-

Modicon
984 Student
Reference Guide
GJ-0001-000 Rev. D
GJ-0001-000 Rev. D

984 Student Reference Guide

 Preface

The information in this document is subject to change without notice

and should not be construed as a commitment by MODICON Inc.,
Industrial Automation Systems Group. MODICON Inc. assumes no
responsibility for any errors that may appear in this document. No part
of this document may be reproduced in any form without the express
written permission of MODICON Inc., Industrial Automation Systems
Group. All rights reserved.

The following are trademarks of MODICON Inc.:

MODICON 084 184

Micro 84 284 884
Compact 984 484 984
Modbus 584 P180
Modvue 384 P190
Modway

IBM is a registered trademark of International Business Machines, Inc.;

IBM PC is a trademark of International Business Machines, Inc.

Copyright 1992, MODICON Inc.

Printed in U. S. A.

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS i

ii TABLE OF CONTENTS 984 STUDENT REFERENCE GUIDE
 Table of Chapters

Chapter 1 Introduction to Programmable Control

Chapter 2 984 Controller and Remote I/O Processor Models

Chapter 3 800 Series Local and Remote I/O

Chapter 4 200 and 500 Series Remote I/O

Chapter 5 Input and Output Module Specifications

Chapter 6 System Level Configuration, Planning and Cabling

Chapter 7 984 Man-Machine Interfaces

Chapter 8 Software System Configuration

Chapter 9 Programming Ladder Logic

Chapter 10 Load, Record, Verify

Chapter 11 Ladder Lister

Chapter 12 Trouble shooting

Chapter 13 Compact 984 and Al 20 I/O

Appendix A Glossary

Appendix B Error Codes

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS iii

iv TABLE OF CONTENTS 984 STUDENT REFERENCE GUIDE
 Table of Contents

Title
Preface i
Table of Chapters iii
Table of Contents v

Chapter 1 Introduction To Programmable Control l-1

Numbering Systemsl-2
Decimal l-2
Binary 1-3
Binary Coded Decimal (BCD) l-3
Hexadecimal (Hex) 1-4
Number System Examples l-4
Controller Basics l-6
Processes Under Control l-8
Input/Sensing Devices l-9
Input Modules l-10
Controller l-1 3
Output Modules 1-14
Output/Working Devices l-1 7
Man-Machine Interface l-l 8
Introduction To Data Communications l-1 9
Information Structure 1-19
Serial Communications l-20
Modulated Serial Communication l-21
W-232-C l-22
Parallel Communications l-23

Chapter 2 984 Controller and Remote I/O Processor Models 2-l

984-380,984-381 and 984-385 2-2

Features 2-2
Controller Status Indicators 2-3
Controller Cartridges 2-4
MODBUS DIP Switch Configuration 2-5
984-480 and 984-485 2-6
Features 2-6
Controller Status Indicators 2-7
Controller Cartridges 2-8
MODBUS DIP Switch Configuration 2-9
984-680 and 984-685 2-10
Features 2-l 0
Controller Status Indicators 2-11
Controller Cartridges 2-12
MODBUS DIP Switch Configuration 2-13
Remote I/O Processor 2-14

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS v

984-780 and 984-785 2-18
Features 2-16
Controller Status Indicators 2-17
Controller Cartridges 2-18
MODBUS DIP Switch Configuration 2-19
Remote l/O Processors 2-20
Controller Housings for 984 Slot Mount Series 2-22
Back plane Connectors 2-23
Compact 984 - 120, 130 and 145 2-24
Features 2-24
Controller Status Indicators 2-25
Back plane for the Compact 984 2-26
The DTA Primary Back plane 2-26
DTA 201 and DTA 202 Secondary Back planes 2-27
Controller Option Modules for 984 Slot Mount Series 2-28
Hot-Standby Processor 2-28
984X 2-30
Features 2-30
Power Supply 2-31
Central Processing Unit 2-32
Multi-Option Processor 2-33
984A 2-34
Features 2-34
Power Supplies 2-35
Central Processing Unit 2-36
Memory Module 2-36
Remote I/O Processors 2-38
Communications Processor 2-40
9848 2-42
Features 2-42
Power Supplies 2-43
Central Processing Unit 2-44
Memory Module 2-44
Remote I/O Processors 2-46
Communications Processor 2-48
Controller Chassis for 984 A, B, and X 2-49
Controller Option Modules For 984 A, B, and X 2-50
Hot-Standby Processor 2-50
MODBUS II Communications Processor 2-52
Dual RS-232 Modem 2-54
Integrated Control Processor 2-56
Resident Instruction Sets for 984 Controllers 2-58
Standard Set for all 984 Controllers 2-58
Enhanced Set for 984 Slot Mount Series 2-59
Loadable Options for All Controllers 2-60
984 System Capabilities Table 2-61
 Chapter 3 Local and Remote 800 Series I/O 3-1

I/O Drop Overview 3-2

Local l/O 3-2
Remote I/O 3-3
Components Common to Local and Remote Drops 3-5
Controller Housings and Chassis 3-5
Secondary Housings 3-7
Auxiliary Power Supplies 3-8
Cables 3-16
Local Drop Configurations 3-17
984-380, 381, 385 Controller 3-17
984-480, 485 Controller 3-18
984-680, 685 Controller 3-19
984-780, 785 Controller 3-20
984X Controller 3-21
Local Drop Size Summary Matrix 3-22
Remote Drop Hardware for SSOS/S929 and S901 I/O
Processors 3-23
800 Series Remote l/O Drops 3-23
Remote l/O Interfaces for S908/929 Systems 3-25
J890/892 Interface 3-30
800 Series Remote I/O with the
S901 I/O Processor 3-35
J81 O/81 2 Interface 3-35
D908 Distributed Control Drop with 984-680 3-41
Distributed Control Drop 3-42
Remote Drop Configurations for S908/S929 I/O Processors 3-44
800 Series Drop 3-44
S908/S929 Drop Size Summary Matrix 3-46

Chapter 4 200 and 500 Series Remote I/O 4-1

P451/P453 Interface using 200 series I/O 4-2

P451 Interface Module 4-4
P453 Interface Module 4-7
P453 Power Supply/Interface for the
S908/S929 I/O Processor 4-11
P453 Power Supply/ Interface for the S901 I/O Processor 4-15
Auxiliary Power Supplies 4-21
Cables 4-22
200 Series I/O Drop - Summary 4-24
P451/P453 Interface using 500 Series I/O 4-25
500 Series I/O Housings 4-26
500 Series Word/Byte Organization 4-27
J540 Adapter 4-29
Interface Connections 4-30
Cables 4-32
500 Series I/O Drop - Summary 4-34

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS vii

 Chapter 5 Input and Output Module Specifications 5-1

800 Series Input/Output Module Overview 5-2

l/O Terminal Connectors 5-3
I/O Module Keying System 5-4
input Module Characteristics and Typical Set-up 5-6
Output Module Characteristics and Set-up 5-14
Input/Output Module Specifications 5-22
800 Series 5-22
200 Series5-26
500 Series 5-28
A120 (Compact 984) Series I/O Modules 5-30
DEP 208 Discrete Input Module 5-31
LED’s 5-31
DEP 208 Characteristics 5-32
DEP 209 Discrete Input Module 5-33
LED’s 5-33
DEP 209 Characteristics 5-34
DEP 216 Discrete Input Module 5-35
LED’s 5-35
DEP 216 Characteristics5-36
DE0 216 Discrete Input Module 5-37
LED’s 5-37
DE0 216 Characteristics5-38
DEP 220 Discrete Input Module 5-39
LED’s 5-39
DEP 220 Characteristics 5-40
DAP 204 Relay Output Module 5-41
LED’s 5-41
DAP 204 Characteristics 5-43
DAP 208 Relay Output Module 5-45
LED’s 5-45
DAP 208 Characteristics 5-47
DAP 209 Discrete Output Module 5-49
LED’s 5-49
DAP 209 Characteristics 5-50
DAP 216 Discrete Output Module 5-51
LED’s 5-51
Resetting the Module After an Overload or Short Circuit 5-52
Protecting the Module from Inductive Back EMF 5-53
DAP 216 Characteristics5-54
DAP 212 Combined I/O Module 5-55
LEDs 5-55
DAP 212 Characteristics 5-57
ADU 204 Analog Input Module 5-59
LED 5-60
Noise Suppression DIP Switch 5-60
Field Wiring 5-61
Calibrating the Analog Input Channels 5-61
ADU 204 Characteristics5-64
ADU 205 Analog Input Module 5-65
LED 5-65

viii TABLE OF CONTENTS 984 STUDENT REFERENCE GUIDE

 DIP Switch Settings 5-66
Field Wiring 5-66
Calibrating the Analog Input Channels 5-68
ADU 205 Characteristics 5-70
DAU 202 Analog Output Module 5-71
LEDs 5-71
Field Wiring 5-72
Calibrating the Analog Output Channels5-73
DAU 202 Characteristics 5-75

Chapter 6 System Level Configuration, Planning, and Cabling 6-1

System Cable Topologies 6-2

Standard Configurations 6-2
Hot Standby Configurations 6-5
Summary Of Legal Remote I/O Configurations 6-8
Illegal Remote I/O Configurations 6-9
Standard Distributed Control Configurations 6-10
Hot Standby Distributed Control Configurations 6-l 3
Summary of Distributed Configurations 6-16
Illegal Distributed l/O Configurations 6-18
Controller Selection 6-19
Controller Memory Usage 6-l 9
Controller Selection Considerations 6-21
984 System Capabilities Tables 6-22
984 Installation Planning 6-24
Controller Location 6-24
Power Sources 6-24
984 Environmental Considerations 6-26
Space Requirements 6-26
Panel Enclosures 6-28
984 PLC Mounting 6-31
Grounding and Shielding 6-34
Cable Installation and Planning 6-38
Cabling Requirements 6-38
Using a Cable Diagram 6-40
Cables, Taps, Splitters and Termination Components 6-44
Remote I/O Cable Selection 6-44
Cable Connectors and Terminators 6-48
Cable Fabrication 6-50
Recommended Tools 6-50

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS ix

 Chapter 7 984 Man-Machine Interfaces 7-l
PI90 Programmer 7-3
General Characteristics 7-3
Front Panel 7-4
Rear Panel 7-6
Cabling 7-9
Tapes 7-13
Personal Computer 7-16
Features 7-l 6
Specifications 7-16
Cabling 7-l 7
Keyboard 7-l 8
Floppy Disks/Part Numbers 7-19
Back Up Disks 7-20
Preparing to use Modicon Executive Software 7-20
964/965 Hand-Held Interfaces 7-21
Features 7-21
Operations7-21
Cabling 7-22
Keyboard 7-23
Software Label Keys 7-24
Alphanumeric Keys 7-24
Display Select Keys 7-24
Control Keys 7-25
Reference Operation Keys 7-25
ON/OFF Keys 7-25
P964 Menu 7-26
P964 Menu Selection Descriptions 7-27
P965 Menus 7-28
965 Menu Selection Descriptions 7-29
P965 MDAP Menu Selection Descriptions 7-31
Unsupported Communication Parameters 7-32
DEC PDP-11 and VAX 7-34
984/DEC PDP-11 7-34
984/DEC VAX 7-34

Chapter 8 Software System Configuration 8-1

Pl SO/Personal Computer Characteristics8-2

Modicon’s P190 Emulation Software for IBM Computers 8-2
Program Selection 8-2
Pl SO/PersonalComputer Softkeys 8-3
Pl SO/Personal Computer Keyboard Comparison 8-4
Configuration and Traffic Copping Software Overview8-5
System Operation 8-6
Dim Awareness and Battery Installation8-6
Configuration Program Features 8-7
Configuration Operations 8-7
Software Media and Part Numbers 8-8
Screen Configurationwith Softkey Menu 8-9

x TABLE OF CONTENTS 984 STUDENT REFERENCE GUIDE

 Use of Reference Numbers 8-l 1
State RAM 8-12
Segmentation and Scheduling of Logic Networks 8-l 4
Move Segment Procedure 8-l 5
Configuration Procedure 8-l 6
Configuration Example 8-l 8
Configuration Menu Tree x984 CONFIG> 8-34
Configuration Menu Tree <984 ATTACH> 8-35
ATTACH UNIT # 8-37
Traffic Cop Program Features 8-38
Pl SO/Personal Computer Software 8-38
Traffic Cop Procedure 8-40
S908 Traffic Cop Example 8-42
Traffic Copping a Standard Drop 8-42
Traffic Copping a Distributed Control Drop 8-54
Traffic Copping a J29O/J291 I/O Drop 8-56
S908 Traffic Cop Menu Tree 8-62
ATTACH UNIT # 8-63
RELEASE 984 8-63
S901 Traffic Cop Example 8-64
Traffic Copping a Standard Drop 8-66
S901 Traffic Cop Menu Tree 8-72
ATTACH UNIT # 8-73
RELEASE 984 8-73

Chapter 9 Programming Ladder Logic 9-l

Programmer Tape/disc 9-2

Features 9-2
Functions 9-2
Operations 9-2
Battery Backup 9-3
Pre-Programming information 9-4
Overview 9-4
984 Set Up 9-4
Reference Numbers 9-6
OXXXX: Coil or Discrete Output 9-6
1xXxX: Discrete Input 9-6
3XXXX: Input Register 9-6
4XXXX: Output Register or Holding Register 9-6
GXXXX: Extended Memory Register 1-6
984 Ladder Logic Elements 9-7
Network Structure 9-8
Logic Solving Sequence 9-9
Element Positional RelationshipsS-10
Programming Information 9-l 2
Program Tape Screens 9-12
Alternate or Reference Screen 9-14
Main Loop Sequence 9-l 5
Background Diagnostics 9-27
Hints to Minimize Scan Time 9-27

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS xi

 P190 Keyboard Functions 9-28
Discrete Traffic Cop Numbers 9-30
Programming Elements 9-31
Relay Contacts 9-31
Transitional Contacts 9-33
Vertical and Horizontal Shorts 9-34
Coils 9-35
Duplication of Programmed Output Reference 9-37
Programming Functions 9-38
Timers 9-38
Counters 9-40
Calculates 9-42
Data Transfer (DX) Move Functions 9-50
Extended Memory Write 9-71
Subroutine Functions - Models 984 - x8x Only9-76
Data Transfer (DX) Matrix Functions Overview 9-81
Special Instructions 9-99
Simple ASCII 9-106
Simple ASCII Overview 9-106
Simple ASCII Configuration g-107
Simple ASCII Screen 9-108
Simple ASCII Message 9-109
Editing 9-114
Function Blocks 9-l 14
Networks 9-114
984 Optimize vs Run Modes 9-118
Programming Menu Tree 9-119
984 Programmer Tape (Reset Level) 9-119
984 Programmer Tape (Exit Level) 9-120
984 Programmer Tape (Exit Level) 9-121

Chapter 10 Load, Record, Verify 10-l

LRV Disk And Tape Loader Tape 10-3

Features 1O-3
LRV Examples 1 o-4
LRV Menu Tree 10-12

Chapter 11 Ladder Lister 11-l

Ladder Lister Floppy Disk and Utility Tape 11-2

Features 1 l-2
Ladder Lister Examples 1 l-2
Ladder Lister Menu Tree 11-8

xii TABLE OF CONTENTS 984 STUDENT REFERENCE GUIDE

 Chapter 12 Trouble shooting 12-I

Introduction 12-3
Tools, Equipment, and the Trouble shooting Process 12-4
Types of Faults 12-4
Isolating Faults 12-5
Flow Charts l-6
Monitoring System Status 12-7
Trouble shooting Flow Chart 12-8
Flow Chart Procedures 12-I 0
The 984/S908 STAT Block 12-16
The S908 STAT Block 12-l 6
System Mainframe Status 12-20
l/O Module Health Status 12-23
Drop Communication Status 12-25
STAT Block Applications 12-32
l/O Module Health Status Application 12-32
Communication Status 12-35
PI90 or Personal Computer
Direct Access to S908 STAT Data 12-38
Procedure for Retrieving 984
Register Information Using the PI90 12-38
P965 Direct Access to S908 STAT Data 12-40
Procedure for Retrieving 984 Register
Information Using the P965 12-40
The 984/S901 STAT Block 12-42
The S901 STAT Block 12-42
Controller Status 12-46
l/O Module Health Status 12-49
Remote l/O Communication Status 12-50
PI90 or Personal Computer Direct
Access to S901 STAT Data 12-51
Procedure for Retrieving 984 Register Information Using the
PI90 12-53
P965 Direct Access to S901 STAT Data 12-54
Procedure for Retrieving 984 Register Information Using the
P965 12-55
Replacement Parts and Technical Support 12-56

Chapter Thirteen Compact 984 Controllers and Al20 I/O 13-I

General Overview 13-2

Special Features of the Compact 984 13-4
CPU User Memory Options 13-4
Auxiliary Memory Upload-Download Capabilities 13-6
Slide Switches 13-7
Modbus Communication Interface 13-7
LED Indicators 13-8
Al 20 I/O Support 13-9
Power Supplies 13-l 1

984 STUDENT REFERENCE GUIDE TABLE OF CONTENTS xiii

 I/O Housings and Drop Configurations 13-13
DTA Back planes 13-13
Drop Layout 13-15
Modbus Plus Hardware on the Compact 984-145 13-18
The MB Plus LED 13-19
The comm parameter slide switch 13-19
Modbus Plus Addressing DIP Switch 13-19

Appendix A Glossary

Appendix B Error Codes

xiv TABLE OF CONTENTS