Basic training for the allen bradley SLC 500

Table of ContentsBefore You Begin...2 Chassis...2 Understanding Addressing of the SLC 500...3 Modular Installation Procedure...4 Modules...5 Processor...5 Description of LEDs on the Proc

Table of Contents

Before You Begin 2

Chassis 2

Understanding Addressing of the SLC 500 3

Modular Installation Procedure 4

Modules 5

Processor 5

Description of LEDs on the Processor 5

Troubleshooting the SLC 5/03 and SLC 5/04 Processors 6

Discrete Input Module 17

Specifications 18

Wiring Diagrams 19

Troubleshooting Your Input Module 20

Relay Output Module 21

Specifications 22

Wiring Diagrams 23

Troubleshooting Your Output Module 24

Analog Input Module 25

Hardware Features 25

Module Installation and Removal 25

DIP Switch Settings to Select Voltage or Current Input 26

Terminal Wiring 27

Module Diagnostics and Troubleshooting 29

Module Operation vs Channel Operation 29

Power-up Diagnostics 29

Channel Diagnostics 29

LED Indicators 29

Channel Configuration 32

Channel Data Word 34

Troubleshooting Flowchart 36

Replacement Parts 37

Thermocouple Input 37

Hardware Features 37

Selecting a Rack Slot 39

Modular Installation Procedure 39

Wiring the Module 40

Module and Channel Diagnostics 41

LED Indicators 42

Channel Configuration Word 44

Troubleshooting Flowchart 50

Troubleshooting Technique 51

Preventive Maintenance 53

1

Basic Training for the Allen Bradley SLC 500

What You Will Learn After completing this lesson, you will be able to recognize and identify the components

of a SLC 500 system You will have a solid understanding of the purpose of the SLC 500system and have the ability to confidently identify and solve most errors

Before You Begin Programmable Logic Controller (PLC) or Small Logic Controller (SLC)

A programmable controller is a solid-state control system with a user-programmable memory that reads input conditions and sets outputs conditions to control a machine or process

Chassis A chassis is the carriage that houses the individual modules of a SLC 500 system

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ProgrammableController

MachineOrProcess

Understanding Addressing of the SLC 500

DO-3/0

Based upon the above information you would be able to locate physically where the point

is located For example, in the above example, DO-3/0, would translate to an address

type of Discrete Output (DO), slot 3, terminal 0 To locate that physical point you would

locate the third slot of the SLC 500 Chassis and find terminal point 0 by opening the door

of the card Also, there is a LED on the face of the module that will allow you to understand what is happening to that specific point based upon the real world The LEDsare discussed further in the sections specific to a module type See next figure for slot addressing of the SLC 500

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I/O AddressAddress

Modular Installation Procedure

1 Align the circuit board of the module with the card guides located at the top and bottom of the chassis

2 Slide the module into the chassis until both top and bottom retaining clips are secured Apply firm even pressure on the module to attach it to its backplane connector Never force the module into its slot

3 Cover all unused slots with the Card Slot Filler, Catalog Number 1746-N2

Attention: Never install, remove, or wire modules with power applied to the chassis or devices wired to the module.

Module Removal Procedure

1 Press the release at the top and bottom of the module and slide the module out of the chassis slot

2 Cover all unused slots with the Card Slot Filler, Catalog Number 1746-N2

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Attention: Never install, remove, or wire modules with power applied to the chassis or devices wired to the module.

Modules There are many different modules that are available for the SLC 500 and they range from

processors to communication However, the primary modules that are used on a typical screw compressor are as listed:

- 5/03 Processor

- Discrete Input Module

- Relay Output Module

- Analog Input Module

- Thermocouple Input Module

Processor

The processor is the CPU (Central Processing Unit) of the SLC 500 The 5/03 processor has six (6) LED’s located on the face of the module There are two rows of LED’s and beside each LED there is a description to help the operator to understand the status of the processor

Description of LEDs on the Processor

RUN Run Mode is when the processor is running and performing the tasks that is has

been programmed to perform This is indicated by the illumination of a green LED beside the word RUN If this LED is not illuminated then the processor has stopped and is not ready for operation To return the processor to the run mode a key is inserted into the key switch located on the face of the processor

By switching the key to the RUN position, this will place the processor back into the run mode and that is indicated by the illumination of the green LED However, if the green LED is not illuminated once the key has been place in the run position, look to see if there are other LEDs illuminated and this help to pinpoint the problem with the processor

FLT Fault (FLT) is illuminated when the processor has occurred an internal

executable problem The operator at this point can insert the key into the key switch located on the face of the processor and switch the key to the PROG position and then back to the RUN position This should clear the fault LED

5SLC 500

5/03 Processor

and return the processor back to the run mode However, if it does not an operator with the proper software must be notified and he/she must clear the fault.

BATT Battery (BATT) is illuminated when the processor’s battery is failing and this

battery must be replaced Without this battery, if power is lost to the panel then the program will be lost as well It is important that this battery is replace once the light is illuminated or once every three (3) years

Force Force is illuminated when a programmer has forced some specific values or

condition internal to the processor As an operator there is nothing you can do

to clear this LED without the software package

DH+ Data Highway + (DH+) is illuminated only when the processor has been

configured and placed on a DH+ network If the processor is on a DH+ networkand operating properly this LED will blink when data is being transferred and received However, if the processor is not on a DH+ network then this LED willnot be illuminated

RS232 RS232 is illuminated only when the processor has been configured and placed

on a RS232 network If the processor is on a RS232 network and operating properly this LED will blink when data is being transferred and received However, if the processor is not on a RS232 network then this LED will not be illuminated

The key switch located on the face of the processor has three(3) positions, RUN, REM and PROG The RUN position will place the processor in the run mode In the run mode, the processor will perform the tasks that it was programmed to perform The REM(remote) position will allow a programmer the ability to switch the processor from run to program or from program to run via the software The PROG (program) position will stop the processor from executing and allow the programmer to make changes to the software

Troubleshooting the Between the time you apply power to the SLC 5/03 and 5/04 processors

SLC 5/03 and SLC 5/04 and have a chance to establish communication with a connected

Processors programming device, the only form of communication between you and the SLC 5/03

and SLC 5/04 processors is through the LED display

When power is applied, all the LEDs flash on and then off while the processor conducts hardware tests This is a part of the normal power-up sequence Following the self test

by the processor, all the LEDs again flash on momentarily If a user program is in a running state, the RUN LED will be on If a fault exists within the processor, the FLT LED is on

Clearing SLC 5/03 and SLC 5/04 Processor Faults Using the Keyswitch

Toggle the keyswitch from RUN to PROG and then back to RUN; this clears the fault Ifthe keyswitch is left in the RUN position, the processor mode cannot be changed from a programmer/operator interface device If you return the keyswitch to the REM position, you can then use a programmer/operator interface device to change the processor mode

ATTENTION: If you clear a processor fault using the keyswitch, the processor will

immediately enter the Run mode.

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Identifying SLC 5/03 and SLC 5/04 Processor Errors

The following LEDs and tables provide you with information regarding error messages, possible cause(s) for the error, and recommended action to take to resolve the error.Refer to the following key to determine the status of the LED indicators:

If the LEDs Indicate:

No LEDs are Illuminated

If fuse blows again, find out why fuse is blowing

Remove line power to power supply Removeseveral output modules from the chassis Wait fiveminutes Reapply power

Inadequate

System Power Power Supply If condition reoccur, re-calculate module configuration

Overloaded power required and verify proper power supply

selection

This problem can occur intermittently if power supply

is overloaded when output loading and temperature varies

Recheck other probable causes

Defective Power Monitor the line power to chassis power supply for

Replace the power supply

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RUN FLT BATT

If the LEDs Indicate:

FLT LEDs is Illuminated

Error Exists

Inadequate Improper Line Verify proper 120/240V power supply jumper

Selection

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RUN FLT BATT

If the LEDs Indicate:

POWER LED is Illuminated

Error Exists

Verify selected processor mode

If the processor is in the Program/Test modes, attempt

Mode Selected or - if keyswitch is in the REM position and there is no key,

have the key, toggle to the Run position.

If in the suspend mode, check user program logic for suspend instructions

Check proper 120/240V power supply jumper selectionLine Power Out of and incoming power connections

Operating Range

Monitor for proper line voltage at the incoming powerconnections

Processor Not in Improper Seating Remove power and inspect the power supply chassis

and/or Processor

in the Chassis Re-install the devices and re-apply power

Attempt Run mode selection of Processor in existing chassis:

- if keyswitch is in the REM position and there is no key, use the programmer

- if keyswitch is in the REM or PROG position, and you

Defective have the key, toggle to the Run position.

Processor, PowerSupply, or Chassis Replace processor in another chassis not in the existing

system Apply power, reconfigure and attempt Runmode selection If unsuccessful, replace processor

Try existing power supply in test chassis If unsuccessful, replace power supply If entry into theRun mode is allowed, replace the existing chassis

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RUN FLT BATT

If the LEDs Indicate:

POWER and RUN LED is Illuminated

Error Exists

Monitor logic in Run mode and verify System User Program desired I/O status

Inoperable, Logic Error

Faults Defective I/O Test inputs and outputs according to I/O

Detected Devices or I/O trouble shooting procedures

Wiring

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RUN FLT BATT

If the LEDs Indicate:

POWER and FLT LED is Illuminated

Faulty Memory Re-install the processor and re-apply power to the

If steady FLT LED changes to flashing, replace the existing memory module with a replacement

Place the processor in another chassis not in the existing system and cycle power If steady FLT LEDreappears, replace the processor

Faulty CPU/Power

Supply If FLT LED clears, monitor the line power going to the

power supply in existing system

Replace existing system power supply if the line power checks OK

Processor If upgrading the processor to a different firmware level,

Firmware Installed verify firmware chip orientation matches the upgrade

Incorrectly kit directions

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RUN FLT BATT

If the LEDs Indicate:

POWER LED is Illuminated and FLT LED is flashing

Error Exists

Use programmer to monitor and clear the fault (or if keyswitch in REM):

Hardware/ - Monitor Status File Word S:6 for major error code

Software Major - Remove hardware/software condition causing fault

Fault Detected - Clear status file S:1/13 major error bits, if set

- Clear status file S:5 minor error bits, if set

CPU Major Erratic repetitive - Clear status file S:6 major error code (optional)

can cause a CPU If unsuccessful, repeat recommended action stpes above

major hardwarefault Use keyswitch to clear the fault Toggle the keyswitch

to PROG and back to Run If fault occurs again, use programmer to get error code and determine the source

of problem

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RUN FLT BATT

If the LEDs Indicate:

POWER, RUN, and FORCE LED is Illuminated

Error Exists

System does User Forced I/O Monitor program file online and identify forced I/O

not operate per Disabling

ladder logic Operation Disable appropriate forces and test system conditions again

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RUN FLT BATT

If the LEDs Indicate:

POWER and RUN is Illuminated and FORCE is Flashing

Error Exists

Monitor program file online and identify programmed

not operate per forces are not

steady

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RUN FLT BATT

If the LEDs Indicate:

POWER and BATT is Illuminated and FLT is Flashing

Error Exists

Verify lithium battery is connected to the processr

Error with Low during Power Replace the battery if you want the RAM back-up

or No Battery Down Period

steps

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RUN FLT BATT

Discrete Input Module

A Discrete Input Module responds to a 15-30VDC signal in the following manner:

1 Input filtering limits the effect of voltage transients caused by contact bounce and/or electrical noise

2 Optical isolation shields backplane circuits and module logic circuits from possible damage due to electrical transients

3 Logic circuits process the signal

4 An input LED turns on or off indicating the status of the corresponding input device

INPUT

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InputFiltering IsolationOptical CircuitsLogic Backplane

LED

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Troubleshooting your Input Module

Your input device will not Device is shorted Verify device operation

On/Closed/ Input circuit is Verify proper wiring Try other inputActivated Your program operates as damaged circuit Replace Module

though it is off Input is forced off Check the FORCED I/O or FORCE LED

in program on processor and remove forces

leakage current Check device and input circuitYour program operates as exceeds input circuit specifications Use load resistor to Off/Open/ though it is on and/or the specification bleed-off current

Deactivated input circuit will not turn off Input device is shorted Verify device operation

or damaged Replace device

Input circuit is Verify proper wiring Try other inputdamaged circuit Replace Module

Input circuit is Check specifications and sink/sourceincompatible compatibiliyt (is DC input)

Low voltage across Check the voltage across input circuitthe input and check source voltage

On/Closed/ Your program operates as Incorrect wiring or an Check wiring and Common Activated though it is off and/or the open circuit connections

input circuit will not turn on Input signal turn on

time too fast for input Check timing specifications

circuit

damaged circuit Replace module

Your input device will not Input device is shorted Verify operation Replace device

Check processor FORCED I/O orOff/Open/ Input is forced on in FORCE LED and remove forces VerifyDeactivated Your program operates as program proper wiring Try other input circuit

Input circuit is Verify proper wiring Try other inputdamaged circuit Replace module

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Relay Output Module

(1746-OW16)

A Relay Output Module controls the output signal in the following manner:

1 Logic circuits determine the output status

2 An output LED indicates the status of the output signal

3 Optical isolation separates module logic and backplane circuits from the field signal

4 The output driver turns the corresponding output on or off

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OutputDrivers

OpticalIsolation

LogicCircuitsBackplane

LED

OUTPUT

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Troubleshooting your Output Module

If your Output And your Output And Probable Recommended Action

Check for duplicate outputs addresses using the search function.

If using subroutines, outputs are left in their last state when not executing subroutines.

Programming problem.

Your program Use the force function to force output off If indicates that the this does not force the output off, output On/Energized output circuit is off circuit is damaged If the output does force

or the output circuit off then check again for logic/programming will not turn off problem.

Output is forced on in Check processor FORCE I/O or FORCE LED

Use the force function to force output off If this forces the output off, then there is a logic/ Output circuit is damaged programming problem If this does not force

the output off, the output circuit is damaged Try other output circuit Replace module.

Low or no voltage across Measure the source voltage and check the load specifications.

Your output device Incorrect wiring or open Check wiring and Common connections.

Off/De-energized will not turn on and circuit.

the program indicates Output device is Check specifications and sink/source that it is on incompatible compatibility (if DC output).

Output circuit is damaged Check wiring Try other output circuit

Replace module.

Output device is incompatible Check specifications.

Output circuit Off-state leakage Check specifications Use load resistor to current may exceed output bleed off leakage current See output Your output device device specifications specifications.

On/Energized will not turn off and

the program indicates Incorrect wiring Check wiring Disconnect from SLC 500 and that it is off verify device operation.

Output device is sorted or Verify device operation.

damaged Replace module.

Output device is damaged Check wiring Try other output circuit.

or the output circuit on then check again for logic/programming will not turn on problem.

Output is forced off in Check processor FORCE I/O or FORCE LED program and remove forces.

Use the force function to force output on If this forces the output on, then there is a logic/ Output circuit is damaged programming problem If this does not force

the output on, the output circuit is damaged Try other output circuit Replace module.

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Analog Input Module The module receives and stores digitally converted analog data into its

(1746-NI8) image table for retrieval by all fixed and modular SLC 500 processors

The module supports connections from any combination of up to eight voltage or current analog signals The 8 high-impedance input channels can be wired as either single-ended or differential inputs Each input channel also provides open-circuit, out-of-range, and invalidconfiguration indication via the LEDs

Hardware Features The module fits into any slot, except the processor slot (0) The

module contains a removable terminal block providing connection for eight analog input channels There are no output channels on the module Module configuration is done via the user program There areDIP switches on the circuit board for selecting voltage or current input

Module Installation and When installing the module in a chassis, it is not necessary to remove

Removal the terminal block from the module However, if the terminal block is

removed, use the write-on label located on the side of the terminal block to identify the module location and type

Label on Terminal Block:

MODULE

Attention: Never install, remove, or wire modules with power applied to the chassis or devices wired to the module.

To remove the terminal block:

1 Loosen the two terminal block release screws

2 Grasp the terminal block at the top and bottom and pull outward and down

TerminalBlock ReleaseScrews

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DIP Switch Settings to Select Voltage or Current Input

Select between voltage and current inputs before installing the module

in the chassis Use the DIP switches on the module circuit board The switch settings are OFF=Voltage Input and ON=Current Input Do thisfor channels 0-7

Modular Installation Procedure

1 Align the circuit board of the analog input module with the card guides located at the top and bottom of the chassis

2 Slide the module into the chassis until both top and bottom retaining clips are secured Apply firm even pressure on the module to attach it to its backplane connector Never force the module into its slot

3 Cover all unused slots with the Card Slot Filler, Catalog Number 1746-N2

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