Allen-Bradley SLC 500 User manual

SLC 500™ Modular
Hardware Style
(Cat. Nos. 1747-L511, 1747-L514,
1747-L524, 1747-L531, 1747-L532,
1747-L541, 1747-L542, 1747-L543,
1747-L551, 1747-L552, 1747-L553)
User Manual
Allen-Bradley PLCs

Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown
in this guide are intended solely for purposes of example. Since there
are many variables and requirements associated with any particular
installation, Rockwell International Corporation does not assume
responsibility or liability (to include intellectual property liability) for
actual use based upon the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Rockwell Automation office), describes
some important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole
or part, without written permission of Rockwell Automation, is
prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
PLC-5 is a registered trademark; and MicroLogix, SLC 500, RSLogix, and RSLinx are trademarks of Rockwell Automation.
Modbus is a trademark of Schneider Automation Incorporated.
DeviceNet is a trademark of Open DeviceNet Vendor Association (ODVA).
ATTENTION
!
Identifies information about practices or
circumstances that can lead to personal injury or
death, property damage or economic loss
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.

iii Publication 1747-UM011C-EN-P - December 2001
Summary of Changes
The information below summarizes the changes to this manual since
the last printing.
To help you find new and updated information in this release of the
manual, we have included change bars as shown to the right of this
paragraph.
The table below lists the sections that document new features and
additional or updated information on existing features.
For this information See
Updated references to related publications page P-2
1747-P6 and 1747-P7 power supplies
wiring page 1-5
heat dissipation Appendix G
Updated SLC 5/03, 5/04, and 5/05
communication parameters table
page 1-8
1784-PKTX interface card pages 1-2, 1-8, and A-4
A list of processors supporting ASCII
instructions
page 2-5
Information on DeviceNet and ControlNet
capabilities
page 2-9
Appendix D
Selecting a memory module for SLC 5/03,
5/04 and 5/05 processors - revised
page 2-21
Revised recommended surge suppressor
catalog numbers
page 2-28
Revised grounding diagram page 3-5
1746-BAS-T module page B-3
Minimizing noise when using SLC 5/04
processor
page C-5
Updated power supply loading worksheet Appendix F
Updated heat dissipation worksheet Appendix G
Allen-Bradley PLCs

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Summary of Changes iv

vPublication 1746-UM011C-EN-P - December 2001
Table of Contents
Preface
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-2
Common Techniques Used in this Manual . . . . . . . . . . . . . P-3
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . P-3
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-3
Your Questions or Comments on this Manual . . . . . . . . P-4
Chapter 1
Quick Start for Experienced Users
Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . 1-2
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2
Selecting Your Hardware
Components
European Union Directive Compliance . . . . . . . . . . . . . . . 2-2
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Overview of Your Modular Control System . . . . . . . . . . . . 2-3
Principles of Machine Control. . . . . . . . . . . . . . . . . . . . 2-4
Selecting Modular Processors. . . . . . . . . . . . . . . . . . . . . . . 2-5
Processor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Processor Communication Options . . . . . . . . . . . . . . . . 2-6
SLC 500 System Test General Specifications. . . . . . . . . . 2-10
Processor General Specifications. . . . . . . . . . . . . . . . . . 2-11
Memory Backup for the 1747-L511, SLC 5/01 Processor . 2-12
Selecting Discrete I/O Modules . . . . . . . . . . . . . . . . . . . . . 2-12
Selecting Specialty I/O Modules. . . . . . . . . . . . . . . . . . . . . 2-12
Selecting Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Power Supply Specifications. . . . . . . . . . . . . . . . . . . . . 2-14
Example for Selecting Power Supplies . . . . . . . . . . . . . 2-15
Example Worksheet for Selecting a 1746 Power Supply. 2-16
Selecting Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Selecting Operator Interfaces . . . . . . . . . . . . . . . . . . . . . . . 2-18
Programming with a Hand-Held Terminal. . . . . . . . . . . 2-18
Selecting a Memory Module for the SLC 5/01 and
SLC 5/02 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Selecting a Memory Module for SLC 5/03, SLC 5/04,
and SLC 5/05 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
EEPROM Burning Options. . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Selecting Isolation Transformers. . . . . . . . . . . . . . . . . . . . . 2-24
Special Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Class I, Division 2 Applications. . . . . . . . . . . . . . . . . . . 2-25
Selecting Contact Protection . . . . . . . . . . . . . . . . . . . . . 2-28
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Table of Contents vi
Chapter 3
System Installation
Recommendations
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Spacing Your Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preventing Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Grounding Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Special Grounding Considerations for DC
Applications using 1746-P3. . . . . . . . . . . . . . . . . . . . . . 3-6
Modification to the SLC 500 Series A Chassis . . . . . . . . . 3-6
Determining the Date of the SLC 500 Series A Chassis . . 3-7
Master Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Emergency-Stop Switches. . . . . . . . . . . . . . . . . . . . . . . 3-9
Power Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Common Power Source . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Grounded ac Power-Distribution System with
Master-Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Loss of Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Input States on Power Down . . . . . . . . . . . . . . . . . . . . 3-11
Other Types of Line Conditions . . . . . . . . . . . . . . . . . . 3-11
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Disconnecting Main Power. . . . . . . . . . . . . . . . . . . . . . 3-12
Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Power Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Periodic Tests of Master Control Relay Circuit . . . . . . . . 3-13
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Chapter 4
Mounting Your SLC 500 Control
System
Mounting Modular Hardware Style Units . . . . . . . . . . . . . . 4-1
4-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
7-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
10-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . 4-2
13-Slot Modular Chassis . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Link Coupler (AIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Data Table Access Module (DTAM, DTAM Plus,
and DTAM Micro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
AIC+ Advanced Interface Converter (1761-NET-AIC)
DeviceNet Interface (1761-NET-DNI)
Ethernet Interface (1761-NET-ENI) . . . . . . . . . . . . . . . . 4-6
Chapter 5
Identifying the Components of
Your Processor
SLC 5/01 Processor Hardware Features . . . . . . . . . . . . . . . 5-1
SLC 5/02 Processor Hardware Features . . . . . . . . . . . . . . . 5-3
SLC 5/03 Processor Hardware Features . . . . . . . . . . . . . . . 5-6
SLC 5/04 Processor Hardware Features . . . . . . . . . . . . . . . 5-8
SLC 5/05 Processor Hardware Features . . . . . . . . . . . . . . . 5-12

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Keyswitch for the
SLC 5/03, SLC 5/04, and SLC 5/05 Processors . . . . . . . . . . . 5-15
RUN Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
PROG Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
REM Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Chapter 6
Installing Your Hardware
Components
Compliance to European Union Directives . . . . . . . . . . . . . 6-1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Installing Your Processor. . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Installing Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installing Your Memory Module. . . . . . . . . . . . . . . . . . . . . 6-4
Removing the Memory Module. . . . . . . . . . . . . . . . . . . 6-5
Installing Your Power Supply . . . . . . . . . . . . . . . . . . . . . . 6-5
Installing Your Chassis Interconnect Cable . . . . . . . . . . . . . 6-8
Chapter 7
Wiring Your I/O Modules
Defining Sinking and Sourcing. . . . . . . . . . . . . . . . . . . . . . 7-1
Contact Output Circuits — AC or DC . . . . . . . . . . . . . . 7-2
Solid-State DC I/O Circuits . . . . . . . . . . . . . . . . . . . . . . 7-2
Preparing Your Wiring Layout . . . . . . . . . . . . . . . . . . . . . . 7-3
Recommendations for Wiring I/O Devices . . . . . . . . . . . . . 7-4
Features of an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wiring Your I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Octal Label Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Applying the Octal Filter Label . . . . . . . . . . . . . . . . . . . 7-7
Applying the Octal Door Label . . . . . . . . . . . . . . . . . . . 7-7
Octal Kit and I/O Module Information . . . . . . . . . . . . . 7-8
Using the Removable Terminal Block (RTB). . . . . . . . . . . . 7-9
Removing the RTB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installing the RTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Chapter 8
Starting Up Your Control System
Procedures for Starting the Control System. . . . . . . . . . . . . 8-1
1. Inspect Your Installation . . . . . . . . . . . . . . . . . . . . . . . . 8-2
2. Disconnect Motion-Causing Device . . . . . . . . . . . . . . . . 8-2
3. Initialize and Test Your Processor . . . . . . . . . . . . . . . . . 8-3
4. Test Your Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Input Troubleshooting Steps. . . . . . . . . . . . . . . . . . . . . 8-6
5. Test Your Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Output Troubleshooting Steps . . . . . . . . . . . . . . . . . . . 8-8
6. Enter and Test Your Program. . . . . . . . . . . . . . . . . . . . . 8-9
7. Observe Control Motion . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8. Conduct a Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
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Chapter 9
Maintaining Your Control System
Handling and Storing Battery, Catalog Number 1747-BA . . . 9-1
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Installing and Replacing the Battery of the SLC 5/01
or SLC 5/02 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Replacing Your SLC 5/03, SLC 5/04, or SLC 5/05 Battery. . . 9-4
Replacing Retainer Clips on an I/O Module . . . . . . . . . . . . 9-6
Removing Damaged Retainer Clips . . . . . . . . . . . . . . . . 9-6
Installing New Retainer Clips . . . . . . . . . . . . . . . . . . . . 9-7
Replacing a Fuse on the Power Supply . . . . . . . . . . . . . . . 9-7
Chapter 10
Troubleshooting
Contacting Rockwell Automation for Assistance . . . . . . . . . 10-1
Tips for Troubleshooting Your Control System . . . . . . . . . . 10-2
Removing Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Program Alteration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Troubleshooting the SLC 5/01 and SLC 5/02 Processors . . . 10-3
Identifying SLC 5/01 and SLC 5/02 Processor Errors. . . . 10-4
Identifying SLC 5/02 Processor Communication Errors. . 10-7
Troubleshooting the SLC 5/03, SLC 5/04, and
SLC 5/05 Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Clearing SLC 5/03, SLC 5/04, and SLC 5/05
Processor Faults Using the Keyswitch . . . . . . . . . . . . . . 10-9
Identifying SLC 5/03, SLC 5/04, and SLC 5/05
Processor Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Identifying SLC 5/03, SLC 5/04, and SLC 5/05
Processor Communication Errors . . . . . . . . . . . . . . . . 10-12
Identifying Processor Errors while Downloading an
Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Returning the SLC 5/03, SLC 5/04, and SLC 5/05
Processors to “Initial Factory Conditions” . . . . . . . . . . 10-17
Troubleshooting Your Input Modules. . . . . . . . . . . . . . . . 10-19
Input Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 10-19
Troubleshooting Your Input Modules . . . . . . . . . . . . . 10-20
Troubleshooting Your Output Modules . . . . . . . . . . . . . . 10-21
Output Circuit Operation . . . . . . . . . . . . . . . . . . . . . . 10-21
Troubleshooting Your Output Modules. . . . . . . . . . . . 10-22

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Chapter 11
Replacement Parts
Replacement Cables and Connectors . . . . . . . . . . . . . . . . . 11-1
Cable Connectivity Summary . . . . . . . . . . . . . . . . . . . . 11-2
Replacement Terminal Blocks. . . . . . . . . . . . . . . . . . . . 11-3
Other Replacement Hardware. . . . . . . . . . . . . . . . . . . . 11-3
Appendix A
Setting Up the DH-485 Network
DH-485 Network Description. . . . . . . . . . . . . . . . . . . . . . . A-1
DH-485 Network Protocol . . . . . . . . . . . . . . . . . . . . . . . . . A-2
DH-485 Token Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
DH-485 Network Initialization . . . . . . . . . . . . . . . . . . . . . . A-2
Devices that Use the DH-485 Network . . . . . . . . . . . . . . . . A-3
1747-AIC Isolated Link Coupler for DH-485 . . . . . . . . . . . . A-4
Example System Configuration . . . . . . . . . . . . . . . . . . . . . A-5
Configuring the SLC 5/03, SLC 5/04, and SLC 5/05
Channel 0 for DH485 . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Important Planning Considerations . . . . . . . . . . . . . . . . . . A-7
Hardware Considerations . . . . . . . . . . . . . . . . . . . . . . . A-7
Software Considerations . . . . . . . . . . . . . . . . . . . . . . . . A-9
Installing the DH-485 Network . . . . . . . . . . . . . . . . . . . . A-11
DH-485 Communication Cable and Isolated
Link Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Installing the DH-485 Communication Cable . . . . . . . . A-11
Connecting the Communication Cable to the
Isolated Link Coupler. . . . . . . . . . . . . . . . . . . . . . . . . A-12
Powering the Link Coupler. . . . . . . . . . . . . . . . . . . . . A-14
Installing and Attaching the Link Couplers . . . . . . . . . A-17
Appendix B
RS-232 Communication Interface
RS-232 and SCADA Applications . . . . . . . . . . . . . . . . . . . . B-1
RS-232 Communication Interface Overview . . . . . . . . . . . . B-1
SLC 5/03, SLC 5/04, and SLC 5/05 processors and RS-232
Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
SLC 500 Devices that Support RS-232 Communication. . . . . B-3
1770-KF3 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
1747-KE Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
1746-BAS and 1746-BAS-T Modules . . . . . . . . . . . . . . . B-3
DF1 Protocol and the SLC 5/03, SLC 5/04, and SLC 5/05
Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
DF1 Full-Duplex Protocol. . . . . . . . . . . . . . . . . . . . . . . B-4
Full-Duplex (Point-to-Point) . . . . . . . . . . . . . . . . . . . . . B-5
DF1 Half-Duplex Protocol . . . . . . . . . . . . . . . . . . . . . . B-5
ASCII Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
DF1 Communication Protocol Modems Overview. . . . . . . . B-7
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Wiring Connectors for RS-232 Communication . . . . . . . . . . B-8
Types of RS-232 Connectors . . . . . . . . . . . . . . . . . . . . . B-8
DTE Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
DCE Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Pin Assignments for Wiring Connectors. . . . . . . . . . . . . B-9
Applications for the RS-232 Communication Interface . . . . B-20
DF1 Full-Duplex Peer-to-Peer. . . . . . . . . . . . . . . . . . . B-20
Half-Duplex with Slave-to-Slave Routing . . . . . . . . . . . B-21
Appendix C
Setting Up the DH+ Network
Data Highway Plus Communication Protocol Overview . . . C-1
SLC 5/04 Processors and DH+ Communication. . . . . . . . . . C-2
DH+ Channel 1, 3-Pin . . . . . . . . . . . . . . . . . . . . . . . . . C-2
DH+ Channel 1, 8-Pin . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Wiring Connectors for DH+ Communication for SLC 5/04
Processors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Minimizing Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Typical DH+ Network Configuration . . . . . . . . . . . . . . . . . C-6
Appendix D
Control Networks
Allen-Bradley Remote I/O Network . . . . . . . . . . . . . . . . . . D-1
Remote I/O Passthru . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
DeviceNet Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
The 1747-SDN DeviceNet Scanner . . . . . . . . . . . . . . . . D-3
The 1761-NET-DNI DeviceNet Interface . . . . . . . . . . . . D-4
DeviceNet Network Length. . . . . . . . . . . . . . . . . . . . . . D-5
ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
The 1747-SCNR ControlNet Scanner Module . . . . . . . . . D-6
The 1747-KFC15 ControlNet Messaging Module. . . . . . . D-6
Appendix E
Communicating with Devices on
an Ethernet Network
SLC 5/05 Processors and Ethernet Communication . . . . . . . E-1
SLC 5/05 Performance Considerations . . . . . . . . . . . . . . . . E-2
SLC 5/05 and PC Connections to the Ethernet Network. . . . E-3
Ethernet Network Topology . . . . . . . . . . . . . . . . . . . . . E-3
Ethernet Channel 1 8-Pin 10Base-T Connector. . . . . . . . E-3
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Configuring the Ethernet Channel on the SLC 5/05 . . . . . . . E-5
Configuration Using RSLogix 500 Programming Software . . E-6
Configuration Via BOOTP . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Using DOS/Windows BOOTP . . . . . . . . . . . . . . . . . . . E-8
Run the Boot Server Utility. . . . . . . . . . . . . . . . . . . . . E-11