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 500 system 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 2 Programmable Controller Machine Or Process Inputs Outputs 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 LEDs are discussed further in the sections specific to a module type. See next figure for slot addressing of the SLC 500. 3 I/O Address Address Type Slot Number Terminal Number 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. 4 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 5 SLC 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+ network and 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 will not 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. If the 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. 6 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: Normal Running State: 7 Indicates the LED is FLASHING Status of LED does not matter 1 The DH485 LED on the SLC 5/03 processor is labeled “DH+” on the SLC 5/04 processor RUN FLT BATT If the LEDs Indicate: No LEDs are Illuminated The Following Probable Cause Recommended Action Error Exists Verify proper line voltage and connections on the power terminals. No Line Power Verify proper 120/240V power supply jumper selection. Check the incoming power fuse, check for proper Power Supply incoming power connections. Replace fuse. Fuse Blown If fuse blows again, find out why fuse is blowing. Remove line power to power supply. Remove several output modules from the chassis. Wait five minutes. 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 Supply possible transient or shorting. Replace the power supply. 8 RUN FLT BATT If the LEDs Indicate: FLT LEDs is Illuminated The Following Probable Cause Recommended Action Error Exists Inadequate Improper Line Verify proper 120/240V power supply jumper System Power Power Voltage selection. Selection 9 RUN FLT BATT If the LEDs Indicate: POWER LED is Illuminated The Following Probable Cause Recommended Action Error Exists Verify selected processor mode. If the processor is in the Program/Test modes, attempt Either Improper Run mode entry: Mode Selected or - if keyswitch is in the REM position and there is no key, User Program use the programmer Logic - if keyswitch is in the REM or PROG position, and you 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 selection Line Power Out of and incoming power connections. Operating Range Monitor for proper line voltage at the incoming power connections. Processor Not in Improper Seating Remove power and inspect the power supply chassis Run Mode of Power Supply, connections and the processor chassis connections. 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, Power Supply, or Chassis Replace processor in another chassis not in the existing system. Apply power, reconfigure and attempt Run mode selection. If unsuccessful, replace processor. Try existing power supply in test chassis. If unsuccessful, replace power supply. If entry into the Run mode is allowed, replace the existing chassis. 10 RUN FLT BATT . 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. 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