES (Cont)
TABLES
3-1 System Memory Sizes
....................................................
3-2
3-2 MICRO 84 Specifications
..................................................
3-2
6-l Supervisory Codes and Actions
............................................
6-8
6-2 LCD Displays During Panel Modes
.........................................
6-15
6-3 Key Usage/Panel Mode
................................................... 6-16
6-4 Panel Mode Entry.. ...................................................... 6-16
A-l Error Messages .......................................................... A-l
vi
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SECTION 1
INTRODUCTION
d
In an industrial environment, relays and solid-state electronic devices are
used to provide the necessary control signals for control system
applications. A relay can be either an electro-mechanical device or a solid-
state electronic device that is “hardwired” to perform a particular function.
When the application in which an electro-mechanical device is used is
changed, the device must be modified (from normally closed to normally
open, for example). In the case of a “hardwired” device, it must be replaced
with one that is tailored to the application.
A programmable controller (PC) is a solid-state device that directly
replaces the relays and “hardwired” electronic circuitry. A programmable
controller can be quickly modified to adapt to a new or changed
application. Gould introduced programmable controllers in the late 1960’s.
The first user was the automobile industry. Programmable controllers
allowed them to avoid the time and expense of rewiring relay control
systems at model changeover. Since then, the use of programmable
controllers has expanded to cover a wide variety of industrial control
system applications. Typical control system applications include
machines used in cutting, grinding, and welding metals; equipment for
assembling, packaging, and testing components and finished products;
machinery for weighing, transferring, and otherwise handling materials;
and systems for processing chemicals and foods.
l-l
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The MICRO 84 is a microprocessor-based programmable controller
designed to replace relay control systems that require 6 to 60 relays. In
addition, the MICRO 84 provides the following benefits:
l Less expensive than an equivalent relay network
l Easily programmed using simple relay ladder diagrams
l Small-fits in an 8” deep NEMA 12 enclosure
l Simple to install
. Easy to use and maintain
l Designed for use in an industrial environment
l User program remains intact even if power fails
l Non-volatile memory (no battery required)
1-2
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SECTION 2
SYSTEM CONFIGURATION
A typical programmable controller is divided into three components as
shown in Figure 2-1. These components are the controller, the input/output
modules, and a programming device. The programming device is the
interface between the user and the programmable controller. The user
program, located in the controller’s memory, is entered using the
programming device.
OPERATOR -
2.1 CONTROLLER
2.1.1 Processor
2.1.2 User Memory
2.1.3 Power Supply
PROGRAMMABLE CONTROLLER
PROGRAMMING
DEVICE
I
CONTROLLER
PROCESSOR
INPUT /OUTPUT
1
MODULES
INPUT
OUTPUT
i”
USER
CONTROL
DEVICES
ISER
YIRING
Figure 2-1. Programmable Controller, System Basic Block Diagram
The controller of the MICRO 84 system contains the processor, user
memory, and the power supply.
The processor, the “brain” of the system, is a microprocessor-based
system designed to replace relays, counters, timers, and sequencers. The
main purpose of the processor is to use the user program and continuously
monitor the status of all input signals from the control devices and to
change the output signal to a device, if required. The processor can also
perform arithmetic computations (addition and subtraction).
A portion of the processor is designated for use by the user’s logic
program. it is in this area that the relay ladder diagram logic is stored. Once
the ladder diagram program is entered into memory, it remains there until
deliberately changed by the user. The program is not altered by power
failure or power off conditions. The P370 Programming Panel is attached,
through a cable, to a connector on the controller housing. This allows entry
of instructions and data and also permits previously entered information
to be monitored and changed.
The Micro 84 can include either an AC or DC power supply. The options are
listed below by controller part number:
AS-M84A-001 or -002 M84A with AC Power Supply
AS-M84A-101 or -102 M84A with DC Power Supply
The AC power supply operates on 115 VAC, or 220 VAC, 50160 Hz. The
appropriate voltage is jumper selectable (see Section 3). The DC power
supply operates on 24 VDC. No adjustment or maintenance of the power
supply is required. A lamp indicates power-ready status. No external
cooling is required; however, free air circulation must be provided. The
power supply has sufficient capacity to operate the P370 Programming
Panel, the input/output modules, and the processor.
2-l
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2.2 INPUT/OUTPUT (l/O) MODULES
A MICRO 84 Programmable Controller can communicate with up to 112
input and output points. l/O modules are either input or output and are
discrete, register or analog. Each module can be connected to eight l/O
points. The controller can handle a maximum of fourteen l/O modules. (See
the configuration rules listed below for basic and expanded systems.) The
input modules contain the circuitry required to convert incoming voltages
to signal levels compatible with the processor. The output modules contain
the circuitry required to convert processor signal levels to levels
compatible with the devices being controlled. All input and output module
circuits are optically isolated from the internal controller circuitry and
therefore can withstand severe voltage transients without damage to the
controller.
2.2.1 Module Characteristics
The simplicity of interlocking the I/O modules together represents a major
savings in time for both the assembly and programming of the system
when compared to competitive systems. A wide variety of l/O modules are
offered. Each is designed to be an output driving or an input handling
circuit.
The controller and l/O units are designed to operate in an industrial
environment; they operate in locations where electromagnetic noise, high
temperature, humidity, corrosive elements, and mechanical shock are
prevalent.
2.2.2 Module Addressing
The terminal connections on the front of the l/O modules are associated
with both an address in the processor (the reference number) and a specific
piece of user equipment. To communicate, the processor selects the
module address needed during operation. The proper addressing order is
accomplished internally by the processor according to the module type
and its physical location. The closer to the processor, the lower the module
circuit address. This allows the installation of additional modules without
repositioning the existing modules.
2.2.3 l/O Configuration Rules
Before configuring the l/O module portion of your Micro 84 PC system, refer
to the serial number of the PC. If the PC serial number ends with “A”, it is
an expanded system. Follow the configuration rules in Section 2.2.3.2. If
the PC serial number does not have an “A” suffix, it is a basic system. For
basic systems, follow the configuration rules in Section 2.2.3.1. Contact
your distributor or local sales office for information on upgrades.
2.2.3.1 l/O Configuration Rules - Basic System
A Micro 84 Basic System has either 13 mixed l/O modules or 8 discrete l/O
modules. The 13 mixed modules can be discrete, register, and analog
modules, according to the following limitations.
a)
A maximum of four 8370 BCD Register Output or B374 4-20mA Analog
Output Modules may be installed on one system.
b) A maximum of one 8371 BCD Register Input, one B373 0-1OVDC
Analog Input, or one B375 4-20mA Analog Input Module may be
installed on .a system.
2-2
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J
26.5 in.
11(673 mm) 1
- - -
- -
r
- -
1
- 2 3.14 5
I I
7
I’)
8 9
1 10 11 IL
1 13 1 14
, I I I
cl
A maximum of 4 discrete input and 4 discrete output modules may be
installed in one system.
2.2.3.2 l/O Configuration Rules - Expanded System
A Micro 84 Expanded System supports up to fourteen 300 Series l/O
Modules, subject to the following configuration rules.
a) The maximum number of discrete inputs and outputs combined
cannot exceed 112.
b) A maximum of 14 discrete modules may be installed in one system.
A maximum of eight discrete input or eight discrete output modules
is allowed.
c) A maximum of 2 analog or register input modules may be installed on
one system.
d) A maximum of 4 analog or register output modules may be installed
on one system.
e) Analog or register modules must be physically mounted to the right
of all discrete modules (see Figure 2.2).
Discrete l/O Modules Discrete (Expanded System Only)
Analog or Register l/O Modules
Figure 2-2. Expanded System Configuration Diagram
Surge withstand specifications for a configuration with more than 8
modules of any type is 1000 VRMS. If a system has 8 or less modules which
are mixed discrete and register, the surge withstand rating is 1500 VRMS.
Systems having a configuration with 8 or less discrete modules have a
surge withstand rating of 2500 VRMS (IEEE 472-1974, ANSI C37.90a).
NOTE
When recording and then reloading a program into the same
controller, remove the P371 Program Pack and then reinsert
it before loading the program. This procedure prevents the
occurence of false error conditions.
2-3
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2.3 PROGRAMMING DEVICES
The principal peripheral devices which allow the user to interface with the
MICRO 84 Programmable Controller are the P370 Programming Panel and
the P371 MICRO 84 Program Pack.
2.3.1 P370 Programming Panel
The P370 Programming Panel incorporates a function keypad and a liquid
crystal display (LCD) in a rugged, compact case. This facilitates hand-held
operation at the controller site. The programming panel connects to the
MICRO 84 Controller and provides a simple method of programming the
user memory from a ladder diagram. The “language” used to program the
controller utilizes familiar relay symbols; there is no requirement to learn
a programming language. In addition, the LCD readout allows rapid and
easy system checkout and maintenance. See Section 6.
2.3.2 P371 Program Pack
The program pack incorporates a memory identical to the user’s portion of
the controller memory. Once a program is loaded into user memory, a copy
of that program can be loaded into the program pack for storage. The
program in user memory is left intact. Once the program pack is loaded
with a program, that program can be reloaded into the same MICRO 84 or
another one that is to perform the same functions. Loading a program into
the program pack is controlled using the P370 Programming Panel.
Loading a program into a MICRO 84 is controlled from the programming
pack. See Section 8.
NOTE
When recording and then reloading a program into the same
controller, remove the P371 Program Pack and then reinsert
it before loading the program. This procedure prevents the
occurence of false error conditions.
2-4
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SECTION 3
SYSTEM INSTALLATION
i
The MICRO 84 Programmable Controller mainframe is easily installed in a
standard 8” deep NEMA rack. Figure 3-1 illustrates a typical system layout,
providing mounting dimensions of all major components. Figure 3-2
provides mounting hole dimensions. For proper heat flow, all units should
be mounted vertically. This allows natural air flow and removal of heat by
way of the heavy duty housing fins. For Class I operating environments
where air tight explosion-proof enclosures are employed, a minimum of six
inches is necessary for heat dissipation between the top, bottom, sides,
and front of the MICRO 84 and the enclosure.
MICRO-84
MAINFRAME
7=’
PROGRAMMER
Figure 3-1. Typical System Installation
3-1
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3.3 CONTROLLER
J
Dimensions (WxHxD):
Mainframe
(w/Power Supply)
Single l/O Module
P370 Programming Panel
Program Pack
3.75 in. X 11.50 in. X 5.875 in.
(95.25mm X 299.lOmm X 149.23mm)
1.625 in. X 11.50 in. X 5.875 in.
(53.95mm X 292.lOmm X 149.23mm)
10.00 in. X 6.50 in. X 1.75 in.
(254.00mm X 165.lOmm X 44.75mm)
2.88 in. X 1.50 in. X 5.00 in.
(73.15mm X 38.lOmm X 127.00mm)
Weight:
Mainframe (w/Power Supply) 5 Ibs., 6 oz. (2.44 kg)
Single l/O Module, output 1 lb., 13 oz. (0.82 kg)
Single l/O Module, input 1 lb. (0.45 kg)
Programming Panel 1 lb., 10 oz. (0.74 kg)
Program Pack 8 oz. (0.23 kg)
Power Requirements, AC:
Voltage Range 115 or 220 VAC, f 15%
47 to 63 Hz, 50 watts max.
NOTE: The 220 VAC option requires the removal of a jumper on the
external power terminals.
Power Requirements, DC:
Voltage Range 24 VDC, + 20%, - 15%
(20.4 to 28.8 VDC)
Polarity Reversal Polarity reversal to the external
power terminals will blow the power
supply fuse. No damage will occur
to the power supply, controller, or
I/O modules.
Current Draw 3A max.
.5A operating
Fuse 5A
Environmental Requirements:
Ambient (Room)
Temperature, mainframe O” to 60°C
Ambient (Room) Temperature
programming panel o” to 4o”c
Relative Humidity 0% to 95% (non-condensing)
Shock 10 G for 11 msec.
Vibration .625 G, 50 to 500 Hz
EMI (electromagnetic Interference) MIL-STD 461 6
Ml (magnetic interference) HELM HOLTZ Co.1
RFI (radio frequency interference) FCC Class A
SWC (surge withstand capability IEEE 472-1974 & ANSI C37.90A
Table 3-2. MICRO 84 Specifications
The MICRO 84 controller (Model M84A) is contained within a rugged metal
housing that is designed to screw mount into a standard 8” deep NEMA
rack. The controller can also be screw mounted onto a wood mounting
panel.
Located on the housing front is a five screw terminal strip and two
indicating lights. The terminal strip is used to co.nnect external AC power
to the MICRO 84 system. The upper indicating light, (POWER), is
illuminated when external AC power is applied to the power supply. The
lower indicating light, (RUN), is on when the processor is solving the logic
networks. Refer to Figure 3-3.
3-3
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Figure 3-3. MICRO 84 Controller
Located on the bottom of the controller are two female sockets that are
used in connecting peripheral (user interface) devices to the controller. The
socket closest to the front of the controller is for the P370 Programmer and
the other is for the P371 Program Pack (see Figure 3-4).
PROGRAM PACK / / P370 PROGRAMMER
CONNECTOR CONNECTOR
Figure 3-4. Bottom of MICRO 84 Controller
3-4
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A female socket is located on the right side of the controller housing. This
socket is the link between the controller unit and the input/output and
register modules. A terminator plug, supplied with the controller, must be
inserted into the rightmost I/O module during system operation. Programs
can be generated in the MICRO-84 without any I/O modules as long as the
terminator plug is inserted into this socket.
3.4 INPUT/OUTPUT MODULES
The B300 Series modules are contained in rugged plastic housings that can
be screw mounted into a standard 8” deep NEMA rack. Located on the
housing front are circuit indicating lights that turn on to indicate when a
particular circuit is active. Screw terminals connect the MICRO 84 to the
user’s equipment. An interconnecting socket is located on each side of the
l/O housing. The left side socket allows communication between the l/O
module and the controller and the right side socket allows communication
between additional I/O modules and the controller. The last I/O module
must have the terminator cap, shipped with the controller, inserted in the
right side socket.
All user control devices that provide input to the MICRO 84 are connected
to the screw terminals located on the input modules. All user devices that
are controlled by the MICRO 84 are connected to the screw terminals
located on the output modules. Refer to Figure 3-5.
J
Figure 3-5. Typical Discrete I/O Module
3-5 -
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