Hello,
I am trying to set up a PLC recently obtained from a salvage outfit. Upon purchase, a quick test was done to verify that the PLC worked. A few people have messed with it, and one apparently got it communicating with my computer. However, after going through the AB Hardware Installation manual and setting it up as it recommends, I seem to get a serious fault. Both the REM I/O and PROC light are solid red. It did not do this before I went through the manual, and I hope I didn't seriously damage it.
The only thing I can thing of is that it might have something to do with the battery. The BAT light is solid red, and we have a new battery on the way. We do not have EEPROM. Could a low battery be causing this problem? If not, does anyone have any suggestions? Thanks for your help.
Full Version: Problems setting up a PLC-5/25
don't panic ... the dead battery has probably just allowed the processor to dump its program ... the red LED "fault" conditions are a natural consequence of a brain-dead processor ... there's PROBABLY nothing physically wrong with the system ...
as long as you're just playing and learning, there's no real reason to wait around for the battery ...
just try to go online with the processor ... you will probably need to autoconfigure the DF1 driver under RSLinx ... the baud rate will probably have been set to its default setting of 2400 ... RSLinx should be able to detect this and automatically adjust when you press the "autoconfigure" button ... RSLogix5 will ask you for a new processor name ... call it "JOE" or something similar ... you should be able to get online and start entering rungs ...
as long as you don't turn off the 120VAC power to the processor, the missing battery should be no problem ... go ahead and get started ...
post again with specific questions if you're not already familiar with the steps listed above ...
best regards,
Ron
PS ... just in case this doesn't work out, here are a couple of things to check ... there's a small jumper on the chassis behind the processor ... make sure that the proper "power supply in this chassis?" selection has been made ... also double check the DIP switches on the chassis backplane ... you'll probably just want to select "one-slot" addressing and "no EEPROM" transfer to get started ...
you can find the DIP switch settings on page 23-4 of this book:
PLC-5 User Manual
hint: turn all DIP switches OFF ... except ... turn 5 and 6 ON ... that should get you going ...
as long as you're just playing and learning, there's no real reason to wait around for the battery ...
just try to go online with the processor ... you will probably need to autoconfigure the DF1 driver under RSLinx ... the baud rate will probably have been set to its default setting of 2400 ... RSLinx should be able to detect this and automatically adjust when you press the "autoconfigure" button ... RSLogix5 will ask you for a new processor name ... call it "JOE" or something similar ... you should be able to get online and start entering rungs ...
as long as you don't turn off the 120VAC power to the processor, the missing battery should be no problem ... go ahead and get started ...
post again with specific questions if you're not already familiar with the steps listed above ...
best regards,
Ron
PS ... just in case this doesn't work out, here are a couple of things to check ... there's a small jumper on the chassis behind the processor ... make sure that the proper "power supply in this chassis?" selection has been made ... also double check the DIP switches on the chassis backplane ... you'll probably just want to select "one-slot" addressing and "no EEPROM" transfer to get started ...
you can find the DIP switch settings on page 23-4 of this book:
PLC-5 User Manual
hint: turn all DIP switches OFF ... except ... turn 5 and 6 ON ... that should get you going ...
Ron,
Thanks for the advice. I went back over all the steps in the manual again and checked the jumpers. I made sure all the switches were firmly in position, and that seemed to do the trick. It cleared the processor faults, and I was able to clear the other error messages.
Now for another noobie-question (while I'm an avid computer tinker-er, I've never messed with PLC's until a week ago). Do I need to somehow tell the processor where/what kind of I/O is in each slot? I have plenty, and I'd like to start sticking them in.
As always, your assisstanc is much appreciated.
- Joe
Thanks for the advice. I went back over all the steps in the manual again and checked the jumpers. I made sure all the switches were firmly in position, and that seemed to do the trick. It cleared the processor faults, and I was able to clear the other error messages.
Now for another noobie-question (while I'm an avid computer tinker-er, I've never messed with PLC's until a week ago). Do I need to somehow tell the processor where/what kind of I/O is in each slot? I have plenty, and I'd like to start sticking them in.
As always, your assisstanc is much appreciated.
- Joe
It depends on what type of processor you are using. If you are using the PLC5, you don't need to configure the I/O to go online. If you are using the SLC's, you must configure each I/O slot to go online. The easist way with the SLC's is hook up the processor and put your I/O in their slots. Now use the auto configure under the I/O Configuration heading using RS Logix 500.
God Luck
God Luck
Joe,
based on the title of your first post, it looks like you’re using a PLC-5/25 ... and so ... as “unregistered” says, you do NOT need to tell the processor what type of I/O cards are in each slot ... just plug them in and start to play ...
and that brings up another thing ... if you do indeed have a PLC-5/25, then you have what is called a “classic” (as in older style) processor ... so the information that I gave you earlier about the DF1 driver in RSLinx is all wrong ... sorry ... I should have paid more attention ... anyway ... you’ll need some way to get online with the processor through its Data Highway Plus communication port ... the classics don’t have a built-in RS-232 port like the newer “enhanced” models do ... so what communication hardware are you using? ... and do you already have RSLogix5 software? ...
but back to your question about the I/O modules ...
suggestion: a good way to learn ... put the processor in the RUN mode ... go to the output table and start turning on various bits by putting ones on the table ... watch the LED’s on the front of your output modules ... keeping turning bits on until something starts to light up ... try to figure out how the addressing scheme works ... idea: you don’t have to wire up anything to your output modules in order to play around ... the LED’s will turn off and on even if nothing is wired up ... exception: there are some older 120 volt modules with neon lamp indicators instead of LED’s ... these modules MUST have power wired up in order for the indicators to light up ...
again, make sure that the processor is in the RUN mode (note: the “classics” will not respond to active inputs unless the processor is in the RUN mode) ... next, wire up the correct voltage to a couple of inputs ... use the software to watch the input table while you cycle the inputs on and off ... hint: the LED’s on the front of the input module will cycle on and off if your wiring is correct ... find out which inputs correspond with the screws on the modules ...
going further ... do you have any analog modules to play with? ... if so, then someday in the future you WILL want to use the I/O Configuration feature to set up those particular modules ... if you post again, it would be a good idea to let us know what specific model numbers you have for your hardware ... the more information we have, the better the answers and the advice will be ...
best regards,
Ron
PS ... here is the correct book for a PLC-5/25:
User Manual for Classic PLC-5 Processors
based on the title of your first post, it looks like you’re using a PLC-5/25 ... and so ... as “unregistered” says, you do NOT need to tell the processor what type of I/O cards are in each slot ... just plug them in and start to play ...
and that brings up another thing ... if you do indeed have a PLC-5/25, then you have what is called a “classic” (as in older style) processor ... so the information that I gave you earlier about the DF1 driver in RSLinx is all wrong ... sorry ... I should have paid more attention ... anyway ... you’ll need some way to get online with the processor through its Data Highway Plus communication port ... the classics don’t have a built-in RS-232 port like the newer “enhanced” models do ... so what communication hardware are you using? ... and do you already have RSLogix5 software? ...
but back to your question about the I/O modules ...
suggestion: a good way to learn ... put the processor in the RUN mode ... go to the output table and start turning on various bits by putting ones on the table ... watch the LED’s on the front of your output modules ... keeping turning bits on until something starts to light up ... try to figure out how the addressing scheme works ... idea: you don’t have to wire up anything to your output modules in order to play around ... the LED’s will turn off and on even if nothing is wired up ... exception: there are some older 120 volt modules with neon lamp indicators instead of LED’s ... these modules MUST have power wired up in order for the indicators to light up ...
again, make sure that the processor is in the RUN mode (note: the “classics” will not respond to active inputs unless the processor is in the RUN mode) ... next, wire up the correct voltage to a couple of inputs ... use the software to watch the input table while you cycle the inputs on and off ... hint: the LED’s on the front of the input module will cycle on and off if your wiring is correct ... find out which inputs correspond with the screws on the modules ...
going further ... do you have any analog modules to play with? ... if so, then someday in the future you WILL want to use the I/O Configuration feature to set up those particular modules ... if you post again, it would be a good idea to let us know what specific model numbers you have for your hardware ... the more information we have, the better the answers and the advice will be ...
best regards,
Ron
PS ... here is the correct book for a PLC-5/25:
User Manual for Classic PLC-5 Processors
Ron,
I do have a copy of the RSLogix software, and was able to sucessfully go online with the processor. I was confused as to the following: when you refer to "output tables", what part of the program are you referring to? I scanned through the menus in RSLogix, but found nothing that seemed relevant.
I also have the older 120 VAC output modules, the ones with the neon lamps that I'm guessing are the same as the ones your referring to (re: having to wire them to get the light to come on). And I also have one of an analog output modules, so could you be so kind as to walk me through how to configure that (once again, I didn't see how to do that using the I/O configuration thing on RSLogix).
This is frustrating, but I'm slowly but surely making my way throught it...
As always, thanks for your help.
Joe
I do have a copy of the RSLogix software, and was able to sucessfully go online with the processor. I was confused as to the following: when you refer to "output tables", what part of the program are you referring to? I scanned through the menus in RSLogix, but found nothing that seemed relevant.
I also have the older 120 VAC output modules, the ones with the neon lamps that I'm guessing are the same as the ones your referring to (re: having to wire them to get the light to come on). And I also have one of an analog output modules, so could you be so kind as to walk me through how to configure that (once again, I didn't see how to do that using the I/O configuration thing on RSLogix).
This is frustrating, but I'm slowly but surely making my way throught it...
As always, thanks for your help.
Joe
Greetings, Joe,
the picture below shows the icons for the output table and the input table ... when you double-click the icon, the appropriate table pops up in a window ... now you can monitor the status of the input and output bits ...
in the picture, bit O:001/3 is highlighted ... this bit contains a 1 ... so the appropriate screw on an output module should be turned on ... notice that you can manually toggle these output bits on and off even WITHOUT a program (specifically: with NO RUNGS) in your processor ...
in the picture, bit I:000/6 is highlighted ... this bit contains a 1 ... so the appropriate screw on an input module is receiving a signal from an input in the field ...
about the analog card ... sorry ... no model numbers – no help ... there are literally dozens of different analog modules ... all with different set up requirements ... as I said before:
the picture below shows the icons for the output table and the input table ... when you double-click the icon, the appropriate table pops up in a window ... now you can monitor the status of the input and output bits ...
in the picture, bit O:001/3 is highlighted ... this bit contains a 1 ... so the appropriate screw on an output module should be turned on ... notice that you can manually toggle these output bits on and off even WITHOUT a program (specifically: with NO RUNGS) in your processor ...
in the picture, bit I:000/6 is highlighted ... this bit contains a 1 ... so the appropriate screw on an input module is receiving a signal from an input in the field ...
about the analog card ... sorry ... no model numbers – no help ... there are literally dozens of different analog modules ... all with different set up requirements ... as I said before:
| QUOTE |
| if you post again, it would be a good idea to let us know what specific model numbers you have for your hardware ... the more information we have, the better the answers and the advice will be ... |
let’s do this the easy way ... you tell us the model number (usually something like 1771-OFE2) printed on the side of the module ... also tell us exactly which slot the module is plugged into ... and also tell us which addressing mode (two-slot, one-slot, or half-slot) you’re using ... you can find the addressing mode on the Processor Status table (the “S2-Status” icon located just under the input table icon is one way to get there) ... once you get to the processor status window, click on the Switches tab ...
friendly advice: don’t worry about the analog module for right now ... you’ve got plenty to do for the next few weeks just learning how to move around through the software ... write a few “switches-buttons- timers-counters” type rungs first ... get your feet wet with the discrete (off/on) signals first ...
have fun ... play safe ...
best regards,
Ron
PS - I have no idea why the pictures I've been posting lately have all been "rough" around the edges ... maybe some administrator can tell me: is it something I'm doing wrong - or this "just the way it is" now? ... everything was neat and tidy a few months ago ... what's changed? ...
Ron,
Sorry about the model numbers. Here they are:
Analog Out (12-bit): 1771-OFE 1 B
120V AC Output: 1771-OA
120V AC Input: 1771-IAD B
1-slot addressing
Slots with 120 AC Out: 12
Slots with 120 AC In: 7,11
(assuming processor is in slot 1)
When I opened the screen showing the inputs and outputs, I had things showing up from I0... to I37... (same with outputs), but I obviously don't have 37 inputs and outputs. What is the deal with that?
Also, which ladder functions would I use to read/modify the data from those I/O modules?
As always, thanks for your time and patience.
- Joe
Sorry about the model numbers. Here they are:
Analog Out (12-bit): 1771-OFE 1 B
120V AC Output: 1771-OA
120V AC Input: 1771-IAD B
1-slot addressing
Slots with 120 AC Out: 12
Slots with 120 AC In: 7,11
(assuming processor is in slot 1)
When I opened the screen showing the inputs and outputs, I had things showing up from I0... to I37... (same with outputs), but I obviously don't have 37 inputs and outputs. What is the deal with that?
Also, which ladder functions would I use to read/modify the data from those I/O modules?
As always, thanks for your time and patience.
- Joe
Back to square one.
A co-worker accidently turned the power to the PLC off. At first, the only thing happening was that I couldn't get it to communicate properly. So I went back and did the things I'd mentioned in my 2nd post, and when I turned it back on, those dang PROC and REM I/O lights were back on. I don't know what it is about this thing, but it doesn't like me. All the DIP switches are in the right positions, as are the ones in the PLC processor. I've tried just about all combos of plugging things in in a specific order. Nothing seems to work. I just can't escape my fate. As always, any suggestions would be appreciated.
btw, the battery will be here tomorrow.
A co-worker accidently turned the power to the PLC off. At first, the only thing happening was that I couldn't get it to communicate properly. So I went back and did the things I'd mentioned in my 2nd post, and when I turned it back on, those dang PROC and REM I/O lights were back on. I don't know what it is about this thing, but it doesn't like me. All the DIP switches are in the right positions, as are the ones in the PLC processor. I've tried just about all combos of plugging things in in a specific order. Nothing seems to work. I just can't escape my fate. As always, any suggestions would be appreciated.
btw, the battery will be here tomorrow.
basic idea: the PLC's memory is sort of like the setting on your alarm clock ... if the house power fails, the time defaults back to zero (well, actually back to 12:00) ... UNLESS the clock has a good battery installed ... the battery allows the clock to keep on ticking until the house power comes back on ...
with the PLC, turning off the power will dump the memory ... UNLESS you have a good battery installed ... if the memory gets dumped, then you'll need to give the processor a name, and then put the program back in ...
the "fault" LED conditions you're describing are just the PLC's way of telling you that it has totally lost its mind and doesn't even remember its name anymore ... the battery should make everything a lot easier to deal with ...
with the PLC, turning off the power will dump the memory ... UNLESS you have a good battery installed ... if the memory gets dumped, then you'll need to give the processor a name, and then put the program back in ...
the "fault" LED conditions you're describing are just the PLC's way of telling you that it has totally lost its mind and doesn't even remember its name anymore ... the battery should make everything a lot easier to deal with ...
Greetings, Joe,
if I understand you correctly, this is your hardware layout listed below ... for simplicity, let’s “number” the slots in the chassis A through Q ... I’m assuming (gosh, I hate that word) that you have a 16 slot chassis (well, actually it has 17 slots – with the PLC-5 system, you don’t count the slot for the processor) ... so the slot at the far left of the chassis is our slot A ... the slot at the far right of the chassis is our slot Q ...
A = PLC-5/25 processor
B = empty
C = empty
D = empty
E = empty
F = empty
G = 1771-IAD/B 120VAC input module
H = empty
I = empty
J = empty
K = 1771-IAD/B 120VAC input module
L = 1771-OA 120VAC output module
M = empty
N = empty
O = empty
P = empty
Q = empty
so you haven’t installed the analog card yet? ... that’s ok ... but it really won’t hurt anything to go ahead and slide it into a slot ...
anyway ... if I’ve got the list above correct ... and if you're using one-slot addressing ... then:
the 8 bits on the output module will be numbered (octally) from O:012/0 through O:012/7 ...
the 16 bits on the first input module (our slot G) will be numbered (octally) from I:005/0 through I:005/17 ...
the 16 bits on the second input module (our slot K) will be numbered (octally) from I:011/0 through I:011/17 ...
so the picture below shows a VERY simple program using the first input module and the output module ... the basic idea is that a couple of inputs (example: switches) are used to control a couple of outputs (example: lamps) ...
go ahead ... wire something up ... let us know how it works ... if you need wiring diagrams, look here:
installation manual for input module
this is for a “C” series but it’s close enough for the wiring part ...
and here:
installation manual for output module
hope this helps,
Ron
if I understand you correctly, this is your hardware layout listed below ... for simplicity, let’s “number” the slots in the chassis A through Q ... I’m assuming (gosh, I hate that word) that you have a 16 slot chassis (well, actually it has 17 slots – with the PLC-5 system, you don’t count the slot for the processor) ... so the slot at the far left of the chassis is our slot A ... the slot at the far right of the chassis is our slot Q ...
A = PLC-5/25 processor
B = empty
C = empty
D = empty
E = empty
F = empty
G = 1771-IAD/B 120VAC input module
H = empty
I = empty
J = empty
K = 1771-IAD/B 120VAC input module
L = 1771-OA 120VAC output module
M = empty
N = empty
O = empty
P = empty
Q = empty
so you haven’t installed the analog card yet? ... that’s ok ... but it really won’t hurt anything to go ahead and slide it into a slot ...
anyway ... if I’ve got the list above correct ... and if you're using one-slot addressing ... then:
the 8 bits on the output module will be numbered (octally) from O:012/0 through O:012/7 ...
the 16 bits on the first input module (our slot G) will be numbered (octally) from I:005/0 through I:005/17 ...
the 16 bits on the second input module (our slot K) will be numbered (octally) from I:011/0 through I:011/17 ...
so the picture below shows a VERY simple program using the first input module and the output module ... the basic idea is that a couple of inputs (example: switches) are used to control a couple of outputs (example: lamps) ...
go ahead ... wire something up ... let us know how it works ... if you need wiring diagrams, look here:
installation manual for input module
this is for a “C” series but it’s close enough for the wiring part ...
and here:
installation manual for output module
hope this helps,
Ron
How much do you know about configuring the PCMK cards? I can't seem to get the communication to start sucessfully. I have a PCMK series A card and the matching cable. I think the problem is that I have multiple drivers installed and its conflicting the signal. Any tips on this matter would be greatly appreciated.
- Joe
- Joe
And the saga twists again...
After about 2 hours of struggling with it, rechecking connections and switches, configuring and reconfiguring drivers, I finally got the communication thing to work, which enabled me to clear the processor and remote I/O faults. Strange how it seems smoothly sometimes, and doesn't the next.
I guess this concludes this thread. I've got the darn thing running, communicating, and working, so I guess its onwards to programming and I/O.
Thanks for all your help Ron,
- Joe
P.S. Don't think your getting a break Ron. I'll have more questions ready in the immediate future.
After about 2 hours of struggling with it, rechecking connections and switches, configuring and reconfiguring drivers, I finally got the communication thing to work, which enabled me to clear the processor and remote I/O faults. Strange how it seems smoothly sometimes, and doesn't the next.
I guess this concludes this thread. I've got the darn thing running, communicating, and working, so I guess its onwards to programming and I/O.
Thanks for all your help Ron,
- Joe
P.S. Don't think your getting a break Ron. I'll have more questions ready in the immediate future.
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