Black & Decker d984 User manual

Models E984,0984 and
K984-X8X Controllers
System Planningand
InstallationGuide
GM-0984-EDK Rev. R
I Modicon I Square D 8 Telemecanique

Modicon
System Planning and
Installation Guide for
984-X8X Controllers
Models E, D, and K
GM-0984-EDK Rev. B
August, 1995
MODICON, Inc.
One High Street
North Andover, Massachusetts 01845

Preface
This guide describes the ten different yet similar 984 slot mount Programmable
Logic Controllers and their available options, together with procedures for system
planning and installation.
The major differences are identified up front for easy reference in Chapter 1.
Throughout the manual a number of sections apply to all models, while others ap-
ply only to certain models as so noted.
The information in this document is subject to change without notice and should
not be construed as a commitment by Modicon, Inc., who assumes no responsibil-
ity for any errors that may appear in this document. No part of this document may
be reproduced in any form or by any means, electronic or mechanical, including
photocopying, without the express written permission of the publisher, Modicon,
Inc. All rights reserved.
0 Copyright 1995 Modicon, Inc.
The following are trademarks of Modicon, Inc.:
ModiconB P190 984A 984-380 984-38 1 E984-381
984-385 E984-385 Micro 984 984 984B 984480
E984-480 984-485 E984-485 984-680 ModbusB 984X
984-685 E984485 984-780 984-785 984-785L E984-785
984-l 20 984-l 30 984-l 45 984-351 984-455 Modsoft@
D984-385 K984-485 D984-785 K984-785 Modbus Plus
IBM8 is a registered trademark of International Business Machines, Inc.; IBM PC
is a trademark of International Business Machines, Inc.
Preface iii

Objectives
This manual will help you plan, configure, mount, wire, connect, check out, and
troubleshoot your 984 slot-mount controller system, including 984/800 Series
Remote I/O. After reading this book:
o A Control Engineer will be able to identify and physically plan the location and
mounting of system components.
o A Plant Electrician/Installer will be able to install, power-up, and check out the
system.
o A Maintenance Technician will be able to recognize, locate, identify, and re-
solve or report system failures.
How To Use This Manual
Chapter 1 describes the various controllers and their functions.
Chapter 2 offers information for planning your installation.
Chapter 3 is an installation procedure for your controller with local I/O and
Remote I/O.
Appendix A gives system specifications.
Appendix B gives troubleshooting assistance.
iv Preface

Related Documents
The Documents listed go beyond the installation and orientation contained herein
and are required for new users in programming environments:
GM-MSF--001
840 USE 101
890 USE 101
890 USE 100
Modsoft Programmer User Guide
Modicon Ladder Logic Block Library
Remote I/O Cable System Planning Guide
Modbus Plus Network Planning and
installation Guide
Minimum Revision Levels
The minimum prom revision levels for the 685/785E (only) slot-mount controller
options are:
Option
S908
s911
5985
Exec Part Number Rev. Level Min. Prom Number
AS-E9081 31 H 1007
AS-S91 l-801
Exec (AS-9490-022) G 1006
AM-S985800 D 1004
The minimum revision levels for programming software diskettes are:
PC
Disks
Part Number Version Description
SW-MS(X)D-9SA 2.0 Modsoft 2.0 (all models)
CR
Note In Hot Standby configuration both controllers and systems must
be at the same hardware and firmware revisions. (Refer to the Redun-
dancy 6851785 section located in Chapter One.)
Preface v

Incoming Inspection Guidelines
Guidelines for Inspection
o Before you do anything, verify your shipment is complete and undamaged. If
the shipment is incomplete or damaged, notify the carrier and your distributor.
o Remove everything from its packing and check for physical defects or damage.
If the equipment is physically defective or damaged, notify your Modicon repre-
sentative.
ID=
Note Save shipping materials until installation is complete.
Sending Something Back?
o Whenever possible, use the original packing materials supplied by Modicon.
o All equipment should be firmly packed so that it cannot move around in its ship-
ping container.
o All equipment should be protected against impact during shipment.
IJ All equipment should be clearly marked with its Return Authorization Number
@A#).
vi Preface

Table of Contents
Chapter 1 Introducing your Controller . . . a
Programmable Logic Controllers (PLC) .
System Capacity . . . . . . . . . . . . . . .
Optimize Mode (685E/785E ONLY) . . .
How Optimize Works . . . . . . . . . .
Local I/O . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O . . . . . . . . . . . . . . . .
Executive NV FLASH Memory and RAM . . .
Executive Functionality . . . . . . . . . . .
Redundancy685785 . . . . . . . . . . . . .
Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote I/O Enclosures . . . . . . . . . .
Status Indicators . . . . . . . . . . . . . . .
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1
2
6
7
8
9
9
11
11
12
13
14
15
Chapter 2 System Planning . . . . . . . . . . . . L, _ . . . . . . . . 17
Planning . . . . . . . . . . . . . .
Overview . . . . . . . . . . .
Space Requirements . . . . . . .
Primary Power Lines . . . . . . . . .
Environmental Requirements . . . .
Mounting Hardware Requirements .
Housing Installation Options . . . . .
Panel or Bulkhead Mounting . .
Rack Mounting . . . . . . . . . . .
Grounding Your Installation . . . . . . . .
Power Supply Function (AC and DC) .
Primary Power Cable (AC/DC) . .
AC Power Cable . . . . . .
DC Power Cable . . . . . . . . . . .
Communications Processing Function .
381 E/385E/385D/480E/485E/485K
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Comm Switch Configuration for MODBUS, Ports ........ 31
Modbus Port Software Configuration ................. 31
Modbus Plus Node Address Setting (385/485 ONLY) .... 33
Modbus Plus Bridge Mode (385/485 ONLY) ............ 34
Table of Contents vii
GM-0984-EDK

Using MSTR Block To Change Modbus Plus Address . . . 35
Modbus Plus Node Address Software Change (385/485 ) 35
MSTR Format . . . . . . . . . . . . . . . . . . . . . 35
Port Delay Timer . . . . . . . . . . . . 37
685El785El785DI785K . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Comm Switch Configuration for MODBUS, Ports . 37
Modbus Port Software Configuration . . . . . . . . . . . . . . . . 38
Modbus Plus Node Address Setting (685i785 ONLY) . . . 41
Chapter 3 System Installation
.....................
43
Panel/Bulkhead Mounting .............................. 44
RackMounting .................................... 50
Procedure Rack Mounting Installation .................. 52
Procedure Connecting Your Field Wiring ................ 55
I/O Module insertion ................................... 58
Procedure I/O Module Installation ..................... 58
PowerSupply ........................................ 60
Power Supply Installation and Wiring ................... 61
Verify Your Local I/O ............................... 64
Controller to IBM PC Programming Panel Software ..... 64
Getting PLC into RUN Mode ....................... 64
I/OQuickCheck ................................. 65
RI/O Head/Receiver ................................... 68
RI/O Head Installation (685E/785E/785Di785K ONLY) ..... 68
Procedure Setup & Install. of S908 RI/OP in Prim. Housing 68
RI/O Receiver Install (480E/485E/485K & 685E/785E,D & K) 69
Procedure Set Drop Address/ASCII Ports for J89X & Install 70
Verify Your RIO Installation .......................... 74
...
VIII
Table of Contents