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1. Introduction to the product Operating instructions Classroom resource H References Other Self study Programming Procedures Advanced programming techniques How did you get this document Received with equipment O Ordered from MODICON Received from Sales or Customer 1 Do not know Service Representative Other Please rate this document Very Excellent Good Good Fair Poor Technical Does the system work the way it is 0 0 described in the manual Readability 15 the manual easy to read C C understand Clarity Are the instructions easy to follow Li D Examples Are the examples helpful and realistic 0 j Are there enough examples 0 Organization ts the organization of the manual logical Is it easy to find what you are looking for o Illustrations Are the illustrations clear and useful Physical What did you think of the layout Attractiveness printing binding etc Y N Are there any terms or concepts that are not defined clearly J If so what are they Y N After reading this document are you able to use the equipment What errors did you find in the manual Please include page numbers Attach an extra sheet if neces
2. i T L i EE i 1 910 T T c 1 EE Lien mo 7 1 a 77 2272711 S E TE aoe 060 x Lo SE ke lei 06501 0909 fpoo 9 00221 09291 39S 01 LON SiHL Sere L igna sng NOLLVHT9IJNOO W3LSAS Sar 001 99 15 9NIMVNO NODIGOW 335 2 oorig be Q3ddVl WO LY3SNI 52 96 SOH 1 96182 5310 gt VIII 5 uonesnByuod Ltr P A 910514 001 785 915 EKA HL9NJI 1200 SNA xvw oesi SONISNOH 2 BNE 826 0802 SONISNOH aesss xww 0852 59 5 ONISNOH 40 30 46 IHL SONISNOH WOLIOG YO 1 9 14371 3WVMJNIVM OL X131VKI3WM 150 SNOLLdO IHL Droi SONISNOH 5 2 SONISNOH 2 Scr 31342610 8 S LNOHLIM W31SAS SSWISnOH SNOISN3WK ONLLNNOW 101 6892 5 9NIMYHO NODION 335 2 nn 09 55 KINO NOLIVWHO4NI 30N3 3434 SNOISNJWIQ TY 1 SONISNOH 9 310N e 1 5
3. be referred to as an ISOLATED OUTPUT MODULE groups of two points The True Low output module requires user load connection to the positive VDC source The negative VDC is wired directlv to the module since the return line is switched by the mod ule logic Note that for bias of the electronic circuits in side the module the positive VDC is also wired directly to the module Self contained clamp diodes suppress transient voltages when inductive loads are driven Each output circuit is fused VI 19 to prevent its circuitry in the case of overload currents LED s are provided for each circuit to indicate blown fuses Separate sets of LED s are provided to indicate status of each output Electrical Characteristics Load Current OFF Current 5 mA max Steady State ON Current 2 amperes max 8 amps per module Recommended Minimum Load 10 mA Inrush Current 7 amps max for 10 ms 5 amps max for 100 ms 5 amps normal blow each output Fuse Rating 5 amps normal blow each output Load Voltage Working Voltage 9 to 56 VDC different source can be used for each group of two outputs in one module Peak Voltage 60 VDC max Output Voltage Drop 1 5V max at 2 amps current Bias Current Each source two required per module should provide the following current Source Outputs Outputs Voltage __OFF ON 24 VDC 6 mA 26 mA 56 VDC 13 mA 32 mA NOTE If one source provides power to
4. B550 115 VAC Output Module Terminal Numbering and 5 6 551 115 VAC Input Module Simplified Schematic re V ls 551 115 VAC Input Module Terminal Numbering ANG CONNECELONGS ivan B552 Universal DC Output Module True High Simplified Schematic VI 9 B552 Universal DC Output Module True High Terminal Numbering and ConnecEtrohS iex CRAS B553 Universal DC Input Module True High Simplified 5 11 B553 Universal DC Input Module True High Terminal Numbering and Connections 12 554 220 VAC Output Module Simplified 1 cS VESLS B554 220 VAC Output Module Terminal Numbering and 5 1 14 B555 220 VAC Input Module Simplified V B555 220 VAC Input Module Terminal Numbering and 15 B556 VDC TTL Output Module Simplified 5 wits ww ast oe cas ONS eo ere va eda Sate Ve LO B556 VDC TTL Output Module Terminal Numbering and 16 B557 VDC TTL Input Module Simplified Schemati 4 40 dod es ore SNe
5. bus MODICON model 484 Programmable Controller equipped with any enhanced executive software package may make use of the 1471 8 1 CONNECTIONS AND MOUNTING The J471 I O Expander is designed to be mounted on any flat vertical surface by the use of 4 EA 5 16 bolts The J471 will attach to the remote end of any standard Now Bus duct as well as the W514 flat cable and the W513 flexible shielded Now Bus extension cable The Expanded Now Bus is then attached to the opposite side of the J471 chassis Access to the Now Bus con nectors on the 7471 PC board is gained by loosening the two ad justible grip latches on the front cover and pulling the top of the front cover out and then down front cover 15 hinged at the bottom and also serves to house the power supply assembly Figures VIII 1 and VIII 2 The expanded I O is al ways connected to the right connector on the inside of the 1471 Data from the 484 always comes into the left connector on the J471 8 2 DIMENSIONS The J471 is approximately 18 H x 11 W x 6 75 D 460 8 CM x 281 6 CM X 172 8 CM and weighs 30 lbs 13 6 kilo grams Figures VIII 3 and VIII 4 8 3 ELECTRICAL CHARACTERISTICS The J471 uses 250 ma at 12 VDC from the power supply of the 484 Controller The 5VDC I O power from the 484 Controller is not used by the J471 to power any circuitry The 0471 has an internal power supply that provides 12 VDC at 3 6 amps and 5VDC at 4 5 amps 5 I O to
6. troller but is temporarily bypassed disables are retentive upon power failure Coils are disabled by placing the cursor on the coil in the LOGIC AREA and depressing the DISARLE pushbutton Inputs 1XXX are similarly disabled by placing the cursor on the input in the REFERENCE AREA Once disabled these references are no longer under control of the controller until manually changed Disabled references freeze their state ON OFF as many references as desired can be simul taneously disabled 11 contacts outputs controlled by this reference wherever they are in the ladder diagram will reflect the ON OFF state of the disabled reference Depressing the pushbutton a second time for a disable reference will return it to the normal enabled condition FORCE This bushbutton can be used to alter the ON OFF State of any disable reference The cursor is placed on a pre viously disabled reference in the ladder diagram only logic III 27 coils and discrete inputs 1 can be disabled When the pushbutton is depressed the state of the reference will be altered e g OFF to ON or ON to OFF Successive depressing of this pushbutton will cause the reference to be toggled OFF to ON to OFF to ON etc 3 4 2 RELAY CONTACT CONTROLS When programming relay contacts into the assembly area the ten pushbuttons plus two spares will control which contact type is selected Changes are easily made by entering the cor
7. Ordering Instructions 1 Provide appropriate billing address and shipping address if dif ferent from billing address Please provide a contact name and phone number in case we have a question about your order Indicate your purchase order number and date You may prepay by enclosing a check for the full amount Give the part number description and quantity for each document ordered Total Delivery Unless otherwise specified all orders are shipped best way surface F O B Andover MA prepay and add if UPS surface collect for truck and air you specify insurance you will be billed for these changes MODICON will not assume any liability in connection with the ship ment nor shall the carrier be construed to be an agent of MODICON Payment Terms are net 30 days from date of invoice Unless otherwise stated partial shipments will generate partial invoices Prices Prices are subject to change without notice Individual prices can be found in the Publications Catalog or obtained by calling an Order Entry Coordinator at 1 800 468 5342 SNOT 07104 LD paaa a NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT 234 ANDOVER North Andover MA 01845 9943 5 7 N 2 o 5 EY e T amp Co t gt 2 28 Ow
8. ee ee ee n n n VI 18 B557 VDC TTL Input Module Terminal Numbering and amp 1 5 1 19 B558 Universal DC Output Module True Low Simplified 5 amp 1 VISA vi LIST OF ILLUSTRATIONS Continued Figure Title Page VI 18 B558 Universal DC Output Module True Low Terminal Numbering and 8 VI 21 VI 19 B559 Universal DC Input Module True Low Simplified Schematic TE PEDE URS VI 20 B559 Universal DC Input Module True Low Terminal Numbering and Connections VI 23 VI 21 B577 Analog Input Module Typical Connections VI 25 VII 1 J470 22 7 4 44 2 VII 1 VII 2 Option Selecter on 3470 Rape rican core cain Wiese VII 2 VII 3 J470 Block Diagram External Connections VII 3 VIII 1 J47l Block DL AGL AM ois seis er UR VIII 4 VIII 2 J471 Mounting Se RU CDD VIII 4 VIII 3 J471 Installation VIII 5 VIII 4 7471 Contig uratlOolhossaue s se Sots tie ees eas Bieta areas VIII 6 LIST OF TABLES Table Title Page I 1 Basic 484 Controller Specifications 1 2 II 1 C484 Mainframe i er II 1 II 2 Summary of Required AC Power TES II 4 II 3 C484 Controller Installatio
9. LLI 42 3 7 5 5 11 43 3 7 6 Self Test PE 46 SECTION TROUBLESHOOTING 4 0 IntroductioDnl 2 2 9 P IV 1 4 1 Indicator Lights uo ew 4 1 1 Power Supply T iri IV 2 4 1 2 RES 4 1 3 Imput Output Section IV 7 4 2 Fault Isolation Flow Charts IV 10 4 3 P180 Error IV 16 1 484 Error IV 16 2 Error Messages e IV 17 4 3 4 3 SECTION V SERVICE CENTER 5 0 V 1 5 1 Forms V 1 SECTION VI 500 SERIES I O DEVICES 6 0 6 1 Discrete I O VI 4 6 1 1 1 5 VI 4 6 2 Register I O Descriptions VI 26 SECTION VII J470 ADAPTER 7 0 re VII 1 iii TABLE OF CONTENTS Continued Page SECTION VIII J471 EXPANDER 8 0 Introd ctlOl exe RADAR VIII 1 8 1 Connections and Mounting
10. 01 318V2 0 1 H2V1 1V3H 3513 3951933 5 3513 ava YATIONLNOD 3411 3 39V 1834 Alddns JAISNI 2 4 3sf4 3A O8ld 30 OJNI 0 14 14715 3015 08 3415 09 0819 ON 133HS WOU3 2 IV 14 0 1 701 1 o Cana S3A 00 08 51 4377104 LNOD 31815 OA ava 31815504 9415 0 1 Qva 31815504 W31SAS NI SQHV2 LndN SONISNOH H3H1O 31315 OVE WOH3 318 0 3H1 3AOW3H 553 SINO QV8 di LS 0009 SS38Q00V34 3 i123 430 31815504 AfidNI 193 1 8 HSNd MS SAYOM S3A 1 1 ave OANI HO4 a1avaodd WANVA t8t JHL NI 8 XlON3ddV 335 91915 0 8 3HL 31782 0 2AOW3M asn4 SS3HOQV S3NO FHL 341193430 4181 0009 39 1 3 553 AMVSS3O3N SI 30 dYMS 9495 1 O31VNIWITTI 411234402 43 TIONLNOD SONISNOH 114100 YOLVIIONI 3 1NGOW mh Lo 5 0 0 1 H3H10 ON 35 3 119110 5
11. Fuse Rating Load Voltage Working Voltage Peak Voltage Output Voltage Drop Bias Current 10 mA 7 amps max for 10 ms 5 amps max for 100 ms 5 amps normal blow each output 9 to 56 VDC different sources can be used for each group to two outputs in module 60 VDC max 1 2 VDC at 2 amps Each source two required per module should provide the following current Source Outputs Outputs Voltage __OFF ON _ 24 VDC 6 ma 26 ma 56 VDC 13 ma 32 ma NOTE If one source provides power to both pairs of outputs a module the above values should be doubled to ob tain the correct load for that module Common Mode Voltage Response Time Output Status Indicator Fuse Indicator OPTICAL COUPLER 200 VAC steady state 15009 for 10 ms OFF to ON 1 ms max A LED is provided for each output The light is ON when the output is ON A LED is provided for each output The LED will be ON when the fuse is blown TO OTHER CIRCUIT DC TO OTHER TS 80 0027 1 3 OUTPUT Figure 5 B552 Universal DC Output Module True High Simplified Schematic 9 TYPICAL TERMINAL NUMBERS REFERENCE DC IN GROUP A DC RETURN GROUP A 0001 OUTPUT 1 0002 OUTPUT 2 DC IN GROUP B DC RETURN GROUP B 0003 OUTPUT 3 TS 80 0028 1 0004 OUTPUT 4 Figure 6 B552 Universal DC Output Module True High Terminal Numbering and Connections B553 UNIVERSAL DC IN
12. inter mediate references are not energized Each sequencer is completely independent since it 15 trolled by separate register values Sequencer references can be used as often as necessary anywhere in the logic where lay contacts are appropriate using calculate logic any sequencer can be made to skip steps and jump forward or move backwards as necessary intermediate references are NOT ener gized Sequencers references are updated as soon as change in the content of a sequencer register is changed Thus network can drive the sequencers and the next network use the most recent value of the sequencer references Sequencer re ferences cannot be used on transitional contacts 3 2 11 BCD CONVERT The BCD CONVERT function allows discrete ON OFF I O mod ules to be referenced as a BCD Binary Coded Decimal regis ter This is if it is desired to wire a thumbwheel switch in put into a set of discrete input modules the BCD CONVERT func tion will allow these 12 inputs to be used as a numerical value in the controller Conversely if it is desired to connect a LED display to a set of discrete output modules the BCD CONVERT function will allow a holding register numerical data to be transmitted to a display 3 2 12 ENHANCED Il INSTRUCTION SET OPTION This instruction set is similar to the Enhanced I Instruc tion option and has the same capabilities plus the foltowing Binary convert discrete i
13. 180 CKSUM P3 PARITY P3 OVERRUN P3 CKSUM ERR 4 3 1 484 ERROR CODE This message appears when P180 is in supervisory status and an error has been detected in the 484 The message will be followed by a two digit number code indicating error type The following list contains the error codes and their meanings Code Definition 01 Communications Overrun 02 Memory Checksum Failed 03 Invalid Node Type Found 04 I O Port Error 05 Scratchpad Diagnostic Failed Fatal No Run Light 06 Coil RAM Checksum Failed 07 CPU Diagnostic Failed IV 16 10 Illegal Memory Configuration Fatal No Run Light 11 Real Time Clock Not Functioning 12 Watchdog Timer Expired 13 Illegal Column Detected 14 End Of Logic Node 4 3 2 ERROR MESSAGES BAD ADR RANGE In general this error message comes from the 484 mainframe and means that the most recent P180 re quest has a serious problem and cannot be processed Specifi cally this message means that the P180 sent a request which would modify memory across an invalid address boundary BAD COMMAND In general this error message comes from the 484 mainframe and means that the most recent P180 request has a serious problem and cannot be processed Specifically this message means that the request code which the P180 sent is not valid BAD LED REQ In general this error message comes from the 484 mainframe and means that the most recent P180 request has a serious problem and ca
14. 4 35 3 39V 1d3M SNISNOH 10345 5 S3 INGOW 0 1 11 3 18v2 3A0W34 SMO38 4 ISNA ULNA V 9 5 H2V3 O1 NO88I3 O I HOV L1V SNISNOH 0 1 3AIL93 430 39v 1d3H 431104 LNOO WOH3 831800 3A0W3H 0009 11116 3 3513 20 21 3513 39V1d34 ASN4 39 19394 350 5 2 3572 303 31815504 371815509 ON 803 03H25 303 1 23H92 Alddns NO MOT 3QISNI 1 3 3514 OV 20 32 71 AL tod CIS IV 11 YO 11V8 6100 08 51 H3 T1041NOO 0908 0872 AMOW3A Ov 1838 SdNV 1 MOLVOIQONI JHL 535 HOIHM QquvOH 1031405 N33A 38 371872 8 YATIONLNOOD 3HLLN3 ATddNS H3MOd TOMINOD ave 31815504 NO 11 8 531334458 39V 1d3H NO 53 11 8 IV 12 0200 08 51 ON SAVS 0814 39971333 318v9 Q3123NNOD 38 11538405 ONY 12345 37855 0914 lt A1 L234HO Q3HOVLLV 0814 SI SXHOM L3N 3NIWVX3 t 133HS NO Q3fINI LNOO 4 NNY 8 1 84n514 3Al128 4430 38 01 1 S3 1nQON JHL JO HO
15. NUMBERS REFERENCE INPUT 1 1001 INPUT 2 1002 INPUT 3 1003 4 1004 5 80 0026 1 Figure 4 551 115 VAC Input Module Terminal Numbering and Connections B552 UNIVERSAL DC OUTPUT MODULE TRUE HIGH MODICON B552 Universal DC Output MOdule True High Figures VI 5 and VI 6 converts the signals used internally in the controller to four independent DC outputs capable of driving relays pilot lamps motor starters solenoids of any other load up to 2 amperes The module uses transistor switches to control loads connected to the user DC source The four output circuits are divided into two groups of two cir cuits each Two different VDC sources can be used for each group The True High output module requires user load connection to the negative VDC source The positive VDC is wired directly to the module since the hot line is switched by the module logic For lamps common the negative VDC is also wired di rectly to the module Self contained clamp diodes suppress transient voltages when inductive loads are driven Each output circuit is fused to protect its circuitry against overload currents LED indi cators are provided to indicate ON status for each output as well as separate LED s for blown fuse indication Electrical Characteristics Load Current OFF Current 5 mA max Steady State ON Current 2 amps per output 8 amps for four outputs VI 8 Recommended Minimum Load Inrush Current
16. ON Voltage Drop Common Mode Voltage Response Time Output Status Indicator Fuse Indicator Compatibility with input Modules FROM OPTICAL COUPLER 10mA 0 5mA 15 amps maximum for 10 ms 5 amps maximum for 100 ms 5 amps normal blow fuse per output 80 VAC to 130 VAC continuous 40 to 70 Hz 150V max for 10 seconds 200 V max for 1 cycle varis tor limited Approximately 1 at 2 amps current Working 200 VAC 1500 max for 10 ms OFF to ON 0 3 to 10 ms max ON to OFF 0 3 to 8 3 ms max at 60 Hz A neon lamp is provided for each output The lamp will be ON when output is ON A neon lamp is provided for each output The lamp will be ON when the fuse is blown The 550 is capable of inter connection with the MODICON B551 and B231 115 VAC Input Modules without the use of additional components TO SECOND CIRCUIT TO SECOND CIRCUIT OUTPUT 80 0023 1 Figure VI 1 B550 115 VAC Output Module Simplified Schematic TYPICAL TERMINAL DUSBUT NUMBERS REFERENCE HOT GROUP A LAMP COMMON GROUP A 0001 OUTPUT 1 0002 OUTPUT 2 HOT GROUP B LAMP COMMON GROUP B 0003 OUTPUT 3 0004 OUTPUT 4 TS 80 0024 1 Figure 2 B550 115 VAC Output Modules Terminal Numbering and Connections B551 115 VAC INPUT MODULE The MODICON 8551 115 VAC Input Module Figure VI 3 and VI 4 contains four 115 VAC isolated inputs Each input draws sufficient wetting current
17. The 484 Controller examines solves each network of inter connected logic elements in their numerical sequence Network One is the first network to be solved on each scan This is followed by network Two Three and so on until all available networks are solved The controller then goes back to network One and solves it and continues solving each network This fixed scanning occurs at very rapid speed typically from four to 20 milliseconds per scan The scanning begins from the time power is applied to the processor until power 15 removed Within each network logic elements are all solved by columns from the left rail to the right rail where coils are located and from top to bottom within each column The result of each network scan is immediately available to all following networks It makes no difference whether this result is a change in coil state or a change in numerical value Networks are solved in order of their numerical se quence number and not by the reference number assigned to coil III 5 All inputs and outputs are updated once per scan The time from solving any individual network on one scan until the net work is solved again on the next scan is called the scan time of the controller The scan time varies depending upon the amount and type of logic entered Typical scans increase with memory size Table III 2 Table 111 2 484 Memory Configurations Typical Elements Typical Contacts Internal Holding
18. VIII 1 8 2 DimenslonS qawau xe RA REIS VIII 1 8 3 Electrical Characteristics 1 8 4 2 8 5 Addressing VIII 2 APPENDIX EXTERNAL 5 A 1 GLOSSARY OF TERMS 1 iv LIST OF ILLUSTRATIONS Title Page 484 Controller 3 Basic Block 1 484 US Ael be P180 CRT Programming 1 1 6 Typical System Layout x VA sea dA 1 1 1 amp 1 II 3 Mainframe Controls and 8 11 5 Mainframe AC Power 5 5 Typical 484 with Single I O 1 11 7 Processor I O Connection 5 8 Typical I O js SACRE ete Input Output Module 1 11 9 Input Output Bus 1 9 Address Selecting of I O Housings 1 10 Field Wiring I O Housing 1 11 11 Installation of I O Housing into I O 1 14 Processor Inte
19. rected contact type anytime prior to entry into the network or construction of new element if the existing logic element of a network is to be altered The relay element can be either normal open contact 4 a normally closed contact Ke a horizontal shunt or a horizontal open In addition any relay element can have a vertical connection to the next lower rung or a vertical connection Ver tical connections are possible only to the right of the ele ment vertical connections are not possible with coils or the bottom seventh rung of a network If enhanced capabilities are available transitional contacts be used f or J otherwise an error message will appear when these contacts are Selected Transitional contacts pass power for exactly one scan when their referenced coil or input goes from OFF to ON or ON to OFF Coils of any network can be normal or latched L all logic coils are latchable Normal coils will be de energized if a power failure occurs latched coils are restored following a power failure to the state ON or OFF that they held prior to the power failure 3 4 3 NUMERICAL ENTRY This set of controls Figure III 17 is used basically to enter numerical values into the assembly area These values can be discrete references to control relay contacts fixed values or register references for numerical elements value for storage in a holding register All four
20. stop the user from using them CHECKING Although this appears in the error line it merely tells the user that the P180 must spend time checking to see if a coil is used This may take several seconds It is displayed to let the user know that the P180 is still alive CHKSUM ERROR In general this error message comes from the 484 mainframe and means that the most recent P180 re quest cannot be processed the way it was sent Specifically this message means that the message from the P180 was received incorrectly THe 484 is not in agreement with the P180 message COIL IN WAY This error message will occur when any multi node item is entered and coil extension is below it Al though the coil may be below and to the left of the multi node to be entered the display position of the coil extends across the screen This prevents any multi node from extending below the coil COIL IS USED This message means that the coil the user is programming is already used as a coil or in a convert No coil may be programmed as an output more than once Converts take 12 coils even though only one number appears on the display If the user has a convert to coil 15 this uses coil 15 through 26 Later programming to coil 17 for example will show USED even though search and display finds NO MATCH COIL NO MATCH This message appears during VERIFY when the coil bits on tape do not match those of the 484 This error may be disregarded if ver
21. 484 IV 22 VERT IN WAY This message appears when the user is trying to program a coil when the cursor is not in the coil column and there is a vertical short coming down immediately to the right of the cursor There may not be vertical shorts down to the right of the coil IV 23 IV 24 SECTION SERVICE CENTER 5 0 INTRODUCTION A Service Center is maintained at MODICON Headquarters in Andover Massachusetts Maintenance assistance is available 24 hours a day 365 days a year Several data telephone lines support computers and exten sive files on all controllers manufactuered by MODICON offered To make maximum use of the Service Center s capabil ities a T158 Telephone Interface must be available This interface connects to the 484 via the J470 Adapter Further these allow support computers to communicate directly to the controller For further information about the MODICON Service Center capabilities and customer options contact any MODICON sales office 5 1 FORMS Necessary support forms will be available from any MODICON Sales Office or Service Center V 1 V 2 SECTION 500 SERIES I O DEVICES 6 0 INTRODUCTION This section describes the discrete I O modules register I O devices and their associated housings which form part of the 500 Series I O System The 500 Series I O System is designed to provide a low pro file reliable and highly modular I O system at a low cost of goods sold Perfor
22. ADDRESSING Discrete I O modules when used on the expanded I O than bus occupy addresses 0129 to 0256 for output modules and 1129 to 1256 for input modules When register modules are used on the expanded I O bus the addressing remains the same as it would be if the register modules were on the normal bus 1 shows these listings VIII 2 Table 3nd3no madur 3nd3no 3ndur zequny sDunsr 71 1 9 1 c v c c I c 1 T T T FOUN VIII 3 BUS DUCT BUS DUCT IN OUT p UP TO I O HOUSINGS TS 80 0045 1 UP TO 10 HOUSINGS Figure VIII 1 4471 Block Diagram BUS DUCT W514 W513 r3 TS 80 0046 1 NOTE J471 may be mounted to either side of the C484 It may be attached by any one of the following cables W513 W514 or W515 Figure VIII 2 4471 Mounting 4 eJnDi 101 5 14 SNISNOH 000 0 1 mini dAl 6025 dal xg a re PETE TE Grit 22952 n i an
23. AS 4965 is supplied with the interface To service the 7474 unit this connector may be removed without distrubing MODBUS communications to the other units provided physical connections are not distrubed Since all options such as baud rate unit number parity stop bits are selected by the wiring of this connector easy re placement and rapid restoration of proper operation lished without extensive testing or interruption of MODBUS operation During replacement of the J474 Communication Inter face the service technician does not need to set dip switches or rotary switches and possibly set the incorrect address Assignment of functions are shown in Table III 3 including optional decoding III 43 Table 111 3 4474 Functions Function Function Protective Ground Binary Address 16 Data Transmitted from J474 Stop Bit Option Data Received by J474 Binary Address 32 Ready to Send RTS Parity Type Option Clear to Send CTS Data Terminal Ready DTR Data Set Ready DSR Parity Enable Signal Ground Binary Address 64 Binary Address 1 MODBUS FULL Duplex In Baud Rate 1 Binary Address 128 Binary Address 2 MODBUS FULL Duplex Out Baud Rate 2 Signal Ground Binary Address 4 Modbus Data in Baud Rate 4 Mode Select 1 Binary Address 8 MODBUS DATA OUT Baud Rate 8 Mode Select 2 1 2 3 4 5 6 7 8 9 Note Pins 1 through 7 and 20 conform to EIA RS 232 C specifications The following illustrates Figur
24. GET NOT DISABLED This message appears when the user tries to a coil which is enabled This is illegal Disable coil first before forcing NOT ENHANCED This message appears when the user is trying to program a function which is not allowed in the basic 484 NOT ENHAN This message appears when the user gramming a function which is not allowed in the enhanced or basic 484 IV 20 NOT LAST This message appears when the user is deleting a node which is in the middle of a network Delete may only be done to 1 The last bottom node in a column or 2 The last node if it is in the top row the right most node only NOT VERTICAL This message appears when it is illegal to have a vertical short on a node type a coil for example ONLY This message appears when the user 15 entering data into an item displayed in the discrete area and it is not a holding register 4XXX OVERRUN ERR In general this error message comes from the 484 mainframe and means that the most recent P180 request cannot be processed Specifically this message means that the 484 receiver filled up with characters which were not processed out quickly enough so they got lost NOTE This condition will cause the 484 to lose its RUN light P180 CKSUM This message means that the response from the 484 was received incorrectly and the P180 does not agree with what the 484 sent This could be a
25. ONISNOH 4759 5509 SONISNOH OI OL 1 91N 00 0 LONG 508 8 SIONTONI 5377051405 v8t 0140 44 94 v4vf 19 TE ecg 09 von et 7691 Noudo 889 SNISNOH 6 APPENDIX EXTERNAL CABLES Cables W510 0XX W511 002 W512 003 W13 010 for J471 5 2183 0 AS W180 XXX AS W181 XXX AS W182 XXX AS W474 001 Bus cable for mounting I O left or right from CPU or Expander XX 2 3 4 6 8 10 slots Bus cable for mounting I O to bottom of mainframe 2 slots Bus cable for mounting I O to bottom of mainframe underduct 3 slots Supplied with 5566 003 I O extension cable shielded for mounting I O or Expander up to 10 ft from CPU Ex pander or bus cable attachment point Only one length from mainframe and length from Expander system Available in 10 ft lengths only Cable included with T152 611 002 58 611 002 Required for 154 611 002 484 com patibility Standard length is 12 ft Also available in 25 50 and 75 foot lenghts Supplied with 180 0 7 in standard 8 foot length Used to attach P180 to 484 7 or J470 X00 Also available in specified length up to 50 feet for direct attachment to C484 XY2 Lengths up to 200 feet may specified for attachment to J470 X00 J474 Attachment cable supplied with 17474 GLOSS
26. Q o Uc 5 A a lt Modicon Inc Industrial Automation Systems One High Street North Andover MA 01845 508 794 0800 24 Hour Support Center 1 800 468 5342 MD Drintad in IEC A
27. be placed at any duct position This does not reduce the number discrete I O housings Follow steps 2 through 4 for installation of register type modules 11 Obtain I O bus cable shipped with I O duct Con nectors are spaced about five inches apart except the ends The end connectors are 15 inches from the closest connector Place cable s into duct s with widely spaced connector at the cessor Red side of cable is facing the rear duct 12 Open processor and locate I O connectors Figure II 13 Route I O bus cable s to I O connectors and insert Figure II 14 with red side of cable facing sides of processor Close processor 13 Within I O duct insert connectors on I O bus cable into printed circuit board edge connector at tov of each I O housing Figure II 9 TI 15 CONNECTORS POWER SUPPLY TS 80 0015 2 Figure 11 13 Processor Internal Components NOTE Extra connectors on I O bus cable can be left in duct for future expansion or maintenance purposes Step Procedure 14 If the 7471 I O Expander is to be installed re move the end plate from an I O duct The expan der can be located anywhere near the end of the I O duct that the optional ten foot cable used with the expander will reach Mount expander following procedures used in steps 6 and 7 to mount processor Route cable to open end of 1 0 duct and insert end into I O duct Secure end plate provided as part of cable to end of I O duct and co
28. capable of communi cating to Service Center It is good practice when placing your call through your com pany switchboard to explain to the operator that you are making a data call Operators have been known to break the connection when they hear a tone rather than voices 3 6 MODEL L206 PROGRAM TAPE LOADER TS 80 0028 2 Figure 111 22 L206 Tape Loader III 34 3 6 1 DESCRIPTION The Model L205 Program Tape Loader Figure III 22 is a mag netic tape cartridge unit designed for field recording and re loading of user programs from the 484 Programmable Controller This loader is also compatible with models 084 184 284 384 and 1084 Controllers with different interface units The Pro gram Loader features ease of operation and fully automatic error detection and protection The Model 206 Program Loader permits the user to Record his control programs on magnetic tape cartridges Load control program from magnetic tape cartridge Verify tape either against the controller s memory or internal tape only parity check The Model L206 Loader is housed a rugged case and re quires a Model J470 Adapter set for any standard baud rate The case also provides space for storage of up to five magnetic tape cartridges Each cartridge can store only one MODICON program regardless of controller type The program from the 484 troller consists of the entire logic memory as well as the dy namic memory
29. connected directly to this recep tacle when used with no other auxilliary devices Adapter J470 is connected to this receptacle when additional peripheral devices are required II 5 Power Connections Below the Mainframe Controls and Indicators is ter board to which AC power is supplied Figure II 4 CONTROLLER NEUT TS 80 0006 2 Figure 11 4 Mainframe AC Power Connections Voltage sensing circuitry is provided in the power supply to detect out of tolerance line voltages If the AC power is not within the specifications Table II 2 the processor may stop operating Operation will be automatically restored when AC power is within tolerances There will be a one scan delay in restoring processor operation after a failure During this time the processor goes through its power up sequence 2 1 4 INPUT OUTPUT CHANNELS All 484 Controllers communicate with an I O channel Each channel has a maximum of 128 input points and 128 output points Figure II 5 The system can be expanded to 256 input points and 256 output points with the use of the Enhanced Instruc tion Set and a Model J471 Expander II 6 TS 80 0007 2 Figure 11 5 Typical 484 with Single Channel Specific I O circuitry is provided on modules Figure II 5 This circuitry converts various voltages to input out put s
30. data report information to be retained and examined at later time errors stored in the order they were detected and data to be multiplexed through the discrete I O structure with the BINARY CONVERT operation The concept is similar to the MOVE codes found the MODICON Model 184 and 384 Controllers which have made them 50 powerful The implementation however is somewhat different The MOVE function can be used for presetting different values in timers and counters doing comparisons etc The MOVE in the 484 Controller is a form of INDIRECT ADDRESSING function takes the form of a block with two register references in it a TO register on the bottom and a FROM register on the top Figure III 15 ENABLE TOR OR ROT AXXX TO TS 80 0013 1 Figure 1 15 MOVE Format III 20 The FROM register may be an input register such as thumbwheel input a holding register 4XXX The TO register must be a holding register A discussion of the two MOVE func tions i e Table to Register and Register to Table follows 3 2 15 TABLE TO REGISTER MOVE Similar to the TR Move the ROT Move allows the loading of a table of registers from one central register whose con tents are changing When the ENABLE signal receives power flow the ROT function will lock at the bottom register TO content to determine the register to be changed The upper register FROM content is the value to be placed in this regis
31. digits must be entered with existing digits moved one position to the left with each new digit entered at the units position Numerical values must first be entered into the assembly area prior to use aS part of the controller s logic All numerical keys except for the digit five have dual functions controlled by a shift key In addition to the entry of numerical values these keys specify non relay functions to the assembly area The upper element of the non relay function is specified by these keys For example if the SHIFT is de pressed and then the digit zero the assembly area will be pre pared to construct the preset of the counter logic When this III 28 element is placed into the ladder diagram the next lower ele ment will be coded to accept a holding register reference since the counter is a two element function If a SHIFT then the seven key is depressed the assembly area is prepared to construct the upper element of ADD function When this element is placed into the ladder diagram the next two elements will be coded for arithmetic references since the ADD is a three element function The non relay functions are listed under the SHIFT operation discussed below SHIFT This pushbutton can be depressed prior to another key to alter its function letter S inside a small rectangle is displayed in the message space next to the assembly area after the SHIFT is depressed The shift will be removed after
32. examining or solving logic netowrks one at a time in their numerical order After the last net work is solved the next scan begains at network one logic is always solved in the fixed cyclic process Circuitry designed using only inte grated circuits transistor diodes etc no electromechanical devices such as relays are utilized High relia bility is obtained with solid state logic which would be degraded by de pending upon electromechanical devices A logic element used to measure and cord the time of an event or sequence Of events Timers can accumulate time in seconds tenths of seconds or hun dredths of seconds The ability to stop a controller from Scanning can be exercised only from a computer or the P180 Programmer The controller can still communicate to the computer but will have all outputs OFF CUT ALONG AEG company Publications Comment Form Document Part Number ML C484 MTN Rev B Title 484 Programmable Controller Maint Manual We are constantly striving to improve the content and usability of our technical documents You can help us by answer ing the questions below and mailing this form to us Also if you find any errors or have any suggestions for improve ment please let us know How do you use this document
33. left pointing arrow directs the eye to the sembly area INIT This message appears when the P180 fails to find the end of logic mark in the 484 means that there is some serious problem in the 484 and the database is not valid Go to SUPERVISOR and clear memory INV These three letters do not appear in the error line They show as register contents in the discrete area when the data in the register is INValid i e exceeds 999 INVALID KEY This appears in SUPERVISOR mode for keys which are invalid in that mode only the message appears network display mode it means that the P180 keyboard hardware has failed INVALID This message appears when the reference number in the assembly area is invalid for the requested function Check the memory size and reference rules LGC This message appears during VERIFY when the network logic LGC on the tape does not match the logic in the 484 MEMORY FULL This message appears when the user enters in formation and the 484 s logic memory is full MEM PROTECT This message appears when the user is mod ifying the 484 memory and the MEMORY PROTECT key is ON MEMORY PROTECT key ON prevents modifications IV 19 MUST COIL This message appears when the user 15 gramming a non coil node in the coil right hand column Only coils and horizontal open are allowed in the right hand column NO ANSWER This message appears w
34. level of programming the 484 Controller This mode should be used only with great care since major changes such as clear all logic can occur once in the Super visory mode Depressing the SUPERVISOR pushbutton clears the screen and displays seven options available to the operator as follows 0 EXIT Supervisory State STOP Controller Sweep 2 START Controller Sweep 3 CLEAR Controller Memory 4 LOAD Memory through ASCII Port 5 DUMP Memory from ASCII Port 6 VERIFY Memory against ASCII Port Entering the proper numerical digit from the keyboard will cause that function to occur Exit returns CRT to normal func tions Stop Start control scanning of controller with all out puts OFF when sweep stopped Clear removes all stored logic from controller memory Dump Memory causes the entire 484 Con troller memory logic and coil register storage to be out putted via an ASCII port built into the 180 Programmer The 26 ASCII device connected to the P180 port should be simple ASCII tape loader capable of operating at 600 baud The scanning of the controller is NOT halted when a dump is made The Load Memory allows a previous ASCII Dump to be placed into the 484 Controller memory scanning must be stopped prior to a load and requires either a start command or AC power to be cycled on the controller to restart the scanning following a successful load Verify will compare controller s memory against tape record made by
35. module Processor Power Supply or I O module is then repaired at a later time A group of connected logic elements used to perform a specific function A network can be from one element to a complete 10 x 7 matrix of elements plus coils as desired by the user Point on a ladder diagram that ceive power from left or provided power flow to right This can be an input to a logic element left side or an out put from a logic element right side G 4 OUTPUT PRESET PROCESSOR RAM Random Access Memory REAL TIME REAL WORLD REFERENCE REGISTER A signal provided from the Controller to the real world can be either dis crete output solenoid valve relay motor starter indicator lamp etc or numerical output e g display of values stored within the Controller The limit established for a counter or timer function The current count or time available from the register re ferred to in the lower element cannot exceed this limit At the preset value the logic output is energized The brain of the Controller system wherein the customer s logic and execu tive is stored all logic solving and decision making is performed the Processor Also called the CPU or mainframe A memory where individual bits are stored and accessed in lieu of groups of bits as used for numerical storage The actual time during which physical events take place The actual world within which physic
36. network power flow is allowed from left to right or up and down It is never allowed to flow from right to left When properly displayed on the P180 CRT Screen power indicated for all relay contacts by intensifying these contact images as power is passed from left to right Model P180 Programming Panel displays in real time the num ber of words used for previously entered logic Data entered into the controller is entered directly into the memory of the controller If power is interrupted before completion of the programming whatever data already entered is retained No additional processing is required such assem bly of data Data entered is sorted for use by the controller Networks can be totally or partially changed added or deleted at any time with the Programming Panel This does not inter rupt the controller s scan Any input or output coil may be tested by simulating inputs or outputs with this disable fea ture Refer to Disable Enable discussion later in this sec tion Pre formatted ladder diagram forms Form 484 are avail able through your local MODICON sales offices III 3 mamo 3ndano 8004 V T v T T S T 4 T v T t T 2 c 4 245 DSNISDOH ANO eoueiejed EHI 91491 He u0330dH doi 3
37. of mounting no more than 32 put and 32 output modules can be connected to the processor unless a J471 Expander is also used Table II 3 summarizes the installation requirements of the 484 Controller II 12 Table Il 3 C484 Controller Installation Specifications Power Requirements Standard Optional Environmental Requirement Ambient Temperate Humidity Dimensions WxHxD Processor w Power Supply Single I O Housing One channel Eight Housings One channel Weight Processor w Power Supply I O Module Single I O Housing w Modules Eight Housings w Modules amp Duct 115 15 60Hz 150 Volt amp max 3 amp peak start up transient 2 amp on 220V 115 220 VAC 15 50Hz 5 150 Volt amps max 3 amp peak start up transient 2 amp on 220V 0 C to 60 C 0 to 95 non condensing 15 in x 20 5 in x 6 5 in 380 mm x 520 mm x 165 mm 5 in x 32 in x 6 in 130 mm x 815 mm x 155 mm 40 x 32 x 6 1020 mm x 815 mm x 155 mm 33 lbs 15 Kg 1 15 0 5 Kg 16 lbs 7 5 Kg 136 lbs 62 Kg II 13 2 2 1 MOUNTING PROCEDURES Figure II 5 shows a typical system mounted with full channel of eight housings each with eight I O modules Mounting hardware is not provided with the controller Tt is suggested the 5 16 x 1 1 2 inch machine bolts 24UNF be used Step Procedure 1 Select type 5540 I O Duct and mount in place at top o
38. partial result A contact referenced to this coil is then placed as the first element in another network Addi tional contacts are entered into the second network The coil of the second network be an output that represents the re sultant logic of up to 19 series of elements or internal coil for further extension The only limit to the number of times the logic can be cascaded like this is established by the memory size of the controller Internal coils can be used with up to ten elements to represent a single block of logic to be repeated in the program An example of extended logic seen in Figure 9 III II bod RR LAIG 1825 1122 8871 0075 1872 8089 att 123 899 Hp ETT IM BARSA JAS NET USED REF vnu ABEB VAL TS 80 0021 2 Figure 111 9 484 Extended Logic Program 3 2 4 TIMERS Timers can be placed anywhere in a network where sufficient space exists Timers are built vertically and require two ele ments one on top the other on the bottom Figure III 10 PRESET CONTROL OUTPUT TXXX RESET CURRENT OUTPUT TIME TS 80 0009 1 Figure 111 10 Timer Format Within all 484 Controllers are three crystal controlled clock signals that drive all timers Any timer can be program med to respond to either the second clock 1 10 second clock or 1 100 second clock There is no limitation on which or how many timers are
39. problem in the link between the 484 and P180 or a serious failure in either P180 OVERRUN This message means that the P180 receiver hardware filled and overflowed This is a failure of the P180 The P180 should be checked P180 PARITY This message means that the P180 receiver de tected a bad bit stream P180 484 should be checked P3 CKSUM ERR This message means that the message from the device on port 3 was received incorrectly The P180 does not agree with what the device sent This could be a problem in the link the P180 or the device OVERRUN This message means that the P180 port 3 re ceiver hardware filled and overflowed This is a failure of the P180 The P180 should be checked P3 PARITY This message means that the P180 port 3 re ceiver detected a bad bit stream The P180 and or device should be checked IV 21 PARITY ERROR In general this error message comes from the 484 mainframe and means that the most recent P180 re quest cannot be processed Specifically this message indi cates that the 484 message receiver hardware detected a bad bit stream PORT 3 EMPTY This message appears when the user is per forming a LOAD DUMP or VERIFY and has not plugged in legal device POWER LED INVALID NETWORK SKIPPED This message does not appear on the error line is not strictly an error It displays whenever the current network on the display is being skipped due to the skip comman
40. protected by a single 1 2 amp Pico fuse MODICON Part No 57 0024 Little Fuse number 276 500 or equal Wiring to the 8577 module is made via 30 pin con nector MODICON Part No 52 2109 Buchanan Part NO PCB2B30A616798 supplied with the module This connector can be removed for replacement of the module without disturbing field wiring to facilitate removal of the module a service loop of field wiring should be left Connections Figure VI 21 to this connector are as follows Circuit Input Input Shield S RE 3 2 4 5 6 3 7 8 9 4 10 11 12 external Power 15 30VDC 29 30 Rs INPUT CHASSIS TS 80 0043 1 Figure VI 21 B577 Analog Input Module Typical Connections VI 25 6 2 REGISTER DESCRIPTIONS The following 500 Series Register I O descriptions will be supplied later B579 001 B581 001 B583 001 B585 001 B586 001 B587 001 Hi Speed Counter Module Absolute Encoder Input Single Ended Module Latched Int Safe Prox Sw Input Module Incremantal Encoder Input Module Ramping Prog Stepper Drive Module Latched Prox Sw Input Module VI 26 SECTION VII J470 ADAPTER 7 0 INTRODUCTION The J470 Adapter Figure VII 1 is a customer option which may be added to any 484 Controller at any time The adapter is mounted adjacent to the controller mainframe The three foot cable plugs into the communication connector This connector is usually used to talk to a programming device Therefore t
41. that indicate the status of the communications points along the with an Enhanced The following is a brief interface Operating power Supply no external power is 0 to 60 C 32 to 140 F 0 95 non condensing 4 75 x 14 40 x 365 8mm x 174 8mm 6 88 120 7mm x 6 lbs 2 8Kg Asynchronous Frequency Modulated 20 to 50 Khz band usage 15 000 feet 4 5 1 to 247 32 devices MODBUS Remote Terminal Unit RTU or ASCII MODBUS or Direct EIA LED indicators These indica tors have the following functions III 42 RUN On whenever DC power is applied via the 484 mainframe and the 7474 diagnostic routines indicate proper in ternal operation of this interface ACTIVE Flashes whenever the J474 interface receives a message via the MODBUS or local EIA port that is addressed to this unit 474 Flashes whenever an error in communications between ERROR the J474 interface and the 484 CPU has been detected Appropriate error response will be sent to the sending device BUS Flashes whenever a message addressed to this device ERROR from either the MODBUS or local EIA port has error within the message Appropriate error response will be sent to the sending device 3 7 5 CONNECTIONS The 0474 Interface is connected to the MODBUS or local EIA device via a single 30 pin connector This connector Buchanan Part No PCB 2B30A616798 MODICON part number 52 2109 with mounting bracket MODICON assembly
42. the ASCII device To prevent accidental changes to the control system when ever 1 Stop or Clear is selected the CRT will dis play the option 7 Confirm operation is performed only after the digit 7 is selected as the second step cancel operation before it is executed select any other option 0 6 controller must be stopped option 1 prior to se lecting a Clear option 3 or Load option 4 DELETE When depressed this pushbutton will cause the element of the ladder diagram where the cursor is positioned to deleted Relay elements can be deleted only from the bottom of a column or from the right of the top rung when only one element remains in the column Elements can always be replaced by horizontal and vertical opens To delete a func tion the cursor is placed at the top of the function all numerical elements of this function will simultaneously deleted If the shift has been previously selected the DELETE pushbutton will cause the entire network that the cursor is on to be removed All existing networks that follow the deleted network will have their step numbers decreased Dele tions occur simultaneously both from the CRT screen as well as the memory of the controller DISABLE Both logic coils and discrete inputs can be dis connected from their normal control when this pushbutton is depressed The normal control still exists within the
43. the Expanded Now Bus to power I O devices The power supply within the 471 contains undervoltage monitor circuitry that will shut off the 5 VI O power to the Expanded Bus if the internal voltages fall to less the 90 of their nominal value or if the 5 I O power from the 484 Controller is not present on the Now Bus VIII 1 7471 is available with compatability to the following power sources Voltage Frequency Current A 117 VAC 10 60 HZ 2 5 Hz 1 amp B 110 VAC 10 50 HZ 2 5 Hz 1 amp C 220 VAC 10 50 HZ 2 5 Hz 0 6 amp The J471 500 is set at the factory for 110 VAC 60 Hz internal jumper change will convert it to 220 VAC 50 Hz input protection is provided by a 1 1 2 slow blow fuse 8 44 INDICATORS Part No 3471 600 3471 500 3471 500 An Power On the front of the J471 are three indicator lights labled and defined as follows POWER When on this light indicates that the J471 power supply voltages are within 10 of normal and 5V I O from the 484 is present on the Now Bus ACTIVE When on this light indicates that the J471 is producing discrete read strobes on the extended bus as commanded by the 484 BUSY When on this light indicates that the BUSY on the Now Bus is being pulled to the true low level by the J471 This will happen if line state any device connected to the Extended Bus is busy or if the J471 s power supply voltages are less 90 of their nominal level 85
44. unless the cursor is at the boundary of the screen At the right and left boundary the cursor will wrap around when forced beyond either side to the opposite side At the top or bottom of the screen there is no wrap around and the cur sor will not move beyond these boundaries Other controls as follows ERROR RESET If an error is detected in the operation of the P180 Programmer a message will be flashed and the ENTER and network controls will be locked out When any other pushbutton including ERROR RESET is depressed the message is erased assuming the error condition does not continue to exist and then the keyboard is completely functional ENTER If MEMORY PROTECT is OFF the ENTER pushbutton will cause the assembly area to be copied into the location selected by the cursor the assembly area is not altered and the cursor remains at its previous location this location is the logic area the entire assembly area will be moved as a logic element after passing appropriate error checking If the cursor is in the reference status area and on a holding register refer ence the numerical content of the assembly area only will be moved into the register III 30 SEARCH This pushbutton initiates a search of all logic entered into the controller s data base The search will be started at the first upper left contact of network and continue through all networks column by column until either the desired e
45. used for outputs but in this case the output device outside the controller is wired to the VXC or grounded since the switching inside the module is done on the High line of the source The True Low modules are vice versa Table VI 2 Input Output Module Terminal Assignments B550 115 VAC B551 115 VAC B552 True High B553 True High B556 B557 B560 B561 B554 220 VAC B555 220 VAC B558 True Low B559 True Low TTL TTL 120 120 Terminal AC OUTPUTS AC INPUTS DC OUTPUTS DC INPUTS OUTPUTS INPUTS INPUTS 1 AC IN DC IN GROUP A INPUT 1 GROUP A 2 GROUE A INPUT 1 GROUP A LAMP COMMON 3 AC IN OUTPUT 1 INPUT 2 OUTPUT 1 AC RETURN OUTPUT 2 INPUT 2 OUTPUT 2 5 DC IN GROUP B INPUT 3 GROUP B 6 AC RETURN AC RETURN DC RETURN GROUE D INPUT 3 CROUP B LAMP COMMON 7 AC IN OUTPUT 3 INPUT 4 OUTPUT 3 8 AC RETURN OUTPUT 4 INPUT 4 OUTPUT 4 VI 3 6 1 DISCRETE I O SYSTEM The Discrete I O System has the following major features 4 points per module Fits in an 8 inch deep NEMA cabinet Module easily replaceable without distrubing wiring User wiring connections easily available at the front of the system Each user connection point will accept up to 2 812 wires Active indicator LED each point Output active indicators are on Load side Each output point is fused Each output point has an
46. 16 This plastic strip covers recessed field termi nals along entire height of housing Space is provided on this strip for color coded labels to identify various I O modules Table II 4 as well as user identification of field circuits Finally AC power is connected to the processor Single phase three wire ground neutral and hot connections are made Figure 11 4 Elect rical loads are summarized in Table II 4 quired voltage characteristics are defined Table II 3 Li 19 Table 11 4 I O Module Colors 115 VAC Output Red 115 VAC Input Pink DC True High Output Dark Blue DC True High Input Light Blue 220 VAC Output Orange 220 VAC Input Melon 5V TTL Output Violet 5V TTL Input DC True Low Output Light Purple Turquoise DC True Low Input Blue 120 Vdc Output Blue 120 Vdc Input Blue Pantone Matching System II 20 SECTION Ill OPERATION 3 0 INTRODUCTION Section III provides information for the basic operation of the MODICON 484 Controller As discussed in Sections I and II of this manual the MODICON 484 Controller is a microprocessor based controller Its circuitry allows relay ladder diagram control logic to be programmed and used in various industrial settings The basic element of programming is the relay contact shown in Figure 1 484 Controller may replace operations which use re lay contacts X X X X
47. 3 093991335 38 1SNW 3NO YATIONLNOD ave 31815504 31955 ion S3 T1081NO2 Qva 37818504 1238802 ON ON ON ON 53 INGON 07 91915 0 1 MO BV INDI 4141 31SAS 1431 NO 1NIOd 0 1 AT3dOud 0 1 30 HOV 3 WOH3 NI 4191 0 1 04 123802 NI NVHL ONINOILONN 31816504 5309 _ JON 534 SSHOLIMS 135 SJA 37805 W3 SAOW3Y 41915 11 IV 15 43 P180 ERROR MESSAGES All P180 error messages are detailed here and are organized alphabetically after the 484 Error Code is described Many errors are caused by illegal user actions There are also a number of SYSTEM ERRORS which seldom appear in func tioning system However if SYSTEM ERRORS do occur the system may be in serious difficulty and needs to be serviced The following list of SYSTEM ERRORS are messages from the 484 which indicate it has received erroneous information ERROR OVERRUN ERR CHKSUM ERROR BAD ADR RNGE ILLEGAL ADDR ILLEGAL NODE 17 BAD LED REQ 12 BAD COMMAND 15 BAD LENGTH OY Ut amp WN The following list of SYSTEM ERRORS are messages from the P180 which indicate that it has received erroneous information BAD RESPONSE P180 OVERRUN 80 PARITY
48. 384 Controllers these units can also be used with the 484 troller without the specialized interface designed for the 084 and 184 384 Controller Regardless of which model Telephone Interface is used all require the use of the J470 Adapter to communicate to the 484 Controller Section IV of this manual The T158 Telephone Interface is housed in a rugged for portability and safe storage No special knowledge or training is required to use any MODICON Telephone Interface duds Me nde on ie te 2 x i 43 43 TS 80 0026 2 Figure 1 20 T158 Telephone Interface 32 The T158 Telephone Interface in its carrying case weighs 20 lbs and has outside dimensions of 14 75 in x 14 x 10 5 in The acoustic coupler can operate in 0 50 C ambient air 10 95 relative humidity non condensing The J470 Adapter has a special mounting hanger that allows it to be temporarily con nected to the front of the mainframe The adapter can operate in ambient air 0 60 C and 10 95 humidity non condensing TS 80 0027 2 Figure 1 21 Controls on Telephone Interface 3 5 2 OPERATING PROCEDURE After complete installation the MODICON Service Center can be called at 617 475 1181 Your phone call will be answered by the Service Center Operator who will want to know 1 Your name and company 2 The serial number or system number of the controller to which you are c
49. 5VAC 6 60Hz 115VAC O Basic 1 Enhanced I 2 Enhanced II C484 162 for example indicates a C484 with Enhanced I Instruction set 60Hz 115 VAC Power Supply and a 1 2K Memory Size 2 1 2 HARDWARE CONFIGURATION A typical system layout is shown in Figure 11 1 This fig ure includes mounting dimensions for all major components of the system For proper heat flow all units should be mounted verti cally Vertical orientation allows the fullest removal of heat via the heavy duty housing fins ful size mounting template may be purchased from any MODICON sales office 1 28194 1 60 79 36 76 2 152 40 57655 BuS DUCT 82599 RE 2 1039 hcl ne heus ENSE n 5 3 5 os beg 1 so 4 k HOUSING OUTLINE 300 00 in Bil eoo eS eee d d sd Crue HOUSING QoOTLiNE TYP FULL YO HOUSING E SK C484 201 Lol 48299 re 15 rise Figure 11 1 Typical System Layout Another system layout frequently used is shown in Figure II 2 This configuration is referred to as Half Housing The housing is four I O modules in the vertical orientation and up to l6 modules in the hor
50. 60 C 40 C to 80 C 0 to 95 0 to 955 15 in x 20 5 in x 6 5 in 38 cm x 53 cm x 16 5 cm 5 x 32 in 6 13 cm x 81 cm x 15 cm 40 in 32 in 6 in 102 cm x 81 cm x 15 cm 33 lbs 15 Kg 115 0 5 Kg 15 lbs 7 Kg 136 lbs 62 Kg RUN light POWER on light BATT OK light MEMORY PROTECT key Circuit Terminal Voltage light Blow Fuse light outputs ONLY S444 4445 4444 4494 4444 4444 1344 TS 80 0001 2 1134 Figure 1 1 484 Controller System typical Figure I 2 is divided into four components Processor Power Supply I O Section and a Programming Device PROGRAMMING DEVICE processor sections sed POWER USER FIELD SUPPLY WIRING TS 80 0002 1 Figure 2 Basic Block Diagram 1 2 COMPONENTS SYSTEM DESCRIPTION Each of the four components of a PC are described briefly in this section Figure I 3 Peripherals available for the Modicon 484 are also introduced 1 3 TS 80 0002 2 Figure 1 3 484 Components 1 2 1 PROCESSOR The processor or brain of the PC is a completely solid state device It is sometimes called the Central Processing Unit CPU and sometimes called the mainframe This is the part of the PC which actually replaces relays and timer counters the MODICON 484 the processor is expandable for computational functions or for simulation of stopper switches The processor is programmed in relay ladder d
51. ARY OF TERMS ADDRESS SELECTOR ARITHMETIC BCD Binary Coded Decimal BINARY BIT CHANNEL CHECKSUM GLOSSARY OF TERMS A switch on the top of each I O Housing to establish housing address Each switch contains four sections one can be selected to establish address at housing 1 to 4 A type of logic used to add subtract multiply or divide two numerical values Optional outputs detect addi tion overflow comparisons greater than equal to or less than and il legal division A system of numbers representing decimal digits 0 9 with four binary ON OFF lines BCD is a recognized industrial standard BCD input e g thumbwheels and output e g numerical displays are readily available A numerical system wherein values are represented only by numbers 1 and 0 ON OFF This system is commonly employed in modern electronic hardware since circuits can be economically signed for ON OFF status A single number whose value can be either a One or a Zero Commonly re presented in hardware by a small mag netic toroid device that can be either magnetized or not magnetized A portion of the total I O capability of the controller Each channel repre sents 50 of the total available I O An error detection code that sums all one bits of a group of data storage lo cations Summing is done without car ries from one column to another The known result is stored any variance from this result indicate
52. DBUS COMMUNICATION CAPABILITY Combined with a MODBUS communications interface unit that attaches the controller to a MODBUS communication system the Enhanced II Instruction Set Option includes the capability to respond to commands received from a remote master For details on configurations and features refer to MODICON MODBUS System User s Manual 3 3 USE OF P180 CRT PROGRAMMING PANEL TS 80 0023 2 Figure 16 P180 CRT Programming Panel 3 3 1 INTRODUCTION The most commonly used programming device is the P180 CRT Programming Panel Figure III 16 This device provides the primary human machine interface that determines how the cessor will be used The programming panel is small keyboard portable and ruggedly built III 22 The keyboard is a dedicated function board Figure III 17 The keys are divided into four basic types network control relay control numerical entry and cursor control CURSOR CONTROL RE HOR ES mI Q TS 80 0014 1 Figure 17 P180 Keyboard RELAY CONTROL Se SIE NETWORK CONTROL III 23 3 3 2 CRT DISPLAY Data is displayed 5 inch CRT white on black screen Figure III 18 screen is divided horizontally into two sections user logic and status assembly LOGIC AREA TS 80 0015 1 ASSEMBLY MESSAGE MACHINE REFERENCE LM IT Ve Joe Figure 11 18 General CRT Sc
53. In addition to user logic all disabled status coil states and holding register contents will be included in a tape record or load 3 6 2 SPECIFICATIONS Dimensions 15 21 8 381 mmx 533mm x 203mm Weight 35 pounds 15 9Kg Cartridge Size 300 feet 9115m Cartridge Capacity 512 blocks each block 256 eight bit words Speed Read Write 18 inches sec Rewind 100 inches sec Write Protect Removing the colored coded flap on the bottom of the tape cartridge inhibits recording on that car tridge Baud Rates 110 150 200 300 600 1200 1800 2400 3500 4800 7200 09600 and 19 200 baud Power Requirements 115V 10 50 60 Hz or 220V 10 50 60 Hz 60 VA III 35 Environment TS 80 0029 2 Ambient Temperatures 10 50 C Hum idity up to 95 non condensing Figure 11 23 L206 Controls and Indicators 3 6 3 CONTROLS AND INDICATORS Figure 111 23 ON OFF MAIN POWER OPERATE VERIFY RECORD LOAD PAUSE TAPE GO RESET Controls application of AC power Indicates when AC power has been applied Selects mode of operation either oper ating with tape record tape of load controller or verify data on tape Selects type of operation either re cording tape or load from tape to controller Spring loaded toward RECORD position Interrupts tape operation tape opera tion continued from where stopped by depressing GO or returned to beginning of tape depressing RESET
54. Modicon 484 Programmable Controller Maintenance Manual ML C484 MTN Rev B AEG TABLE OF CONTENTS SECTION 484 GENERAL INFORMATION Page 1 0 TAELOGUCELON esc 1 1 General System Definition 1 1 1 2 Components System Description 1 3 l PrOCeSSOIL 60 99 424 4 2 Power 5 3 Input Output I O Section 155 4 CRT Programming Panel I 6 5 15 1 6 1 3 I 7 SECTION INSTALLATION 2 0 Introductioh4i4 4 439 s ca ae o 1 ad 2 1 System 1 amp 1 11 1 2 1 1 Mainframe 11 1 2 1 2 Hardware Configuration II 1 2 1 3 Processor Power Supply II 2 LED 1 11 4 Memory 11 5 Interface 11 5 AC Power Connections II 6 2 1 4 Input Output I O Channels II 6 2 1 5 Input Output 1 0 Bus Connector Cable Il 2 1 6 I O Module Fuses and Bus 5 11 9 2 1 7 I O 51 10 2 1 8 I O Field Wiring II 11 2 2 System 11 II 12 2 2 1 Mounting Procedures
55. N PRO PO PO PO WWWWWW WW WW C2 CO e C2 CO CO CO WW e e PRP PPE 1 BW 3 3 Use of 80 Programming Panel III 22 3 3 1 111 22 3 3 2 Display 111 24 3 4 Programming Instructions 111 26 l Network amp 1 111 26 42 Relay Contact Controls 1111 28 23 Numerical 111 26 4 Entry amp 1 111 29 3 5 Use of Model T158 Telephone 111 32 1 setae eh vase eee sata ILL232 2 Operating III 33 3 6 Model L206 Program Loader III 34 1 111 35 2 111 35 3 Controls and Indicators III 36 4 Operating Procedures III 37 5 Functional Description III 40 TABLE OF CONTENTS Continued Page 3 7 2474 Communication Interface MODBUS 79 111 40 3 7 1 DescriptiOnssssiexo See wee 3 7 2 InstallatilOni e6e4 vue miim eee III 42 3 7 3 5 1 1 amp 1 111 42 3 7 4 IndicatOrS c
56. NDICATOR OUTPUT STATUS TS 80 0010 2 TS 80 0011 2 34 a a a a d Figure 11 9 Input Output Bus Connections II 9 2 1 7 ADDRESSING Addressing is done within the channel at each housing At the top of each housing is a set of four switches to address the housing Figure II 10 HOUSING ADDRESS SELECTION TS 80 0012 2 Figure 11 10 Address Selecting of 1 Housings One switch is closed to select address Any housing can have any address from one to four Within a housing the eight modules can be of any type input or output However since there are a maximum of eight housings and only four index posi tions two housings have the same address selected Any two housings with the same address must have I O configuration which are opposite from each other Thus the top module one must be an input and the other an output if the housings are addressed the same The same is true for every module pos ition in the housing pair A channel with four I O housings can be addressed to four and I O modules may be inserted in any order There is no II 10 restriction relative to the mixing of voltages Beyond four housings each housing must contain the exact opposite of the previously similarly addressed housing 2 1 8 FIELD WIRING Field wiring can be installed on the I O housings either before or after the I O modules are installed H
57. P A LAMP COMMON GROUP A 0001 OUTPUT 1 0002 OUTPUT 2 HOT GROUP B LAMP COMMON GROUP 0003 OUTPUT 3 0004 OUTPUT 4 TS 80 0032 1 Figure VI 10 B554 220 VAC Output Module Terminal Numbering and Connections B555 220 VAC INPUT MODULE The MODICON 555 220 VAC Input Module Figure 11 VI 12 contains four 220 VAC isolated inputs Each input draws sufficient wetting current to inhibit the buildup of contami nants on the surface of silver contacts used pushbutton limit switches pressure switches etc The input signal re quirements for each of the four inputs are as follows Electrical Characteristics ON Conditions Input at high level Input indicator ON neon lamp Controller input ON ON Level 140 to 260 VAC source in series with impedance less than ohm 40 to 70 Hz OFF Condition Input at low level open circuits Input indicator OFF Controller input OFF OFF Level Input voltage less than 90 VAC or less than 150 VAC with source impedance greater than 80K ohms Switching Level Approximately 120 VAC Input Impedance Approximately 32K ohms at working frequency Common Mode Voltage 400 VAC steady state 60Hz 1500 volts for 10 ms Response Time OFF to ON 10 ms max ON to OFF 20 ms max VI 14 Compatibility with output modules The B555 is capable of inter connection with the MODICON 8554 and 8234 220 VAC Output Modules without the use of additional compone
58. PUT MODULE TRUE HIGH The MODICON B553 Universal DC Input Module True High Figures VI 7 and VI 8 conditions four independently useable DC input signals sharing common source and return to the signals used internally in the controller This module pro vides the capability of using discrete input voltages varying from 9 to 56 volts DC The True High module requires the in puts to be wired to positive VDC since the module defines an ON condition true as high voltage level Electrical Characteristics Input signal requirements for each of the four inputs ON Condition Input High short circuit to positive VDC Input in ON Control input line ON ON Level 9 to 56 VDC reference to com mon one source per module Input is ON when greater than 60 of source voltage ON Current Approximately 0 75 mA at 24 VDC Approximately 1 6 mA at 48 VDC OFF Condition Input low short circuit to common or open circuit Input indicator OFF Control input line OFF VI 10 OFF Level Switching Level Common Mode Voltage Response Time Input Status Indicator Bias Current Compatability with output modules Protection Less than 40 of VDC source 40 60 of the supply voltage 200 VAC steady state 1500V for 10 ms OFF to ON 7 ms max ON to OFF 14 ms max A LED is provided for each input A LED is ON when input is ON Source Inputs Inputs Voltage __ON 9
59. Pushbutton that initiates selected mode of operation Pushbutton that terminates operation and returns tape to beginning 36 CONTROLLER TYPE RUN PAUSE IDLE DC PWR OK NO COMM ERR HALT COMM ERR TAPE ERR REWIND BOT EOT WRITE PROTECT RECORD BAUD RATE Twelve position thumbwheel used to select type of controller that is nected to program loader Set to four for 484 Controller Indicates when loader is operating con dition Blinks when loader is in pause condition Indicates when loader is not operating but available Indicates DC power from internal power supply is within regulation Indicates when operation was started but terminated due to inability to commun icate with controller Indicates when operation was halted by detection of sufficient errors to result in unreliable operation Indicates whenever error is detected in communications between controller and loader Indicates whenever error is detected in tape operation On when rewind in progress or tape has been completely rewound On when tape is at beginning of tape BOT or end of tape EOT On when tape inserted is protected from being written on On when tape is being recorded from troller Four indicators that indicate baud rate and an active communication channel to controller 3 6 4 OPERATING PROCEDURES Set up Connect communications cable to J470 Adapter with
60. RS REFERENCE 956V0F oc iw 2 RETURN iNPUT 1 1001 INPUT 2 1002 5 CONNECTED 6 NOT CONNECTED INPUT 1003 INPUT 4 1004 Figure VI 20 B559 Universal DC Input Modules True Low Terminal Numbering and Connections B577 ANALOG INPUT MODULE The B577 Analog Input Module is available three options each capable of servicing up to four analog signals Model 577 005 is designed to handle 1 5 VDC signals model B577 010 handles 0 10 VDC and model 577 015 handles 10 to 10 VDC signals factory established selection Any analog input module can be addressed to one of four groups of four consecutive input registers This selection is made by setting one of four switches on the rear of the module as follows VI 23 ules Switch Group A Input Registers S1A 3001 3004 S2A 3009 3012 S3A 3017 3020 S4A 3025 3028 A second set of four switches allows specific input regis ters to be Locked out or not serviced by this module Regis ters not serviced can be used by other properly addressed mod if another module is not servicing them these registers will contain zero at the CPU The exact register effected by each of these four switches is also controlled by the module address as follows Switch Group B 1 52 S3A S4A SIB 3001 3009 3017 3025 S2B 3002 3010 3018 3026 S3B 3003 3011 3019 3027 S4B 3004 3012 3020 3028 Electrical Characteristics Input Voltage Maximum In
61. Register I O three digit numeric interfaces to from the register multiplexer analog I 0 special purpose modules RS232C peripheral interface from the EIA Adapter using the appropriate MODICON protocol MODBUS Communication Interface Used in connecting communication options to a computer or other intel ligent device 1 5 Field inputs consist of up to 128 discrete points or 256 with the I O expander unit Each has an ON or OFF state Each has up to 32 inputs or register data Register data is repre Sented by a decimal number in the range of 0 to 999 All dis crete inputs are read once during every scan 1 2 4 CRT PROGRAMMING PANEL The Model P180 CRT Programmer Figure I 4 is a 5 CRT in a rugged case It is easily carried to the work site near the controller The entire CRT unit is well suited to the industrial setting It is designed to operate in locations where electromagnetic noise high temperatures and humidity mechanical shock or other threatening environmental problems be present TS 80 0003 2 Figure 1 4 P180 CRT Programming Panel The P180 CRT connects directly to the 484 Controller It provides a simple method to program the processor The ladder diagram language used for programming the PC is familiar relay symbology There are no required programmer languages to learn The CRT also allows easy rapid System checkout and maintenance A delux CRT permits the use of standa
62. S9NISnOH JHL SNISNOH 0 1 10345 5 S371NdGOW 0 1 3AOW3H NO 53405 dWV NOM V SONISNOH O I 318 2 88 NI 38 OL Suv3ddv WA 180ud ON 3snvo NO 31815504 303 12346 1 53 saevo 0 1 HOVLIV3M 34 3371091405 31042 305532044 531780 0 1 3 0W3u ON SNOILO3NNOO 35001 303 LINN 10345 34 NO dWV1 NNY u3MOd 2 371942 34 NO dWv 1 Nn IV 13 8 4 uonejos ney 6 1 1 00 08 51 QVO 134 8 35 31815504 303 93 32V 1d3y LYVLS AWHOW3W YV3T9 3015 1 04 AYOSIANAdNS QL 09 0814 NO AYO 8350 3Hl HV3i 9 01 AMVSS3O3N SI 037193 19915 MO AVS 9814 SHL aia ON 34123333 51 HO 1 WANN ONISNOH 1234506 IHL 0 1 LON 5300 2 4 TILNN V SONISNOH 0 1 WOU 97895 NOGSIY 0 1 JAOWSY NI 38 OL SYV3dd W3180Hd 3snvo 3181SSOd 303 10345 5 NO dWY1 ON NOH 9NI Ta v2 1 12056 30 0 1 NI W3 80Hd 31915509 1293dSNI ON
63. Scan Time Words amp Coils Maximum I O coils Reg M Sec Inputs Outputs 3 1 4 MEMORY PROTECT The 484 Controller is provided with a Memory Protect hard ware feature designed to prevent accidental or unauthorized changes to the memory When the MEMORY PROTECT keylock switch Figure II 3 is placed in the position the user s logic cannot be altered by any external device such as the Program ming Panel Tape Loader Telephone Interface or Computer In terface Thus by placing MEMORY PROTECT ON and removing the key maintenance personnel can use the Programming Panel to monitor the system but they cannot make unauthorized changes Only specific personnel who are provided access to the key can change the system The Memory Protect feature does not protect those elements that normally change such as registers and I O status 3 1 5 DISABLE ENABLE The Disable function is another built in feature in all controllers This feature simplifies the checkout and main tenance of a control system The Disable status may be changed only when the MEMORY PROTECT is OFF Any logic coil selected III 6 the CRT cursor may be disconnected from its logic by depres sing the DISABLE pushbutton Figure III 17 If the coil was OFF when the pushbutton was depressed the coil will remain OFF If the coil was ON it will remain ON To re enable a logic coil the DISABLE pushbutton is depressed second time while the cursor is under that
64. Standard 15 100 130 RMS Optional 15 187 265V RMS Transient Voltage Standard Max 10 seconds 30 80 150V RMS Max 17 sec 100 0 200V RMS Transient Voltage Optional Max 10 seconds 30 160 3007 RMS Max 17 m sec 100 0 400V RMS Line Spikes 100V max 500 usec duration 0 5 max duty cycle Frequency Standard 60 Hz 5 57 63 Hz Optional 50 Hz 5 47 5 52 5 Hz Normal Load 50 Volt amps min 150 Volt amps max depending upon I O and peripheral de vices connected Recommended Distribution Transformer 500 Volt amps fuse secondary at 5 amps 3 amp peak ON transient On the front of the processor power supply unit three LED indicators a memory protect lockswitch an interface con and AC power connections Figure 11 3 They are as follows LED Indicators The three LED indicators show proper operation of The power supply POWER The controller RUN The batteries BATT OK II 4 TS 80 0005 2 Figure 11 3 Mainframe Controls and Indicators Memory Protect The MEMORY PROTECT lockswitch protects the user logic from being changed or lost when the lockswitch is in the ON position Items that must change during normal operation are not included in the operation of the MEMORY PROTECT lockswitch Interface Connector The connector next to the indicators is used to nect the auxilliary devices to the controller P180 CRT Programmer is
65. VDC 6 25 mA 56 VDC 22 mA 60 mA The B553 is capable of inter connection with the B552 Uni versal DC Output Module True High without the use of ad ditional components Polarity reversal of bias supply and operation with parallel unclamped inductive loads shall not cause circuit failure OPTICAL ISOLATOR 5 80 0029 1 Figure VI 7 B553 Universal DC Input Module True High Simplified Schematic VI 11 TYPICAL TERMINAL INPUT NUMBERS REFERENCE OC IN DC RETURN INPUT 1 1001 INPUT 2 1002 NOT CONNECTED NOT CONNECTED INPUT 3 1003 INPUT 4 1004 TS 80 0030 1 Figure 8 B553 Universal DC Input Module True High Terminal Numbering and Connections B554 220 VAC OUTPUT MODULE The MODICON B554 220 VAC Output Module Figures VI 9 and VI 10 conditions the signals used internally in the controller to four independent 220 VAC outputs capable of driving sole noids motor starters or other loads up to two amperes each The four output circuits in the module are divided into two groups Each group containing two output circuits is fully isolated This module can be referred to as an ISOLATED OUTPUT MODULE in a group of two points Different 220 VAC sources drive each group Each module uses four triac devices to switch the loads of the user supplied VAC line Self contained damping networks and voltage limiting varis tor suppress line voltage spikes and prevent false triggering Each output is prov
66. X338 J470 adapter Select either EIA both and S5 to zero no parity ILIe37 RECORD LOAD VERIFY Turn loader s AC power ON Ensure controller has AC power applied and RUN light lit Select CONTROLLER TYPE four 484 Controller Insert tape cartridge with side A up Ensure WRITE PROTECT indicator is not lit Select OPERATE mode and RECORD operation Depress GO pushbutton Loader will automatically select proper baud rate starting with 19 200 baud that matches the setting on the Adapter to which it is connected A record of the program be made with the troller operating or not operating RUN light out record operation will not change the status of the controller s RUN light At the end of the record the tape is automatically rewound to the beginning At controller turn MEMORY PROTECT to the OFF pos ition At loader select OPERATE mode Depress and hold spring return switch toward LOAD opera tion simultaneously depress GO pushbutton Re lease both switches Loader will automatically select proper baud rate Starting with 19 200 baud that matches the set ting on the Adapter to which it is connected Once communication at the proper baud rate is established the loader automatically traps the controller ceasing its scanning RUN light goes off To untrap the controller a load verify must be done At the end of the load the tape is automatically rewound to the beginn
67. XXXX X XXX X XXX NORMALLY OPEN NORMALLY CLOSED TS 80 0003 1 CONTACT CONTACT Figure 1 Relay Contact Types The C484 is composed of the Processor the I O Section the Power Supply and a Programming Device The most commonly used programming device is the P180 CRT Programming Panel Section III includes the following information Important machine concepts to enable the reader to understand later descriptions of the 484 Controller functions Detailed discussions of basic logic functions relay timer and counters Detailed discussions of optional functions available with enhanced capabilities Instructions for using the P180 CRT Programming Panel for entering or altering stored logic and other data Instructions for using the L206 Tapeloader the 0470 EIA Adaptor and the T158 Telephone Interface 1 3 1 IMPORTANT MACHINE CONCEPTS 3 1 1 PROGRAMMING FORMAT The 484 system controls user equipment operation by means of a program stored in the processor CPU memory The CPU program is communicated to the outside world via the tion The CPU and the I O Section communicate with each other via the 50 Conductor Ribbon cable This communication is shown in block diagram form in Figure III 2 The multi node format allows up to ten program elements in each horizontal rung of the ladder diagram Up to seven of these rungs may be combined to form a network of relay tacts Other progr
68. ader or model 158 Telephone Interface These are discussed in Section II of this manual If neither a magnetic tape nor a Service Center dump have been made operation of the controller may be restored ini tializing memory with the P180 Programming Panel Initializing memory will restore all logic to the null state which contains no customer program If the RUN light cannot be restored by the appropriate peripheral device the processor should be replaced as follows 1 Disconnect AC power connections from power terminals at lower right of mainframe 2 Open mainframe and locate I O connectors Figure 11 13 Disconnect I O connector s on the end of the I O bus cable s Remove from mainframe into I O duct If an I O bus cable is used to connect the I O housings at the bottom of the mainframe the entire cable needs to be removed from the mainframe and saved 3 Loosen the support of the mainframe at the bottom Do not remove bolts completely Support the mainframe 33 pounds and remove the upper bolts NOTE To reduct the weight of the mainframe to 12 pounds the power supply section may be removed before the base section of the mainframe Lift the mainframe clear of bottom supports 4 Take the mainframe to work area for futher testing If necessary package and ship to MODICON for repair 5 Reverse steps 1 through 3 to install new mainframe The second indicator for the mainframe operation is BATT OK When thi
69. al events take place Four digit numbers used in the con struction of the customer s logic Re ferences can be either discrete logic coils inputs or sequencer steps register input or holding A location within the Controller allo cated to the storage of numerical values up to 999 All holding regis ters are retentive on power failure There are three types of registers input whose contents are controlled by the real world outside the Con troller holding registers whose con tents are controlled from within the Controller and output registers which are special holding registers since their contents can also be provided to the real world RELAY ELEMENT REMOTE PRESET RS 232C RUN LIGHT SCAN SOLID STATE TIMER TRAPPED START STOP A logic symbol used to simulate the effect of relays Contacts can be nor mally open normally closed or transi tional contacts The capability for placing the preset for a timer or counter line into a register and referring to that register in the upper element of the logic The preset is no longer fixed since the contents of the register and thus the preset can be altered at any time Electronic Institute of America standard for data communications RC 232 type Data is provided at various rates eight data bits per character A LED indicator on the Processor that indicates when lit that the logic is being processed The technique of
70. al Ground available on pin 7 The following chart summarizes available options and their associated connections yes connect to ground no leave unconnected III 45 Pins Option 17 19 21 Two stop bits no parity yes yes yes One stop bit no parity no yes yes Two stop bits no parity yes no yes One stop bit no parity no no yes Two stop bits odd parity yes yes no One stop bit odd parity no yes no Two stop bits even parity yes no no One stop bit even parity no no no 3 7 6 SELF TEST Upon power up the 1474 conducts an internal diagnostic test to verify proper operation of CPU ROM RAM Indicators Timers Parallel Port and Asynchronous Bus When the error test is being performed the indicators on the front of the J474 are used as diagnostic indicators The four indicators will cycle through the following pattern once on power up if no internal errors are detected Test Indicator 1 2 3 4 5 6 7 8 RUN Off Off Off On On On On On ACTIVE Off Off On On Off On Off 484 ERROR Off On On On Off Off Off Off BUS ERROR On On On Off Off Off Off Each test pattern lasts for appproximately 150 milliseconds total 1 2 seconds of power up tests If an error is de tected testing stops and the indicators can be used to cate the test level that failed MODICON Field Service person nel can correlate the test number to the internal component failure When the MODBUS connector is removed or if the Inter nal Tes
71. am elements such as timers counters and se quencers may be entered Each network may have up to seven coils The coils are automatically placed on the extreme right of the network Figure III 3 The network is the basic build ing block of the ladder diagram program It is defined as a group of program elements compromising one to seven rungs Each rung has up to ten connected elements 1 0 SECTION al gt o gt INPUTS USER LOGIC PROGRAM OUTPUTS COIL REGISTER STORAGE TS 80 0004 1 Figure 2 Mainframe Block Diagram The quantity of networks or logic elements that may be en tered depends upon the memory size of the controller being used and the complexity of each network Each program element uses two words of memory as does each coil This format allows very efficient memory utilization since each word is eight bits long Efficiency increases as the programmer s efficiency in programming increases The basic element of programming is the relay contact mally open or normally closed Figure III 1 III 2 ANY MIX OF RELAY CONTACTS TIMER COUNTER AND ARITHMETIC ELEMENTS MAX 7 COILS ANY REFERENCE ANY ORDER TS 80 0005 1 Figure 3 Multi Node Program Format Below each contact is a four digit reference number that controls the power flow of the contact Refer to Controller Reference Numbers discussion later in this section Within a
72. both pairs of outputs on a module the above values should be doubled to ob tain current load for that module Common Mode Voltage 200 VAC steady state 1500 Volts for 10 ms Response Time OFF to ON 1 ms max ON to OFF 1 ms max Output Status Indicator A LED is provided for each output The light is ON when the output is ON Fuse Indicator A LED is provided for each output The LED will be ON when the fuse is blown VI 20 Compatibility with input modules OPTICAL COUPLER The B558 is capable of inter connection with the MODICON B559 and B233 DC Input Mod ules without the use of addi tional components TO OTHER CIRCUIT TO OTHER CIRCUIT OUTPUT TS 80 0039 1 Figure 17 B558 Universal DC Output Module True Low Simplified Schematic TYPICAL OUTPUT REFERENCE DC IN GROUP 1 0001 0002 0003 0004 TERMINAL NUMBERS TS 80 0040 1 Figure 18 B558 Universal DC Output Module True Low Terminal Numbering and Connections B559 UNIVERSAL DC INPUT MODULE TRUE LOW The MODICON B559 Universal DC Input Module True Low Figures VI 19 and VI 20 conditions four independently useable DC input signals sharing common and return to the signals VI 21 used internally in the controller capability of using discrete input voltages varying 56 VDC The True Low module requires the inputs to be the negative line of the source since the This modu
73. c reference energized at each position of the stepping switch These references start with the digit 2 in the form 2XXX The significance of the remaining three digits of the reference is as follows Sequencer No 1 through 8 XX Step Number 1 through 32 Sequencers are controlled by mumerical values placed in specific registers 4051 to 4058 by any of the non relay func tions such as counter timers or any arithmetic operations A value of zero or above 32 will result in all references to that sequencer being de energized Values between one and 32 will result in that single reference being energized and all other references to that sequencer being de energized Figure III 14 2301 2312 o 2302 2311 m 79 O eo 2306 2307 TS 80 0012 1 Figure 11 14 Twelve Step Sequencer and Equivalent Circuit The counter has a preset of 12 and stores its current count in register 4053 Every time input 1047 is energized the value in register 4053 is incremented by one This is equiva lent to moving the stepping switch one position If register III 18 4053 contains the value five reference 2305 third sequencer step five is energized When the current count equals the preset 0012 the stepping switch stops with reference 2312 energized Whenever coil 0031 is energized the counter is reset to zero and the stepping switch goes back to home references energized regardless of its current count
74. coil When DISABLE is operating the coil disabled is no longer controlled by the operator or user via the CRT Programming Panel The coil can be toggled ON OFF ON OFF by consecutively depressing the FORCE pushbutton Figure III 17 When disabled the logic coil all references to this coil the ladder diagram and any outputs driven from the coil will be affected by the Disable function Internally program med logic remains in the controller and will re establish con trol when the coil is enabled The internal logic is pletely by passed for the coil because of the DISABLE function The disable status for any coil is permanent until changed by a programming device New networks can be displayed other coils disabled power interrupted MEMORY PROTECT turned ON or any other change made to the system but the disable status of a coil does not change programming device must be used to change the disable status of any coil CAUTION THE USER MUST TAKE CARE NOT TO CREATE UNSAFE CONDI TIONS WITH MACHINE OPERATIONS BY USING THE DISABLE FUNCTION ALL COILS DISABLED SHOULD BE RETURNED TO THEIR ORIGINAL STATE PRIOR TO REMOVING THE DISABLE FUNCTION Discrete inputs can also be disabled in a manner similar to logic coils The selected input is placed in the reference area by the GET command Then the cursor is placed on the in put and the DISABLE pushbutton is depressed This action re moves control of that input from the real w
75. d REG NO MATCH This message appears during VERIFY when the tape does not match the 484 This error may be disregarded if verifying while running SPARE KEY The key which the user has struck has no func tion START FAILED This message appears when the user tried a START function but the 484 status shows that it would not start There is a serious problem in the 484 mainframe NOTE In earlier releases of P180 revisions A amp B this message was FCN FAILED START LOGIC This message means that the user tried to call up a network before the first network Therefore his is at the start of his logic STOP FAILED This message appears when the user has tried a STOP function and the 484 status shows that it did not stop There is a problem in the 484 See START FAILED 484 This message appears when the user 15 loading a smaller 484 with a dump from a larger 484 The amount of user logic in the larger is more than the size of the smaller The P180 tries to load larger to smaller and will succeed if the amount of memory actually programmed in the larger 484 will fit in the smaller 484 257 BATT OK This message appears when the user 15 trying to program a coil with reference 8257 Since this is the BATTERY OK coil is is already used and may not be programmed UNK CONTACT This error message appears when the P180 is reading a network and finds a node type which is invalid It means a serious problem in the
76. dules respond to the data This includes local or expanded I O s as well as register modules B547 B458 are register I O housings Register ad dressing selection is accomplished on the register I O module 4 2 FAULT ISOLATION FLOW CHARTS This part of Section IV contains five fault isolation flow charts These are designed for use by MODICON customers Ser vice personnel recommend users attempt to isolate faults before calling MODICON service center The fault isolation flowcharts are as follows Figure IV 6 DC POWER Lamp Fault Isolation Flowchart Figure IV 7 BATT OK Lamp Fault Isolation FLowchart Figure IV 8 RUN Lamp Fault Isolation FLowchart Figure IV 9 RUN Lamp Fault Isolation FLowchart Continuation of A from Figure IV 8 Figure IV 10 1 0 Section Fault Isolation Flowchart IV 10 1 8100 08 51 due 2 9 1N3WdinO3 01 39vWva NI 111533 91105 OS Od OL 38071v4 5371872 9NI2V 1d3H ONIAOW3Y 3480338 83110518002 38 LSNW H3MOd OV 4 3Sn4 21 YSNNVW 318 2 0 1 HOVLIV3N 83110 1 02 38113 1 NO 230 J 1NGOW 0 1 103330 3M SMO18 4 38 3 TANN INIL V 0 32v 4 35 4 IGA Zit 4 O T H2VL1V3H
77. e ment in the assembly area any portion of the assembly area not specified i e left blank indicated by white area will not be altered when new logic is entered All portions of the as sembly area must be specified if new logic is to be entered into vacant spaces of the ladder diagram Any combination of relay contacts vertical connections and non relay functions timers counters arithmetics etc are possible as long as there is space within the 10 x 7 network format Logic coils can be entered at the end of any rung The logic format requires the top rung to be complete for any column that will store logic Each column that stores any logic must be programmed from the top down to the last element desired by the user Where necessary elements must be programmed with horizontal shunts or horizontal opens to complete the format Non relay elements can be entered int any column with suf ficient space as long as the existing logic is blank Non relay elements cannot be replaced with relay elements directly the non relay functions must first be deleted and then the re lay functions entered Programming starts at the top of the left most column and can then proceed along the top rung to wards the right or down the first column There are four pushbuttons marked with arrows 4 2 that control the position of the cursor When one of these controls is depressed the cursor is moved one position in the direction indicated
78. e 0 4V max at 75 mA Rated current 75mA continuous 100 mA 10 ms 20 duty cycle 5V Supply Supplied by User Voltage 5 0 0 25 VDC Current 325 mA max current all outputs ON Common Mode Voltage 200 VAC steady state max 50 60 Hz 1500 VDC for 10 ms Response Time OFF to ON 4 ms max ON to OFF 13 ms max Output Status Indicator A LED is provided for each output The light is ON when the Output is in logic one state Compatibility with input modules The B556 is capable of inter connection with the B557 and B237 Input Modules without the use of additional components B557 VDC TTL INPUT MODULE THe MODICON B557 VDC TTL Input Module Figures 15 VI 16 conditions up to four independent 5 VDC input signals to the signals used internally by the controller Electrical Characteristics Input signal requirements for each of the four inputs Logic One State Conditions Input High or open circuit Input indicator ON Controller input ON Level 2 0V minimum II 0 1 mA max at 5 5V V source 5 0V Maximum input voltage 8 0 volts Maximum positive clamp cur rent 25 mA VI 17 Logic Zero State Conditions Level Common Mode Voltage 5V Supply Supplied by User Response Time Input Status Indicator Compatibility with output modules TO OTHER CIRCUITS TO OTHER CIRCUITS INPUT 3 TS 80 0037 1 Inp
79. e III 25 a typical tion for half duplex operation at 9600 baud slave number 26 with even parity one stop bit and ASCII mode TS 80 0016 1 Figure 111 25 Typical 4474 Connections III 44 Baud rates are selected by connecting pins 9 11 13 and 15 to Signal Ground that is available at pin 7 For convenience the following chart wil summarize all available baud rates yes connect to ground no leave unconnected Pins Rate 9 11 13 15 50 yes yes yes yes 75 no yes yes yes 110 yes no yes yes 134 5 no no yes yes 150 yes yes no yes 300 no yes no yes 600 yes no no yes 1200 no no no yes 1800 yes yes yes no 2000 no yes yes no 2400 yes no ves no 3600 no no yes no 4800 yes yes no no 7200 no yes no no 9600 yes no no no 19200 no no no no The slave address is established by binary numbers pins 8 10 12 14 16 18 22 and 24 Connect to Signal Ground pin 26 for a zero bit and leave unconnected for a one bit For example address 26 in binary is 00011010 which requires connection of pins 24 22 18 12 and 8 to pin 26 as shown above example Specific modes of operation are selected by connecting pins 28 and 30 to Signal Ground pin 26 in the following configur ation yes connect that pin to ground no leave uncon nected Pins Mode 28 30 ASCII yes yes RTU yes no Not valid no yes Test no no The remaining options stop bits and parity are selected by connecting 17 19 and 21 to Sign
80. e lower left node controls the enable reset of the counter Whenever this signal is de energized the counter is reset to zero This count is held until the signal is again energized The number of events to be counted up to 999 is entered into the upper element of the counter The current count is stored in a holding register identified in the lower element of the counter Separate registers should be used to Store the current time or count of each timer counter Do not share holding registers between timers and counters The output of the counter is energized whenever the current count equals preset Counting stops at the preset value Whenever the counter is reset to zero via the lower node on the left side the coil is de energized The current count is re tained during the power failure since it is stored in a holding register reference Counters also have second output that provides power flow as long as count is NOT at its preset 3 2 6 CASCADED COUNTERS TIMERS Timers and counters can be cascaded or interconnected to satisfy any required logic Figure III 11 shows a cascade of timer and counters to produce a calendar measuring time in seconds minutes and hours TS 80 0022 2 we NETA USED w854 VALS Figure 11 Sample Timer Counter Cascaded Logic III 14 Any 484 Controller can be equipped with a factory installed option that provides extended capabilities in addition to re lays tim
81. equnN exa zamon T E 9pGd puooeg 4 eT Tes III 4 3 1 2 CONTROLLER REFERENCE NUMBERS Four digit reference numbers are used to build user s logic throughout the programming of any 484 Controller These refer ences are divided into two broad categories discrete and re gisters Discrete references are used for individual items that can be ON or OFF These items include limit switches pushbuttons relay contacts motor starters relay coils and solenoid valves Register references are used to store numer ical values such as counters timers analog values and the like All register references are three BCD digits long imum 999 Only five types of references are required to program a 484 Controller Any specific reference can be used as many times as needed by a particular application There are no limits other than memory availability References are identified as follows OXXX coils discrete outputs 1XXX discrete inputs 2XXX sequence steps Available only with 3XXX input registers enhanced capabilities 4XXX holding registers output registers The address of each I O housing Section II of this manual is very important in establishing proper references Table III 1 defines the exact reference for each I O module installed in channel one Similar numbering is used for channel two with each reference increased by 128 3 1 3 SCAN
82. ers and counters This option is available without regard to memory size Features that are included in this op tion and discussed in the following paragraphs are as follows Arithmetic operations add subtract multiply divide Register Input Output Transitional Contacts Eight separate sequencers BCD Convert Discrete Inputs to Register Register to Discrete Outputs 3 2 7 ARITHMETIC OPERATIONS This option provides all standard arithmetic operations addition subtraction multiplication and division Each arithmetic element has control input ENABLE line holding re gisters and up to three outputs Figure 111 12 The arith metic operation is performed on every scan of the controller in which power is applied to the ENABLE line The outputs can be tied to contacts other function blocks or coils as the appli cation requires OUTPUT 1 ENABLE FIXED NUMBERS OR HOLDING REGISTERS OUTPUT 2 OUTPUT 3 TS 80 0010 1 Figure 1 12 General Format for Arithmetic Option The ADDITION function adds the upper value to the middle value and places the result in the lower referenced holding register If the result of an add function is a value greater than the holding register can store three digits maximum value 999 the portion of the result that will fit into the register is placed there For example if 850 is added to 325 the re sult is 1175 The value 175 three least sign
83. ers at the same time to ensure synchronism of dis tributed processors further capability allows the Master to control inputs and outputs and thus simulate or force the operation of th controller s I O structure Finally the Master could be programmed to alter the logic in any all con trollers thus from one station via a TTY or CRT all control lers could be reprogrammed without use of the P180 Programming Panel Some of th commands provided in the protocol include III 41 1 READ COILS 2 READ INPUTS 3 READ INPUT REGISTERS 4 READ HOLDING REGISTERS 5 WRITE HOLDING REGISTER 6 FORCE COIL 7 POLL STATUS 8 POLL COMPLETE 9 PROGRAM 3 7 2 INSTALLATION The 0474 communication mounted adjacent to the 484 mainframe either on the to the right or left interface Figure III 24 be bottom or It physically replaces a Half High 1 0 Housing B547 B549 both in size and mounting dimensions In addition to data communications this interface also provides a voice communications between any two or more The 484 Controller must be equipped II CPU to communicate with a 1474 MODBUS summary specification of the J474 is obtained form the 484 Power required 3 7 3 SPECIFICATIONS Temperature Humidity Size WxHxD Weight Communications Maximum Bus Distance Device Address Operating Modes Connections Options 3 7 4 INDICATORS On the front of the J474 interface are four
84. es 11 14 SECTION Ill OPERATION 3 0 IntroductiOn 22 4 229 454 rrr urs lc 3 1 Important Machine Concepts III 2 1 Programming 111 2 2 Controller Reference Numbers 11 5 3 SGA dae Ws eos OSes doe 4 Memory 111 6 5 111 6 TABLE OF CONTENTS Continued Page 3 2 Basic 111 8 Relays ee waves LLL Latche S n LEE 11 Extended 11 5 111 14 Cascaded Counters Timers III 14 Arithmetic Operations III 15 Register ty Era Transitional III 17 Sequencers a Ya als 18 BCD Convert 2594 6 19 Enhanced II Instruction Set Option s III 19 Binary 1 19 Move LIT 20 Table to Register Move TSR III 21 eeu du qq E 1 0 35 MODBUS Communication 111 22 t2 F2 F3 XO 0 Nr DOD Y
85. f mounting surface Bolt duct in place Do NOT install cover 2 Select one B545 or 546 I O housing 3 Insert the housing into the bottom of the duct Keyhole slots are available the duct to sup port the I O housings Figure TI 12 4 Bolt the I O housing in place CAUTION THE KEYHOLE SLOTS ARE NOT CAPABLE OF SUPPORTING FULL I O MODULES SECURE THE HOUSING PRIOR TO WIRING AND INSERTING I O MODULES TS 80 0014 2 Figure 11 12 Installation of 1 Housing I O Duct II 14 Step Repeat steps 2 through 4 for all remaining I O housings 6 Start bottom bolts for mounting of processor 7 Remove end plate from processor where I O duct is to be connected Figure 6 Place processor onto bottom two bolts and secure with top two bolts NOTE To reduce weight of processor to 12 pounds remove the power supply Disconnection and reconnection proce dures for Power Supply are found in Sectio IV of this manual 8 If I O housings are to be installed at the bottom of the processor perform steps 2 through 4 for these two housings I O duct is built into bot tom of processor expand I O duct to three housings use Underduct Expander 5566 003 9 If I O housings are to be placed on both sides the processor repeat steps 1 through 5 for oppo site side 10 Model B547 and B548 Housings are used to mount register type modules analog or multi plexer These housings can
86. fy continuity of internal fuses Figure IV 2 If all internal fuses are operational the indicator is still off and the LED itself is operational the Power Supply should be replaced as follows 1 Remove AC power from mainframe terminals 2 Unlatch and swing mainframe open 3 Disconnect wiring harness and ground strap from power supply side of mainframe Figure 1 2 Also dis connect ribbon cable at power supply IV 2 4 Support power supply approximately 20 pounds lift up to separate hinges that connect power supply section to fixed portion of mainframe 5 Remove power supply to work area for further testing or packaging for shipment to MODICON for repair 6 Reverse steps 1 through 4 to re install new power supply DISCONNECT HERE FUSE 57 0006 FUSES 2 57 0013 TS 80 0031 2 Figure 2 Power Supply Location of Fuses IV 3 4 1 2 PROCESSOR The main function of the processor is to monitor the staus of all inputs continuously and direct the status of all out puts There are two LED indicators that when energized re flect proper operation of the processor Figure IV 1 The first indicates proper operation of the processor RUN the second proper battery voltage BATT OK If the RUN light goes out and the DC POWER light is lit the processor has ceased operation If the processor fails its memory should be restored by one of the peripheral devices such as the model L206 Tape Lo
87. he 7470 has two connectors one is for the device com puter and the other for a programming panel Simultaneous operation with both units is possible However when the RIA device is actively communicating the programming panel stops for about a half second During this lockout time the gramming panel displays a COMM BUSY message It also stores requests made until the communication port is available Power flow and screen displays freeze The controller itself con tinues to operate during lockout time TS 80 0034 2 Figure VII 1 4470 Adapter 1 The user selects the EIA communication speed baud rate parity and quantity of stop bits needed Avaible baud rates are shown in Table 1 Table VII 1 Setting of J470 Adapter Option Swps BAUD RATE gt STOP BITS 54 0 two stop bits 1 one stop bit PARITY S5 S6 as follows S5 Activates parity 0 Inhibit 1 Enable S6 Selects parity 0 Odd 1 Even NOTE When shipped from factory 2470 Adapter will set for 9600 baud no parity one stop bit and both ports active TS 80 0035 2 Figure VII 2 Option Selector J470 Adapter VII 2 Shown in Figure VII 2 is select switch that must used to indicate device or devices are being used with the 7470 Any combination of baud rate parity or stop bits is allowed The P180 Programming Panel alwa
88. hen the P180 makes quest to the 484 and gets no response Check cables and proper 484 functioning COIL HERE This message appears when the user 15 gramming a coil which would be in the middle of the logic NODE IN WAY This message appears when the user 15 enter ing a coil and the row already contains another node to the right Remember that the coil may be entered when the cursor is not in the coil right hand column It then takes the rest of the row for display purposes only NODE TOO LNG This message appears when entering a two node item e g counter on the last row of a three node item on the next to last or last row The function is too long to fit in the seven row network NO MATCH This message appears during SEARCH when the 484 cannot find a match to the pattern being searched for Searching for a coil or register implicit in function e g CONVERT MULT DIV shows no match even though it is used NO NETWORK This message appears when the user is per forming a function on a network and there is no network dis played or in 484 memory NOT 1XXX This message appears when the user is forcing an item displayed in the descrete area which is not a 1000 series input coil Only 1 references can be forced in this area NOT ALLOWED This message appears when the user is getting a reference in the discrete area and the cursor is not in that area The cursor must be in the discrete area to
89. iagram lan guage The program uses up to ten relay contacts per rung The processor operates on DC power furnished by the power supply This internal DC power is routed throught the pro cessor to operate the I O Section When the program 15 entered into the processsor it remains until changed deliberately by a user Power failure or power off conditions do not destroy the program An access port enables entry of instructions and data and permits monitoring of perviously entered information The most common method of entering data or programs into the processor through this port is with the P180 CRT Programming Panel Other devices that may be connected to this port are a Tape Loader a Computer or a Telephone Interface Communication with these devices is done via an adapter which allows simul taneous operation with the CRT Programming Panel I 4 1 2 2 POWER SUPPLY The Power Supply mounts inside the front cover of the cessor It operates on 115 VAC 60Hz or 115 220 50Hz non interchangeable adjustments or maintenance required A lamp indicates power ready status No external cooling is necessary although free air circulation is required The Power Supply has sufficient capacity to operate the processor 128 inputs and 128 outputs An expander power supply 15 used to extend the PC s capability to 256 inputs and 256 outputs 1 2 3 INPUT OUTPUT I O SECTION A major characteristic of the 484 Controlle
90. ided with a fuse to protect its circuitry from overload current The following are the electrical char acteristics of the B554 output module Electrical Characteristics Load Current OFF Current 5 mA max ON Current 2 amps continuous 8 amps per module Recommended Minimum Load 10 mA ON Holding Current 0 5 mA Inrush Load Current 15 amps for 10 ms 5 amps for 100 ms Fuse Rating 5 amps normal blow one fuse per output Load Voltage VI 12 Working Voltage Transient Voltage ON Voltage Drop Common Mode Voltage Response Time Output Status Indicator Fuse Indicator Compatibility with input modules FROM OPTICAL COUPLER 160 to 260 VAC 40 to 70 Hz 300 VAC max for 10 secs 400 VAC max for 1 cycle Approximately 1 volt at 2 amps currrent Working 400 VAC 1500 volts max for 10 ms ON to OFF 0 3 to 8 3 ms max at 60 Hz OFF to ON 0 3 to 10 ms max A neon lamp is provided for each output The lamp will be ON when the output is ON A neon lamp is provided for each output The lamp will be ON when the fuse is blown The B554 is capable of inter connection with the MODICON B555 and 8235 220 VAC Input Modules without the use of additional components ACHOT TO SECOND CIRCUIT TO SECOND CIRCUIT OUTPUT TS 80 0031 1 Figure VI 9 B554 220 VAC Output Module Simplified Schematic 13 TYPICAL TERMINAL OUTPUT NUMBERS REFERENCE HOT GROU
91. ificant digits of result is placed in the holding register and the output ener gized to indicate an overflow has occurred Only output 1 is III 15 functional with addition and always indicates the value 1000 when energized The SUBTRACTION function provides one of the most versatile tools available to the control designer With this function the designer can compare two numbers located in holding register and control subsequent operations with one of the three outputs Thus this function can be used for set point control of analog loops alarming functions dead band func tions etc The format for subtraction is as follows OUTPUTS 1 is ON if upper value is greater than middle value 2 is ON if upper value is equal to middle value 3 is ON is upper value is less than middle value The outputs can be tied together so that a greater than or equal to or less than or equal to logical function be performed outputs are mutually exclusive that is only one will be energized when power flows to the enable The holding register referenced in the lower element will always contain the absolute numerical value of the subtraction opera tion i e the difference of the two numbers In MULTIPLICATION two 3 digit values are multiplied 6 digit product is obtained Double precision accuracy is a valuable feature of the multiplication function The register referenced in the lower element is in reality two c
92. ified troubleshooting with diagnostic indicator lights at major points Easy maintenance with modular replacement The MODICON 484 is one of the finest examples of tech nology available It is designed to replace control systems of 10 to 400 relays Advantages over relays and other solid state devices include Lower hardware costs Faster scan rate 4 to 20 ms depending on memory size Expandable memory in six sizes 1 4 to 8 Expandable Input Output I O with four point modules Easier installation Retentive memory for logic and timer counter values Direct plug in programming devices Real time on line programming Table 1 1 lists the specifications for a basic 484 Con troller and Figure 1 shows the controller system I 1 Table 1 1 Basic 484 Controller Specifications Power Requirements Standard Optional Environmental Requirement Ambient Temperature Humidity non condensing Dimensions WxHxD Processor w Power Supply Single I O housing including I O Duct Eight Housings One Channel Weight Processor w Power Supply I O Module Single I O Housing w Modules Eight Housings w Modules amp Duct Controls and Indicators CPU I O Modules 115 VAC 15 60 Hz 150 amp peak Volt amps max 3 start up transient 115 220 vac 15 50 Hz 5 150 Volt amps mac 3 amp peak start up transient 2 amp on 220 V Operating Storage oc to
93. ifying while running COMM BUSY This message does not appear on the error line and is not strictly an error It is displayed when the P180 wants to communicate with a 484 but some other device is al ready communicating The P180 waits END OF LOGIC This message means that the user tried to call up a network beyond the last network The user is at the end of the logic 484 RUNNING This message appears when the user 15 trying to perform a function which requires that the 484 stopped first Example Clear Memory IV 18 ILLEGAL ADDR In general this error message comes from the 484 mainframe and means that the most recent P180 I O re quest cannot be processed Specifically this message means that the P180 sent an address which is completely wrong ILLEGAL NODE In general this error message comes from the 484 mainframe and means that the most recent P180 request cannot be processed Specifically this message means that the P180 sent a node type which is not known by the 484 ILLEGAL RPLC This message appears when the user via ENTER is trying to change one node type for another and the change is not allowed These changes are listed 1 node for 2 or 3 nodes 2 nodes for 1 or 3 nodes 3 nodes for 1 or 2 nodes INCOMPLETE This message means that the assemply area is not completely explicitly set for ENTER When programming new node all three fields contact reference vertical must be stated
94. ignal levels compatible with the processor Input output modules have four circuits each which must be used as either all input or all output The modules are installed in I O housings which accomodate up to eight modules of either type Usually eight housings are connected to a processor making one complete channel 2 1 5 INPUT OUTPUT BUS CONNECTOR CABLE The I O Bus Connector Cable is connected to the processor and to the I O channel Processor board connection locations are found on the right and left top of the processor board Figure II 6 Connections on the I O channel are made on intermediate connectors on each housing Figure 11 7 These connections are shielded an I O duct which mechanically connects the I O section to the processor Up to eight discrete I O housings can be connected to a single bus cable II 7 CONNECT ION TS 80 0008 2 Figure 11 6 Processor I O Connection Options TS 80 0009 2 Figure 11 7 Typical Module II 8 2 1 6 MODULE FUSES AND BUS CONNECTIONS All output circuits AC or DC have field replaceable fuses and a blown fuse indicator The blown fuse indicator is view able from the front of the module Figure II 8 There is one blown fuse indicator per circuit To replace fuses the module must be removed from the housing Fuses are located on the left side of the module Figure II 9 shows bus connections also viewable from the front of the module BLOWN FUSE I
95. igure II 10 One of these switches must be depressed moved toward the wiring con duit to establish the address of the housing NOTE For proper operation of the I O channel only one switch must be selected If two switches lected all housings in that channel with either of these two addresses will respond in parallel NOTE Up to two housings in one channel have same ad dress Between two housings with same address modules must be installed from top to bottom with exact opposite inputs versus outputs H GUIDE PINS d Cie ae Figure 11 15 Installation of Modules II 18 step 19 Procedure After addressing I O housings insert mod ules I O modules are inserted straight into I O housing using large guide pins Figure 15 to align module into rear connector Once engaged at rear module is rotated towards wiring conduit to engage field terminals NOTE Red slide lock can be either up or down to allow in sertion It must be down to allow module removal up to lock module in place 20 21 CIRCUIT IDENTIFICATION STRIP COLOR LABELS MATCHING MODULES TS 80 0018 2 FEEEREEEREEEEEEEE FT ET 2 En ri ET Kn de Bon Hn Em Figure 11 16 Installation of I O Module Labels After I O modules are inserted the housing iden tification strip can be inserted Figure 11
96. ing Select VERIFY mode Two types of verify pos sible selected as follows 1 Verify tape format parity check Select RECORD operation 2 Verify tape against controller memory Select and hold LOAD operation MEMORY PROTECT must be OFF at controller After type of verify is determined depress GO pushbutton to start COMPARE Verify will NOT alter the RUN light status if it is done against the controller s memory III 38 Failure of the verify will result termin ating of the operation with ERR HALT indica tor ON NOTE When performing a Load Verify the controller must have perviously been loaded with the tape and the RUN light must NOT have been re established OPERATING 1 Once an operation has begun all trols have no effect on the operation except the RESET and PAUSE The RESET pushbutton when depressed terminates any operation progress and rewinds the tape to the be ginning The PAUSE TAPE switch causes operation in progress to be suspended tape stopped All other controls can be repositioned without affecting any operation once begun 2 The following indicators will be on for the various modes of operation MODE RECORD BAUD RATE RECORD LOAD VERIFY TAPE VERIFY AGAINST MEMORY 3 The dust cover can be opened without affecting an operation in progress 4 If a tape is not rewound to the begin ning at the start of the operation it wil
97. ith a number which depends on 1 Which point on the module it is 1 through 4 top to bottom 2 Which module on the I O housing is involved 1 through 8 top to bottom on 8 module housings 1 through 4 top to bottom on 4 module housings VI 1 3 Which I O houing select code has been selected for that I O housing Each module has eigth terminal connection points for user wiring Each terminal connection point can accomodate up to 2 12 wires User wiring is fed to these connection points via a wiring tray provided in each I O housing from underneath the system Data is transferred between the I O modules and the troller via an 8 bit open collector twelve volt data bus When an input module pair is selected by the controller the input data is applied through the signal conditioning electron ics directly onto the 8 bit data bus When an output module pair is selected by the controller the data on the bus is loaded into storage latches on the output modules where out puts are controlled until updated All opto isolator power in the I O modules is supplied through indipendent power bus This power is controlled by the controller such that in the event of problem lack of line power the controller will first shut off the opto iso lator power This forces all outputs off as part of the shut down procedure On start up the opto isolator power will re main off until the controller has established control o
98. izontal orientation 2 1 3 PROCESSOR POWER SUPPLY The latest techniques in CMOS semi conductor memory with battery backup are used the 484 Controller Controller mem ory is not affected when the AC power supply is lost provided good batteries are installed in the unit Batteries can be re moved while the system is operating on primary AC power When loss of primary power occurs the alkaline batteries will main tain memory for approximately 1 1 2 years Shelf life is two years Lithium batteries that maintain memory for approxi mately five years are available as an option Their shelf life is ten years Battery life is calculated for worst tem perature memory size and bit configuration The processor is mounted directly onto a back panel for other vertical support The power supply is joined to the front door of the processor It may be removed separately System operation is not interrupted when the door is opened The internal components of the processor and power supply may therefore be accessed without halting the system System operation is halted only when the power supply is completely halted Table II 2 summarizes the AC power requirements 11 2 6 wo mm ewe t T a gt in rr d owow www wre wow TS 80 0004 2 Housing Configuration Figure 11 2 Half 11 3 Table 11 2 Summary Required AC Power Normal Voltage
99. l be automatically rewound prior to commencing the operation 5 Whenever an error is detected single tone is provided by the loader Tf the error is recoverable the operation con tinues and a valid result is obtained if the error is not recoverable the operation is halted with ERR HALT indicator lit Poor communications or gradual degradation of the tape after many uses can be detected by the number of tones issued during suc cessful load III 39 6 Communications are compatible with RS 232 type D the Service Center posi tion the communications cable can be nected to a computer via Telephone Inter face if necessary to load record from the computer 3 6 5 FUNCTIONAL DESCRIPTION All data is recorded at least twice in 256 word blocks with parity on each block If the first block has good parity the second is not used if the first has incorrect parity data is obtained from the second block During a record operation parity is verified on each block If incorrect parity is de tected successive blocks are written until at least two blocks have valid parity The record is terminated if more than seven blocks are required to record any single block due to succes Sive parity failures During a load operation invalid parity when reading from the tape causes successive blocks to be used until good parity is obtained invalid parity is obtained for all records of the same block the operation is
100. le provides the from 9 to wired to logic defines low voltage level on an ON condition true Electrical Characteristics Input signal requirements for each of the four inputs ON Condition ON Level ON Current OFF Condition OFF Level Switching Level Common Mode Voltage Response Time Input Status Indicator Bias Current Compatibility with output modules Protection Input Low short circuit to negative VDC Input indicator ON Control input line ON Source 9 to 56 VDC Input ON when less of supply voltage Approximately 1 2 mA at 24 VDC source and input at zero volt Input High or open circuit Input indicator OFF Control input line OFF Input greater than 60 of supply voltage 40 60 of supply voltage 200 VAC steady state 1500V for 10 ms OFF to ON 7 ms max ON to OFF 14 ms max than 40 LED is provided for each input The LED is when input is ON Source Inputs Inputs Voltage OFF ON 9 VDC 8 mA 25 mA 56 VDC 30 mA 60 mA THe B559 is capable of inter connection with the B558 and 8232 DC Output Modules with out the use of additional components Polarity reversal of bias supply and operation with parallel unclamped inductive loads shall not cause circuit failure VI 22 OPTICAL ISOLATOR TS 80 0041 1 Figure Vi 19 8559 Universal DC Input Module True Low Simplified Schematic TYPICAL TERMINAL INPUT zd NUMBE
101. lement is located or end of logic is detected Searches are performed based upon data in the assembly area portions of the element left blank undefined will not sidered during the search example if all references to input 1029 are desired normally open or normally closed tacts with or without vertical connector only the reference value 1029 is entered into the assembly area When this push button is depressed the search begins and the first network using the reference is displayed in its entirety If additional networks are desired the SHIFT key is depressed pripr to closing this pushbutton a second time the shifted search will continue the search from where the previous match was found not at start of logic GET This pushbutton is used to load the reference status area The desired reference is entered into the assembly area and the cursor positioned in the reference right side status area where the operator desires to display its status The Status of logic coils discrete inputs 1 regis ters 3XXX or 4XXX can be displayed sequencer references 2YXX cannot be displayed Up to six references of any type can be displayed simultaneously with the reference number on top and the status immediately below it Discrete status will be provided as ON or OFF a D prior to the input status indi cates a disabled reference Register statuses are provided as a three digit value indicati
102. mance of user side I O circuits is equiva lent to the high performance attainable with similar 200 Series I O devices 500 Series I O Modules are designed for compat ible operation with each other and with 200 Series I O Modules of the same type The overall I O system is designed for direct connection to the 484 Series of controllers using a suitable interface assembly the system may also be used with 184 384 and 584 Controllers The discrete I O modules plug into I O housings which con tain the user wiring terminal connections and which interface the I O modules to the controller system There are two sizes of I O housings available B545 one to eight modules and B546 one to four modules The I O housings are connected to an I O duct W55X A variety of these ducts are available Choice depends on the system size The duct forms the mechanical intercommunication among the I O housings and the controller and serves to support and shield the I O bus cable assembly An I O channel consists of a maximum of 128 input points and 128 output points or a total of 256 Input Output points or 64 modules An I O channel can be driven by any one of three possible units 484 Controller 484 Discrete I O Expander or J540 184 384 Adapter 484 Controller equipped with an optional I O expander may control a maximum of 256 inputs and 256 outputs for a total of 512 1 0 points An Input Output point is referenced by the programmer w
103. mulating the function of relays timers and counters All programming is done on the basic format of up to ten elements in each horizontal row or rung and up to seven of these rungs connected together form a network A network can bea single rung two rungs or up to seven rungs There must be some connection between the elements of each rung This connection may be as simple as the left leg of the ladder diagram Each network may have up to seven coils Coils are shown on the CRT screen at the extreme right of the rungs of the network These coils may be assigned any valid logic coil number available in the controller Logic coil numbers can be used only once The quantity of logic coils discrete inputs stor age locations and the like depends upon memory size Table III 2 3 2 1 RELAYS The basic programming element is the relay contact The possible relay contacts available are shown in Figure III 4 Contacts cannot be placed vertically Power flow occurs only form the left leg towards the right or vertically up or down Power flow is not possible in the reverse direction Below each contact is a reference number that controls the power flow of that contact III 8 Without Vertical With Vertical Normally Open Hr Normally Closed 2N TS 80 0006 1 Figure 111 4 Relay Contacts With and Without Verticals Logic coils 0XXX references are divided into references that can be used to control discrete outputs or to p
104. n Specifications 11 13 II 4 I O Module 1 II 20 III 1 I O Reference llle 2 484 Memory 1 amp 1 111 6 3 7474 5 111 44 VI 1 Signal Conditioning Module Options VI 3 VI 2 Input Output Module Terminal Assignments VI 3 VII 1 Setting of J470 Adapter Option Swps kiss VIII 1 Address Listings ela vii SECTION 484 GENERAL INFORMATION 1 0 INTRODUCTION The introduction provides a general overview of Program mable Controllers PC and specific orientation to the MODICON 484 All topics discussed here are discussed in more detail in other sections of the manual For information on family trees refer to Appendix A and for information on external cables to Appendix A Glossary of Terms is included at the back 1 1 GENERAL SYSTEM DEFINITION A Programmable Controller PC is a solid state device designed to make logic decisions in industrial control situa tions Relays and solid state electronics can be replaced with a PC Outstanding features of a PC include Reliable fast responses hostile environments Programmable and reprogrammable with ladder diagram language Simpl
105. ng the content of the register Successive depressions of the GET pushbutton with the cursor on a reference in the status area will cause that reference to increase by one for each depression The assembly area will also copy this reference regardless of its previous content remove a reference from the status area a DELETE is selected while the cursor is on that reference area GET NEXT When depressed the network following the one currently on the screen will be displayed For example if the network on the screen is step number 23 this pushbutton will cause the network step 24 to be displayed no network is on the screen network one will be displayed GET PREV This pushbutton operates similar to the GET NEXT except that when depressed the previous network is obtained Using previous example with network 23 on the screen this pushbutton causes network 22 to be displayed For complete programming details see GOULD MODICON USER S MANUAL January 1979 pages A 10 through A 21 III 31 3 5 USE OF MODEL T158 TELEPHONE INTERFACE 3 5 1 DESCRIPTION MODICON Telephone Interface Figures III 20 and 111 21 is a device which allows the Programmable Controller to be linked to the MODICON Service Center over standard voice grade telephone lines The Model T158 is an acoustical data coupler which mates with the standard telephone hand set Models 151 and 152 are designed to be used with 084 184
106. nnect expander cable to nector I O bus cable Expander end of W513 cable is similarly secured to expander Connection within expander is installed with red cable to sides of expander CAUTION MISARTICULATION MAY RESULT IN DAMAGE TO CONNECTOR OR BOTH onto duct with sharp blow 16 side J471 15 Secure cover of I O duct by pushing cover of step 16 RED SIDE TS 80 0016 2 Figure 1 14 Processor with Memory Module Removed Procedure If 7470 EIA Adapter is to be used mount the adapter along side processor whenever I O connection is NOT made left right or bot tom Insert three foot cable attached to adapter into processor communications con nector Figure 4 NOTE Field wiring can be installed or altered with I O mod ules installed For user convenience it is recom mended that the field wiring be installed prior to the installing of the I O modules 17 Install field wiring through conduit on left side of I O housing Figure 11 11 Connect to screw down terminals Each terminal is capable of accomodating eight Model 545 or four Model 546 I O modules each with eight terminals Terminal one is at top of each module 11 17 Step Procedure 18 TS 80 0017 2 Prior to installing the upper module in each 1 0 housing the housing s address must be estab lished Behind a small opening to the left of the top of the I O module is a series of four dip switches F
107. nnot processed Specifically this message means that the P180 sent a bad Element Status power request BAD LENGTH In general this error message comes from the 484 mainframe and means that the most recent P180 request has a serious problem and cannot be processed Specifically this message means that the I O request which the P180 sent had too few or too many characters BAD RECORD This message appears during LOAD DUMP VERIFY when the tape being processed has the wrong information BAD RESPONSE This message appears when the P180 has re ceived a response from the 484 but is is so erroneous it is un recognizable The P180 and or 484 are in serious trouble Should be diagnosed BAD SHIFT The SHIFT key was set for a key for which it is meaningless BAD TAPE This message appears during loading or verifying when the tape does not contain the information expected to be on a good tape BLANK NODE This message appears when the user is trying to DELETE a node which is not there or the cursor is on a blank node The cursor must be on a real node in order to delete it IV 17 BLANK OR This message appears when the user is entering a new node but the node above up arrow or to the left left arrow is blank This is illegal BY PASS I O When the user enters registers 4059 or 4060 this message will warn the user that these registers are re versed This is a warning message only The P180 will not
108. nputs to register register to discrete outputs Register to table move Table to register move SKIP and BY PASS I O MODBUS Communication Interface 0000 3 2 13 BINARY CONVERT This function is similar to the BCD CONVERT except that now the input and output modules do not receive numerical data as such but BINARY data This BINARY data is in the form of bits ones and zeros contained in a register Conversion is done with ten bits III 19 The BINARY CONVERT function allows the transfer of discrete inputs to be made to registers and the transfer of the binary bit pattern of registers to be made to discrete outputs This capability is very useful when for example known bit pattern is desired to be outputted upon reaching a step cycle The bit pattern l energize O de energize could held a register and then simply moved to the output upon acutation of a cycle When a new step is reached a different bit pattern can be retrieved from another register and trans ferred to the output modules In a similar fashion the status of inputs may brought into the controller and stored as bits in a register This may be a method for setting different bit patterns for the output status discussed previously 3 2 14 MOVE FUNCTION The MOVE function allows numerical data register contents to be moved from one register to another command These functions allow a table to be utilized with recipe or source
109. nts 10K 68K Q AC HOT 1 OPTICAL COUPLER Q CHARACTERISTIC TS 80 0033 1 Figure VI 11 B555 220 VAC Input Module Simplified Schematic TERMINAL TYPICAL NUMBERS INPUT REFERENCE INPUT 1 1001 INPUT 2 1002 INPUT 3 1003 INPUT 4 1004 TS 80 0034 1 Figure VI 12 B555 220 VAC Input Module Terminal Numbering and Connections 15 B556 VDC TTL OUTPUT MODULE The MODICON B556 VDC TTL Output Module Figure VI 14 conditions the signals used internally in the to four independent outputs capable of driving up to TTL or DTL loads The module uses four transistor VI 13 and controller 75 mA of drives to control logic loads associated with an externally applied 5 VDC source Electrical Characteristics Logic One State Line output ON Output transistor OFF Output indicator ON Output voltage 4 0V minimum at 1 mA current supply at 4 75 VDC TO OTHER TO OPTICAL CIRCUITS COUPLER and 5V TS 80 0035 1 3 OUTPUT Figure VI 13 B556 VDC TTL Output Module Simplified Schematic TYPICAL TERMINAL INPUT NUMBERS REFERENCE 5VDC IN 5 0 RETURN 0001 OUTPUT 1 0002 OUTPUT 2 NOT CONNECTED NOT CONNECTED 0003 OUTPUT 3 0004 OUTPUT 4 TS 80 0036 1 Figure 14 B556 VDC TTL Output Module Terminal Numbering and Connections VI 16 Logic Zero State Line output OFF Output transistor ON Output indicator OFF Output voltag
110. of field wiring terminals fail ures may be isolated to the processor I O module power sup ply or customer s hardware MODICON maintenance philos ophy is based on the assumption that when a major subsystem is proved faulty it should be immediately removed and replaced in its entirety This procedure greatly increases system avail ability 4 1 INDICATOR LIGHTS The mainframe has a series of three LED indicators Figure IV 1 Each LED is energized when a major portion of the main frame is operating NOTE AC power must be applied to mainframe before any LED will function In addition to the mainframe each I O module has four dicators to show the field voltage status of each of its cir cuits controller need not be functioning for the input indicators to operate The only requirement is for the proper field voltage to exist Output indicators are on only when the controller is in operation IV 1 5 80 0005 2 Figure 1 Indicators on Mainframe 411 POWER SUPPLY The Power Supply is located in the front cover of the frame Its proper operation output of both 5DCMF and 12 VDC is indicated by the DC POWER light on the mainframe As long as this LED is lit the Power Supply is supplying the proper voltages If this indicator is off verify proper supply vol tage at AC power terminals With proper AC power voltage the internal fuses should be checked Open the mainframe ver i
111. ogrammed Networks 111 25 T158 Telephone 111 32 Controls on Telephone 1 33 1206 Tape 34 Controls and 111 36 Interf cel vs ees oon meh eds E eee ees bi Typical 7474 111 44 IV 1 IV 2 IV 3 IV 4 IV 5 IV 6 IV 7 IV 8 IV 9 IV 10 VI 1 VI 2 VI 3 VI 4 VI 5 VI 6 7 VI 8 9 VI 10 11 12 13 14 15 VI 16 VI 17 LIST OF ILLUSTRATIONS Continued Title Page Indicators on Mainframe RE WR Re Ne 2 Power Supply Location of 3 Memory Module with 5 Wiring of Batteries ee ous mo J471 Expander Installation eius bes P vua ibd DC Power Lamp Fault Isolations Flowchart IV 11 BATT OK Lamp Fault Isolation Flowchart 12 RUN Lamp Fault Isolation Flowchart IV 13 RUN Lamp Fault Isolation Flowchart Continuation of A from 8 1 14 I O Section Fault Isolation Flowchart IV 15 B550 115 VAC Output Module Simplified SchematlGOo e 4 9 0 ah wveew Ss xev One
112. onnected 3 What service you desire If the call is for diagnostic service the operator will probably ask other questions After this discussion the operator will request that vou switch over to Data At the MODICON end this entails switch ing from phone to data If you are still listening you will hear an audible tone At your end to make the Data connec tion you must place the handset firmly into the rubber cups of III 33 the acoustical coupler One of the cups is lettered CORD which identifies the cup receiving the CORD end of the handset The rubber cups fit snugly about the headset receiver and trans mitter reducing the possibility of room noise affecting the communications When you have placed the handset correctly into the coupler and the Service Center Operator has switched from voice to data the green CARRIER lamp on your acoustic coupler will light The Service Center Operator is now in control During this service you must watch this green CARRIER lamp When the lamp goes off the Operator has switched to voice and is waiting for you to pick up the handset again Since reliable error checking cannot be done on communica tions while the controller is operating you will notice that shortly after switching to data a short communication will occur which will turn off the controller RUN lamp as well as all out puts Although the controller will not be scanning its logic running when the RUN light is off it is
113. onsecutive registers the one named and the next one The one named will contain the three most significant digits of the result The output coil will be ON as long as there is power flow through the Enable contact In DIVISION a double precision number up to 999999 in two consecutive registers can be divided by a fixed number or by a register content This capability allows the following func tions to be performed Scaling of analog signals to engineering units Controlling ratio Solving of formulas Splitting register contents 9000 The format for division is as follows OUTPUTS 1 is ON if upper value is greater than middle value 2 is ON if upper values is equal to middle value 3 is ON if upper value is less than middle value The output represents successful division or results of il legal division such as dividing by zero or obtaining result greater than one register can hold III 16 3 2 8 REGISTER I O Register I O provides the capability of handling numerical values in the I O structure These numerical values can be both received from an external source input registers and driven to an external destination output registers Each register includes a three digit quantity values from 000 to 999 There are 32 input registers assigned references 3001 to 3031 and 32 output registers references 4001 to 4032 The input registers receive their values from devices connected to the I O structure and can be only
114. open fuse indicator AC output points turn at zero crossing Each DC input point thresholds at approximately one half the supply voltage Rach input point is filtered for spike rejection Each input and output point is optically isolated User Labeling surfaces are provided on the 1 0 housings 6 1 1 MODULES B550 115 VAC OUTPUT MODULE The MODICON B550 115 VAC Output Module conditions the sig nals used internally in the controller to four independent 115 VAC outputs capable of driving solenoids motor starters and other loads up to two amperes The four output circuits the module are divided into two groups Each group contains two output circuits and is fully isolated This module can be ferred to as an Isolated Output Module in a group of two points Different 115 VAC sources can drive each group Each module uses four triac devices to switch the loads of the user supplied VAC line Self contained damping networks and voltage limiting varis tor suppress line voltage spikes and prevent false triggering Each output circuit is provided with a fuse to protect its cir cuitry from overload current Figure VI 1 and VI 2 Electrical Characteristics Load Current OFF Current 5MA max ON Current 2 amps continuous for each output 8 amps per module VI 4 Recommended minimum Load ON Holding Current Inrush Load Current Fuse Rating Load Voltage Working Voltage Transient Voltage
115. orld and assigns that control to the operator via the CRT Programming Panel The input can be forced ON or OFF All logic that uses this discrete input will now respond to the disable status and not the real world The disable status is permanent and may be altered only by programming devices with MEMORY PROTECT OFF At any one time as many logic coils and discrete inputs as desired can dis abled each ON or OFF NOTE Since the disable status is permanent a record of all disabled logic coils and inputs should be kept so that they can be enabled later ladder listing will show the disable state of any logic or input III 7 The disable function may be used to verify the proper wiring and operation of all discrete inputs Each output is displayed in a network on the CRT Programming Panel and then disabled coil can be cycled ON OFF ON OFF and so on 50 that the operation of the discrete device is observed It is recommended that the logic coil checked be enabled before the next output is tested to prevent undesirable disable statuses from occuring If an input such as a limit switch fails to operate perly its effect can be temproarily simulated by disabling the input and forcing it to the required state ON or OFF This is particularly useful if the input is preventing the control system from functioning 3 2 BASIC PROGRAMMING All 484 Controllers are provided with the capability of being programmed and of si
116. output stops passing power only when the timer is at its preset The timer will accumulate time whenever the upper node to the left receives power The upper signal can be turned ON OFF ON as many times as necessary and the timer will accumu late how long the signal was ON up to the preset value Each time the upper node is re energized time begins to be accumu lated from its previous value held in the storage location re gardless of how long the signal was OFF Timers are accumulative They are reset only by the lower node signal They retain their stored information completely during power failure Whenever the reset signal is de ener gized regardless of the time value the timer will be reset to zero It holds at that value until the reset signal is ergized The number entered into the lower element of the timer must be a storage register reference 4XXX wherein the current time is stored Normally each timer has its own holding register selected by the user Thus the maximum number of timers available with each memory size is the quantity of holding registers Do not use a holding register as the storage location for than one timer III 13 3 2 5 COUNTERS Counters operate the same way as timers except for the trol node The counter increments its current count by whenever the control signal goes from OFF to ON Only on this positive transition OFF to ON is the count incremental Th
117. owever for user convenience it is recommended that the field wiring installed prior to I O modules The I O housing address can be readjusted at any time by removing the 1 0 modules Figure 11 11 LI LI 5 5 b 5 b m rr am ee TS 80 0013 2 Figure 11 11 Field Wiring Housing Conduit II II 2 2 SYSTEM INSTALLATION The various parts of the MODICON 484 Controller system are packaged in separate containers as follows Container Contents C484 Processor unit with power supply B545 546 Discrete I O Housing up to four housings per box B547 548 Register I O Housing up to four housings per box 5540 5541 Input output Duct with I O cable BXXX Input output Modules up to four modules per box 4 8 12 boxes carton J 471 Discrete I O Expander B571 570 Register Multiplexers up to four multiplexers per box J470 EIA Adapter The 484 Controller is easily installed on any vertical sur face capable of sustaining its specified weight Each unit has holes for mounting Figure 11 1 shows typical mounting plan This may be used to mark the wall prior to bolt hole drilling Input output housings be mounted to the left of the processor to the right of the processor or below the processor maximum of two locations may be used Regardless of the location
118. put Voltage Common Mode Rejection Cross Talk between inputs Input Impedence Frequency Response Setting Time within 0 01 of final value Resolution Linearity Error Accuracy Temperature Coefficient Offset and Linearity Gain External Power Requirements Isolation Input to input Input to Controller Input to External Power Supply Each analog input will be converted and new data to the controller each scan the controller will vary linearily from 000 to 999 as log input signal varies from minimum to maximum illustrates typical numerical values 1 5 VDC Model 005 0 10 VDC Model 010 10 to 10 VDC Model 015 220 VAC 70 dB 70 dB 2 Mohms DC to 100 Hz 2 dB points 10 msec 1 bit in 1024 Less than 0 05 of full scale 0 05 of full scale at 25 C 0 25 of full scale at 0 657 0 005 per of full scale 0 005 per C of input voltage 15 30 VDC at 250 ma 1 mohm 300 VAC continuous 1500 V for 100 msec 500 VDC presented The numerical value supplied to the ana The following VI 24 Voltage 005 010 015 10 VDC 000 000 000 5 voc 000 000 250 0 VDC 000 000 500 1 VDC 000 100 550 2 5 VDC 500 250 625 5 VDC 999 500 750 10 VDC 999 999 999 Each B577 Analog Input Module incorporates an Active indi cator Active LED will be ON as long as the CPU communi cates to the module at least once each 100 msec The external power supply is
119. r is the input and output control devices that are directly connected to the controller User wiring to and from the controller is lished through heavy duty housings These housings are de signed to hold up to eight I O modules Each module contains four circuits either input or output A smaller I O housing accommodating up to four I O modules is available The covered wireway I O duct enables easy installation and access to the wiring A wide variety of I O modules is offered The modules are output driving or input handling circuits These solidly con structed units are easily removed from or plugged into their housings Once inserted electrical contact is automatically made through plated spring connectors I O modules can be re moved and replaced without removing power on the field devices or internal logic There is no need to shut down the system to replace I O modules Each input and output circuit is isolated by photo diodes thus preventing transients on the field wiring from affecting the internal logic No periodic maintenance is required The 484 output modules AC or DC have individual output fuses Indicators on each module show the field power status out put fuses condition I O modules and field wiring be lo cated in any possible configuration regardless of voltage level There are four classes of signals between the 484 svstem and the user s equipment Discrete I O connections
120. rd RS232C printer Thus a hard copy of the ladder diagram contained in the troller can be generated 1 2 5 PERIPHERALS Several standard MODICON support units are available for use with the 484 Controller These units provide a wide va riety of support functions Complete system support is always 1 6 available The support units use the 7470 EIA Adapter for con nection to the processor This adapter allows a P180 Pro grammer and another peripheral device to be connected to the controller simultaneously Available support equipment includes 158 Telephone Interface for communication with MODICON s service center L206 Universal Tape Loader for local recording of the user s program MODBUS Interface 7474 which allows plant wide or nation wide communications 80 CRT Programmer for entering user logic J470 Communications interface 7471 I O Expander for additional I O capacity 13 SUMMARY Programmable controllers are used in industrial settings to replace relays and other solid state electronic devices Con trollers are faster to respond to instructions and operate with maximum reliability They are easily programmed with ladder diagram language Because they are modular they are easier to maintain and install and less space 15 required Hardware costs are lower They operate in hostile environments A typical controller is divided into four components Pro cessor Power Supply I O Sec
121. reen Format The upper seven lines display the user logic in any order selected by the operator The smallest unit displayed is a network A network is a group of logic elements relay tacts fixed numerical values register references coils so on These are connected together at some point points Networks are identified a step number assigned when net work is constructed The minimum size of a network is one rung of the ladder Maximum network size is seven rungs Figure III 3 shows the program format for the user logic display Figure III 19 shows typical programmed networks The lower two lines contain four status areas Figure III 18 which provide information to the operator The first is the assembly area on the left Program elements must assembled here before being entered into ladder diagram All portions of an element must be specified before the processor will accept it Any white area in the assembly portion indi cates part of the element is missing Next to the assembly area is the message space Messages such as MEMORY PROTECT ON Bad Node and Illegal Reference are provided for the operator III 24 var cer v lt 1001 1682 1003 1804 6602 0005 8257 0188 e res I gt 2181 1127 1128 0079 1618 0065 2201 0001 2301 0258 USED REF 4001 1010 000 1001 0001 9108 VAL gt 901 D OM OFF D ON TS 80 0024 2 1025 0971 NETS USED REF g
122. referenced not altered from within the controller The output registers are Special holding registers references 4001 4032 that can perform the dual purpose of storing holding numerical values as well as driving them to the outside world 3 2 9 TRANSITIONAL CONTACTS In addition to the conventional normally open and normally closed contacts that are available with all 484 Controllers the Enhanced Instruction Set options also provide transitional contacts Figure III 13 Transitional contacts can be used anywhere in networks where the more conventional NO and NC con tacts had previously been utilized These transitional con tacts will pass power for exactly one scan whenever the signal to which they are referenced is transitioned from either OFF to ON or ON to OFF depending upon transitional type selected They can be referenced to any input or coil output or inter nal but cannot be referenced to sequencer steps TRANSITIONAL CONTACT TYPE SELECTED OFF TO ON ON TO OFF JF Ji CLOSE CLOSE OPEN TS 80 0011 1 CONTACT POWER FLOW ONE ONE SCAN SCAN TIME TIME Figure 1 13 Transitional Contacts III 17 These contacts respresent shot which is sometimes necessary when performing a function e g multiplication or division only once 3 2 10 SEQUENCERS Eight independent 32 step sequencers provided Each sequencer operates similarly to a stepping switch with single specifi
123. referenced to any of the three clock signals III 12 There are two nodes for entry of relay contact type control to the left of the timer The upper node controls when the timers accumulate time The lower node controls when the time is reset to zero The timer is enabled when the lower node re ceives power flow It resets when no power flow is available The upper element of the timer contains the preset value which limits the maximum value of the timer This preset may be fixed value of three digits 0001 to 0999 These digits represent up to 999 seconds or up to 9 99 seconds The timer can never exceed this preset value The lower element refers to a storage location within the controller where the current timer is stored In the center of the timer is a display to indicate the rate at which that par ticular timer is programmed to operate T1 0 seconds T0 1 tenths of seconds and T 01 hundredths of seconds On the right of the timer are two nodes from which the log ical output of the timer are available These nodes will pro vide power to any contact shunts or coils programmed to the right of the timer The upper node provides power only when the timer is at its preset value This output is de energized and stops receiving power When this output is energized the timer stops No further accumulating of time beyond the preset is possible The lower node provides power whenever the timer is NOT at its preset This
124. rnal Components cou Ta 16 Processor with Memory Module 11 17 Installation I O 1 11 18 Installation of I O Module 15 11 19 Relay Contact III 1 Mainframe Block 1 111 2 Multi Node Program Relay Contacts with and without Verticals III 9 Relay Logic 1 1 9 Assumed I O Wiring Logic in Figure III 5 III 10 484 Program Equivalent to Assumed I O Wiring in Figure 6 10 484 Latched Coil 111 11 484 Extended Logic 111 12 Timer Cas dee ce Sample Timer Counter Cascaded Logic III 14 General Format for Arithmetic Option III 15 Transitional 1 17 Twelve Step Seguencer and Equivalent Circuit III 18 Move 11 20 P180 CRT Programming 1 111 22 P180 lt lt 955 545454555599 III 23 General CRT Screen 111 24 Typical Pr
125. ront of mainframe and then close mainframe 8 If OK indicator is not illuminated replace lamp or power supply or memory board Figure IV 6 Memory boards can be removed stored transported and exchanged without loss of memory as long as the batteries are inserted There is no indication of battery level except when installed in controller with AC power applied Memory sizes of any controller can be changed by replacing the board 4 1 3 INPUT OUTPUT SECTION Communications from the mainframe to the real world is complished via the I O Section This section isolates all in put and output devices to prevent external noise from affecting the internal logic of the 484 Controller system The circuitry in the I O Section is specially designed to filter inputs drive outputs at voltage levels compatible with the user s equipment There are no limitations on the placement of the modules in the I O Section relative to their voltage handling capacity circuits do not have to be isolated from cir cuits nor do high voltage i e 220 VAC have to be separated from low voltages i e 5 DCMF Whenever a failure is suspected in the I O Section the following steps should be taken to systematically locate the failure IV 7 1 SINGLE I O CIRCUIT Connect Programming Device Call up input 1XXX reference or output reference that is suspected When it is an input compare its status with tha
126. rovide com pletely internal references as follows 0001 0256 Output Coils 0258 0512 Internal Coils NOTE Internal coil 0257 is an internal indicator of battery voltage This reference is ON as long as the voltage in the batteries is sufficient to ensure retention of memory Whenever the batteries reduce their capacity to a minimum level coil 0257 will de energize the BATT OK LED will extinquish Figure II 2 This is a warning level only The batteries will still be able to maintain memory for at least seven days without AC power Any output or internal logic coil can be used as a coil only once References to contacts controlled by a coil can be used as many times as required There is no limit to how many times any reference is used in a program Output coils that are not used to drive discrete outputs can still be used as coils in programming Therefore any unused output coils can be used for internal functions exactly as internal coils are used example of Relay Logic is shown in Figure III 5 PERMISSIVE SAFETY START STOP TS 80 0007 1 Figure 1 5 Relay Logic Example III 9 If the logic Figure III 5 was implemented in the 484 Con troller the control elements must be connected to input cir cuits in the I O configuration and outputs assigned Any available inputs of the proper voltage level used Figure III 6 illustrates the assumed input assignments and wiring details Output number 12 is assigned
127. ry without AC power 3 Insert new battery into vacant holder as follows Lithium batteries are inserted with positive red wire towards center Alkaline batteries inserted with positive red wire towards left side CAUTION REVERSE POLARITY WILL CANCEL VOLTAGE OF EXISTING TERY AND ELIMINATE BATTERY SUPPORT LEFT HOLDER RIGHT HOLDER CONNECTIONS FOR LITHIUM BATTERIES BLACK RED RED a g BLACK 1 4 56 ET N O E5 8 El TS 80 0017 1 CONNECTIONS FOR ALKALINE BATTERIES Figure IV 4 Wiring of Batteries IV 6 4 Connect wires to slide terminals on Rev C memory board Figure IV 4 Lithium batteries are supplied with wires for connection Place batteries in holders and con nect red wires to center terminals and black wires to terminals towards side of memory board Connect jumper between terminals below right holder Alkaline batteries are placed in spring clip holders wires are supplied with these bat teries To connect these batteries series jumper is placed between terminals El and Connect only one jumper either below right holder or between holders depending upon battery type 5 Remove the second old battery from its holder if two batteries are in the controller Replace with second new battery following steps 3 and 4 above 6 Record battery change on memory board in space pro vided 7 Verify operation of BATT OK indicator on f
128. s LED is energized there is sufficient battery capacity to retain memory upon loss of AC power IV 4 AC power is required to operate BATT OK indicator troller system Batteries are designed only to retain memory They will not run the controller When the BATT OK LED is not illuminated check the POWER LED If illuminated replace batteries If not illuminated verify voltage at AC power terminals at bottom right of main frame The BATT OK LED is a warning about battery voltage When this indicator goes off there is sufficient capacity to main tain memory for at least seven days The following procedure should be used when the batteries to be replaced It is recommended that AC power to troller be left on while replacing batteries Memory will lost if the AC power is removed while either of the alkaline batteries is not installed Memory will not be lost when power is removed if either lithium battery is installed One lithium battery is sufficient to retain memory TS 80 0032 2 BATTERY HOLDERS Figure IV 3 Memory Module with Batteries IV 5 Procedures for replacement of alkaline lithium batteries are basically the same and are as follows 1 Open mainframe swing out power supply and locate memory board Figure IV 3 2 If both battery holders contain batteries remove ONE to create a vacant holder Remember that one alkaline battery is insufficient to maintain memo
129. s data has been altered Checksums can be pared for any portion of logic memory coil storage or register content CMOS CORE MEMORY COUNTER CPU Central Processor Unit DISABLE DISCRETE DOUBLE PRECISION DUMP ELEMENT FORCE Advanced semi conductor memory that re quires DC power to retain its content However the amount of DC power is very low when compared to other memory tech niques allowing relatively small bat teries to maintain this memory for years without application of AC power An electronic component used to store data magnetically for future utiliza tion that is retentive upon power fail ure type of logic that is used to simu late the operation of external counters See PROCESSOR The capability to disconnect logic coil or a discrete input from its mal control and force it ON or OFF References that can be either ON or OFF can be input output or internal references The technique of storing a single nu merical value two consecutive regis ters Since each register can store up to three digits maximum value 999 double precision allows magnitudes of up to 999 999 to be stored Recording the entire memory of a Con troller onto disk by the Service Center Generally accomplished by use of a Telephone Interface at the Con troller The basic building block of the 484 logic An element can be a relay con tact horizontal shunt or open fixed n
130. sary Do you have any comments or suggestions Name Street Title City Dept Mail Stop State Country Company Code Telephone Thank you for your help JNN SNOW 0104 2 E gt lt Ok lt 2 22125 BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 234 ANDOVER Postage will be paid by addressee North Andover MA 01845 9943 Attn Technical Publications 7 2A MODICON Inc 1 High Street ALONG Publications Order Form an AEG company TO ORDER BY PHONE CALL 1 800 468 5342 and ask for an Order Entry Coordinator Bill To Ship To if different Customer Contact Name Purchase Order No Date Telephone Document Part Number Description Quantity Unit Price Total Price see Authorized Signature Date Sub Total Freight
131. t 1009 4025 0101 1100 9092 0118 VAL gt DOFF 2 OW OFF TS 80 0025 2 Figure 11 19 Typical Programmed Networks III 25 In the center of the status area are two values related to the controller program status First is the step number of the network on the screen The amount of memory in 8 bit words already used is also shown in this area The final status area is at the right It is programmed the operator with up to six legal references These can be 10 gic coils inputs or registers References will have their current status displayed at all times no matter where the cur sor may be Discrete references 1 are indicated as ON or OFF Registers have their numerical content displayed 000 to 999 3 4 PROGRAMMING INSTRUCTIONS 3 444 NETWORK CONTROLS These controls Figure III 17 are discussed as follows pushbuttons indicated with an asterisk will not function unless MEMORY PROTECT is OFF START NEXT This pushbutton causes a new network to created immediately after the network on the screen All net works following the current network will have their step num bers increased by one If no logic is on the screen the new network will be created at network number one before all existing logic All existing networks will have their step numbers increased by one providing space for the new logic at network one SUPERVISORY This pushbutton allows the operator to enter the most powerful
132. t Mode is selected pins 28 and 30 disconnected the internal Self Test will operate continuously The 0474 will halt its operation when an error is detected during diagnostic testing While in the Halt mode no communications with the MODBUS nor the controller is possible The diagnostic testing can be restated and possible reactivation of communications cycling J474 ON OFF ON III 46 SECTION IV TROUBLESHOOTING 4 0 INTRODUCTION The MODICON 484 Controllers are rugged heavily protected modular systems designed specifically for industrial environ ments They require no regular maintenance In the event of failure components may be quickly replaced Indicator lights are provided to indicate proper operation of the mainframe s subassemblies If a suspected failure is encountered there several procedures to be followed by the customer to determine that there is a failure in the MODICON system and to isolate that failure to a particular assembly These procedures are out lined in this section They require no special test equip ment As basic understanding of the functions of the com ponents is necessary The major troubleshooting methods available to the user are checkouts of the processor using the programming panel This panel allows any network input output or register to be ex amined and changed in any proper manner desired Through the combination of logic examination and visual inspection or electrical test
133. t of the indicator of the input mod ule If they agree the input is operational field wiring external device should be examined If not the input module should be replaced NOTE When possible cycle input device such as limit switch pushbutton etc ON OFF ON to confirm opera tion When it is an output compare its status with that indicated on output module If they agree the output is operational and the field wiring external device should be examined If not the output module should be replaced Verify that a blown fuse is not being indicated at output module before replacing module NOTE When possible use DISABLE function Paragraph 3 1 5 to force output ON OFF ON etc MEMORY PROTECT must of OFF CAUTION BE VERY CAREFUL THAT OUTPUT WILL NOT CAUSE UNSAFE USER EQUIPMENT OPERATION 2 MULTIPLE I O CIRCUITS Connect Programming Device to verify I O operation and select appropriate procedure from the following ONE MODULE Verify proper power supplied to module If voltage exists replace module If not troubleshoot field wiring and power source WITHIN ONE I O HOUSING CAUTION MAIN AC POWER TO 484 SYSTEM SHOULD BE REMOVED FIRST DO NOT REMOVE CABLES WITH POWER ON 484 MAINFRAME Open I O duct and reseat I O bus connector If this does not correct fault use spare I O bus connector rotating connectors with in duct as necessary to move spare connector to desired housing I
134. ter and thus alter its content ENABLE EXAMPLE 4100 If 4100 contains the value 43 register TOR 4043 4000 043 will have its content 4001 transferred to register 4001 In either MOVE function it is recommended that the 484 Manual and 484 Application Notes be reviewed for operation and typical applications ENABLE EXAMPLE 4095 4120 contains the value 225 register RT 4225 40004225 will be loaded with the 4120 content of register 4095 3 2 16 SKIP The SKIP function allows a designated network or set of networks to be skipped by the scan of the controller This effectively reduces the potential scan time from that required to solve all networks to that required by the minimum toring logic until a certain event happens e g timer times out set point reached limit switch activated level achieved etc 3 2 17 BY PASS Similar to the SKIP function BY PASS I O allows unused to be by passed and not serviced in the scanning function Portions of both the discrete I O as well as the register I O 21 can by passed with separate user controlled limits Maximum savings is 7 msec on the scan time Because SKIP and BY PASS functions are very powerful tools their use should be considered only by those designers that are totally familiar with the 484 Manual and its precautions Using both SKIP and BY PASS I O the 484 can be operated at a minimum scan time of 1 5 msec 3 2 18 MO
135. terminated with TAPE ERR in dicated Once good parity is obtained all successive records of that block will be ignored until the next block is located Time required to record load depends upon baud rate and me mory size The following are some typical times to record a 4K 484 program Baud Rate Time 9600 15 Seconds 4800 25 Seconds 1200 90 Seconds 300 5 Minutes 110 14 Minutes Loading or verifying typically takes 50 of the time required to record a program 3 7 J474 COMMUNICATION INTERFACE MODBUS 3 7 1 DESCRIPTION This interface Figure III 24 allows a Master such as a computer to communicate to a group of 484 Controllers Up to 32 controllers can be connected together each with J474 and be monitored controlled by a single port on the Master Each controller can be polled by the Master one at a time based upon the program within the Master Hardware interfacing via J478 conforms to EIA Specification RS 232 a standard III 40 option on most computers Software protocol is described separate document discussing the MODBUS capabilities TS 80 0030 2 Figure 1 24 4474 Interface This MODBUS system allows the 484 Controller to be easily integrated into a data processing system The Master can collect information for management reporting while the 484 Con troller continues to direct the production equipment Alter nately the Master can down load receipts standards into all 484 Controll
136. the depressing of the key a second time or after any of the twelve dual function keys are depressed The SHIFT key oper ates similar to the upper case shift control on a typewriter A complete discussion of shifted controls is provided part of the discussion of basic keys functions The following is a list of dual function keys Basic Key Label Shifted Upper Case Upper Label Function DELETE Element DELETE Network Netwrk T R Register to Table Commence SEARCH Continue Search Cont 0 zero Counter Ctr 1 one Timer 1 100 Sec 01 2 two Timer 1 10 Sec T0 1 3 three Timer Seconds 1 0 4 four Subtract 6 7 seven Add 8 eight Convert CONV 9 nine Multiply X CLEAR Assembly Area CLEAR Entire Screen ALI CLEAR When depressed this pushbutton clears the assembly area If a SHIFT has been commenced prior to the CLEAR the entire CRT screen will be cleared including assembly area error codes and step network number 3 4 4 ENTRY CONTROLS These controls Figure III 17 relate to the entry of the logic elements into the ladder diagram from the assembly area Changes are made to the controller s memory and these elements checked for validity only when their entry into the ladder dia gram is attempted The element is moved from the assembly area to the ladder diagram where the cursor is positioned If logic TII1 29 exists at the cursor position it will be replaced by the el
137. tion and a Programming Device The processor is the brain of the PC The processor ates on DC power furnished by the power supply The I O Sec tion is the controller s Link with the real world The pro gramming panel is the main device used to program the troller The MODICON 484 Programmable Controller is desigend to re place control systems of 10 to 400 relays It has able I O with four point modules It also has an expandable memory in six sizes ranging from 1 4K to 8K The P180 Program ming Device is connected directly to the 484 All of these features make the MODICON 484 Programmable Controller one of the most up to date PC s on the market todav I 7 1 8 SECTION II INSTALLATION 2 0 INTRODUCTION The MODICON 484 Controller is microprocessor based con troller Its circuitry allows relay ladder diagram control 10 gic to be programmed Section II describes the system configuration and gives in formation necessary for installation 2 1 SYSTEM CONFIGURATION 2 1 1 MAINFRAME CODE The 484 is manufactured with several basic options The customer chooses from six memory sizes two power supply varia tions and three instruction sets These choices are reflected in the Mainframe Code shown in Table II l Table Il 1 Mainframe Code Code C484 XYZ Y represents 7 represents Power Supply Memory Size X represents Instruction Set 5 50Hz 11
138. to inhibit the buildup on contami nants on the surface of silver contacts used pushbuttons limit switches pressure switches etc The input signal re quirements for each of the 4 inputs are as follows Electrical Characteristics ON Condition Input at high level Input indicator ON neon lamp Controller input ON ON level Input voltage greater than 80 VAC and less than 130 VAC continuous Source impedance less than 1K ohms 40 to 70 Hz OFF Condition Input at low level open circuit Input indicator OFF neon lamp Controller put OFF OFF level Input voltage less than 48 or less than 150 VAC with source impedance greater than 40K ohms 40 to 70 Hz VI 6 Switching Level Input Impedance Input Current Common Mode Voltage Maximum Input Voltage Response Time Compatibility with output modules AC NEUTRAL AC INPUT HOT Q CHARACTERISTICS Approximately 60 VAC Approximately 16K ohms at working frequency Approximately 8 mA at 115 VAC 200 VAC steady state 60 Hz 1500V for 10 ms 150 VAC for 10 seconds 200 VAC for 1 cvcle 16 7 ms at 60Hz OFF to ON 10 ms max ON to OFF ms max The B551 is capable of inter connection with the MODICON B550 and B230 115 VAC Output Modules without the use of additional components OPTICAL COUPLER TS 80 0025 1 Figure VI 3 B551 115 VAC Input Module Simplified Schematic TYPICAL TERMINAL INPUT
139. to operate the external device internal logic programmed into the troller may be seen in Figure III 7 ees 00 1006 PERMISSIVE 1002 0012 5 SAFETY 1027 OVERLOAD 5 80 0008 1 ASSUMED INPUT ASSUMED OUTPUT CONNECTIONS CONNECTIONS Figure 11 6 Assumed I O Wiring Logic in Figure 111 5 1001 1006 1002 1818 1827 9012 NET USED REF gt 6600505 0881 8952 VAL Figure 11 7 484 Program Equivalent To Assumed Wiring In Figure 111 6 III 10 3 2 2 LATCHES Any logic coil can be latched so that it is returned to its previous state ON or OFF after a power failure This is sim ilar to a latching relay Therefore if a latched coil is and power is lost it will return to ON state when power is restored regardless of how long the power was off If the coil was OFF it will remain OFF when power is restored All logic coils that are not latched will be de energized when power is restored All logic coils are latchable If the logic coil in Figure III 7 were latched it would be programmed as such and displayed on the CRT Screen Figure III 8 mm 1991 1886 1882 1018 1827 9012 USED REV DX 8981 8052 VAL gt TS 80 0019 2 Figure III 8 484 Latched Coil Program 3 2 3 EXTENDED LOGIC If more than ten elements are required in a rung to satisfy a complex control function an internal coil may be used to represent a
140. umerical value register reference or coil representation The pushbutton on the P180 Programming Panel that can be used to change the state of a Disable reference The re ference will be changed OFF to ON or ON to OFF every time this pushbutton is depressed G 3 HEXADECIMAL INPUT I O LATCH MAINFRAME MEMORY PROTECT MODULE NETWORK NODE The numbering system that represents all possible statuses of four bits with Sixteen unique digits 0 9 then A F A signal that provides information to the controller can be either discrete input pushbutton relay contacts limit switches etc or numerical put thumbwheel external solid state device etc Input Output the Controller connection to the real world includes both dis crete and register signals The type of coil that is retentive upon power failure be used similar to a latching relay Normally coils are reset to OFF conditions upon power up those coils selected by the user as latched L will not be altered thus retain their previous condition ON OFF See PROCESSOR The hardware capability to prevent a portion of the memory from being al tered by an external device This hardware feature is under keylock trol Hardware sub assembly that can be easily replaced for maintenance pur poses a failure occurs the module is rapidly replaced to restore the con trol system with minimum downtime The failed
141. ut low Input indicator OFF Controller input OFF VIL 0 8V max IIL 1 1 mA max at V source 5 25V and VIL OV Max negative input voltage 2 volts Max negative clamp 15 mA 200 steady state max 50 60 Hz 1500 for 10 ms Voltage 5 0 0 25 VDC Current 65 mA max OFF to 4 ms max ON to OFF 13 ms max LED is provided for each input The light is ON when input is logic one state The B557 is capable of inter connection with the MODICON B556 and B236 Output Modules without the use of additional components TO OPTICAL COUPLER Figure 15 B557 VDC TTL Input Module Simplified Schematic VI 18 TYPICAL TERMINAL INPUT NUMBERS REFERENCE O 5VDC IN 2 5VDC RETURN 3 INPUT 1 1001 4 INPUT 2 1002 5 NOT CONNECTED NOT CONNECTED INPUT 3 1003 INPUT 4 1004 TS 80 0038 1 Figure 16 B557 VDC TTL Input Module Terminal Numbering and Connections B558 UNIVERSAL DC OUTPUT MODULE TRUE LOW The MODICON 8558 Universal DC Output Module True Low Figures VI 17 and VI 18 converts the signals used internally in the controller to four independent DC outputs capable of driving relays pilot lamps motor starters solenoids any other load up to two amps The module uses transistors switches to control loads connected to the user DC source The four output circuits are divided into two groups of two cir cuits each The two groups are fully isolated and the module
142. v 8 Remove I O modules at time from sus pected housing if fault continues If faulty module begins to operate when an module is removed replace that module and inspect its connector on housing backplane Replace I O housing or its backplane when removing all I O modules does not correct fault TS 80 0033 2 Figure IV 5 4471 Expander Installation MULTIPLE HOUSINGS Remove top I O module from faulty housings and verify selection of address Only one switch should b positioned housing Figure II 14 Reset all switches if no obvious errors are detected Open I O duct and remove I O bus connectors from suspected housings one at a time if the fault still exists Reconnect in the same order while examining I O operation with programming device If one housing creates the fault only when connected to the bus it or its backplane should be replaced IV 9 Remove the entire bus cable one connector at a time Replace in same order searching for a faulty I O housing Finally replace entire I O bus cable 3 OTHER I O DEVICES The model 7471 Expander Figure 5 is maintained similarly to the power supply dis cussed above Its I O structure be troubleshot following the procedure listed above All I O modules are parallel to the I O bus communi cations therefore all I O data is seen by each mod ule via the I O bus cable Only appropriate mo
143. ver the outputs The height of an installed 8 module housing and duct is 32 inches Additional room must be provided for wire runs The height of an installed 4 module housing is 18 inches Each 1 0 housing requires 5 inches in mounting surface width The I O system will operate in standard NEMA cabinets internal ambient air temperatures from 0 to 60 centigrade pro vided that nothing restricts the free flow of convection air currents Table VI 1 shows the signal conditioning module options Input Output Module terminal assignments are shown in Table VI 2 2 Table VI 1 Signal Conditioning Module Options Type Color Code conditions 115 VAC outputs red conditions 115 VAC inputs pink conditions 9 56 VDC outputs Universal DC Module True High dark blue conditions 9 56 VDC inputs Universal DC Model True High light blue conditions 220 VAC outputs orange conditions 220 VAC inputs melon conditions 5 VITL outputs violet conditions 5 VITL inputs light purple conditions 9 56 VDC outputs Universal DC Module True Low turquoise conditions 9 56 VDC inputs Universal DC Module True Low blue conditions 90 150 VDC outputs blue conditions 90 150 VDC inputs blue The term True High means that the controller sees the input as True ON when the input is High Using true high input module the input device outside the controller should be wired to the source The same terminology is
144. ys communicates at 9600 baud even parity with one stop bit Communications to a computer can be at any option selected by the user 7470 Adapter is also required to operate with 1206 Universal Tape Loader and T158 Telephone interface hus the 484 Controller can be simultaneously connected via the 1470 Adapter to the P180 Programming Panel and one of the following Universal Tape Loader Model 1 206 Telephone Interface Model T158 EIA Compatible Computer MAINFRAME ADAPTER DEVICE lt 200FT SEE TABLE MAX Maximum Maximum Device Distance L Baud Rate L206 50 9600 7158 100 300 Computer W O Adapters 50 9600 Computer 1642 Adapter 2000 300 Computer W 1643 Adapter 1000 9600 TS 80 0044 1 Figure VII 3 4470 Block Diagram External Connections Figure VII 3 is a block diagram of the various connections to the J470 Adapter and the distance limitations Most com puters are compatable of communicating at distances up to fifty feet per EIA specification RS 232C however the 17470 Adapter is capable of driving up to 1000 feet of cable baud rates up to 9600 or 2000 feet with baud rates equal to or less than 300 VII 3 VII 4 SECTION VIII 4471 EXPANDER 8 0 INTRODUCTION 7471 I O Expander enables the 484 Programmable troller to access an additional 256 discrete I O points beyond the basic 256 discrete I O points All register devices may also be used on the extended

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