Modicon 984 Programmable Controller Systems Manual GM--0984--SYS Rev. B May, 1991 MODICON, Inc., Industrial Automation Systems One High Street North Andover, Massachusetts 01845 DOK- 1 2 DOK- Table of Contents Chapter 1 The 984 Programmable Controllers.......... 1 Modicon’s Family of Programmable Controllers....................... 2 The 984 Family............................................... 2 Controller Compatibility.......................................... 3 984 Controller Performance and Capacity Characteristics.............. 4 How a 984 System Provides Application Control....................... 6 The 984 Control Architecture: An Overview......................... 6 Reliability and Maintainability..................................... 7 P190-Style Panel Software Support................................. 8 Standard Panel Software Editors.................................. 8 Special Loadable Software....................................... 9 MODSOFT Panel Software Support................................ 10 Sequential Function Charts...................................... 10 MODSOFT Macros............................................. 11 MODSOFT Operating Modes.................................... 11 Overview of the 984 Instruction Set................................. 12 Chapter 2 Optional and Peripheral Control Devices... 15 Programming Panels............................................. 16 The P230.............................................. 16 The P190 Panels.............................................. 17 Using Industry-standard PCs as Programming Panels............... 17 The P965 Data Access Panel...................................... 18 Physical Design.............................................. 18 How the P965 Can Be Used..................................... 19 The Hot Standby Option Modules.................................. 20 How a Hot Standby System Functions............................ 20 Controller Compatibilities........................................ 20 The Coprocessing Option Modules................................. 22 The C986 Copro for Chassis Mount 984s.......................... 22 The C996 Copros for Slot Mount 984s............................ 23 Enhancing Your Processing Environment with a Copro................ 24 Application Mode.............................................. 24 Immediate DX Processing....................................... 24 Deferred DX Processing........................................ 25 Optional Communication Modules.................................. 26 GM--0984--SYS Table of Contents v Modbus Modems.............................................. 26 Modbus II Modules............................................. 26 The Modbus Plus Options....................................... 27 The Distributed Communications Option........................... 27 Chapter 3 984 I/O Subsystems...................... 29 I/O Subsystems................................................ 30 Input and Output Modules....................................... 30 I/O Module Types.............................................. 30 Local and Remote I/O........................................... 31 Local I/O................................................ 32 Remote I/O................................................ 33 Remote I/O Drop Interfaces...................................... 33 ASCII Communication at the Remote I/O Drops...................... 34 RIO Interfaces that Support ASCII Communication.................. 34 ASCII Device Programming...................................... 34 The ASCII Operator Keypad..................................... 35 Overview of I/O Support for 984 Controllers.......................... 36 800 Series I/O Modules........................................... 37 800 Series Discrete Input Modules............................... 37 800 Series Discrete Output Modules.............................. 37 800 Series Analog Input Modules................................. 38 800 Series Analog Output Modules............................... 38 800 Series Special Purpose I/O Modules.......................... 39 800 Series Intelligent I/O Modules................................ 40 800 Series MMI Operator Panels................................. 40 Power Supplies for Local and Remote 800 Series I/O Drops........... 41 200 Series I/O Modules........................................... 42 200 Series Discrete Input Modules............................... 42 200 Series Discrete Output Modules.............................. 42 200 Series Analog Input Modules................................. 43 200 Series Analog Output Modules............................... 43 200 Series Special Purpose I/O Modules.......................... 43 500 Series I/O Modules........................................... 44 500 Series Discrete Input Modules............................... 44 500 Series Discrete Output Modules.............................. 44 500 Series Special Purpose I/O Modules.......................... 45 A120 Series I/O Modules.......................................... 46 A120 Discrete Input Modules.................................... 46 A120 Discrete Output Modules................................... 46 A120 Combo Modules.......................................... 46 A120 Analog Input Modules..................................... 47 A120 Analog Output Module..................................... 47 vi Table of Contents GM--0984--SYS A120 Special Purpose Module................................... 47 300 Series I/O Modules........................................... 48 300 Series Discrete Input Modules............................... 48 300 Series Discrete Output Modules.............................. 48 300 Series Analog I/O Modules.................................. 49 300 Series BCD Register I/O Modules............................ 49 Chapter 4 984 Communications Capabilities......... 51 Modbus Capabilities.............................................. 52 The Modbus Port Parameters.................................... 52 Modbus Port Pinouts for the P230 Programming Panel................ 54 Modbus Port Pinouts for the P190 Programming Panel................ 55 Modbus Port Pinouts for an IBM-XT................................ 56 Modbus Port Pinouts for a Modicon Comm Modem................... 57 A Modbus Network............................................... 58 Network Capacity.............................................. 58 Communication Media.......................................... 58 Communication Parameters..................................... 58 A Modbus Plus Network........................................... 60 Network Capacity.............................................. 60 The Logical Network............................................ 61 The Physical Network........................................... 61 Adding and Deleting Nodes from the Network...................... 61 Joining Modbus Plus Networks..................................... 62 A Modbus II Network............................................. 64 Modbus II Software............................................. 64 Distributed Control Processing..................................... 66 Distributed Control Applications.................................. 67 Network Topology Overview....................................... 68 Chapter 5 984 Memory Allocation................... 71 User Memory................................................ 72 System Overhead.............................................. 72 User Logic.............................................. 73 User Memory Storage.......................................... 73 State RAM Values................................................ 74 A Referencing System for Inputs and Outputs...................... 74 How Discrete and Register Data Are Stored in State RAM........... 75 State RAM Structure.............................................. 76 The Required Minimum State RAM Values........................ 77 GM--0984--SYS Table of Contents vii Storing History and Disable Bits for Discrete Values................. 77 The Configuration Table........................................... 78 Assigning a Battery Coil......................................... 79 Assigning a Timer Register...................................... 79 TheTimeofDayClock.......................................... 79 TheTrafficCopTable............................................. 82 Determining the Size of the Traffic Cop Table...................... 82 Writing Data to the Traffic Cop Table.............................. 82 Chapter 6 984 Opcode Assignments................. 83 Translating Ladder Logic Elements in the System Memory Database.... 84 Translating Logic Elements and Non-DX Functions................. 84 Translating DX Functions in the System Memory Database............ 86 How the x and z Bits Are Used in 16 Bit Nodes..................... 86 How the x and z Bits Are Used in 24 Bit Nodes..................... 87 How the y Bits are Utilized for DX Functions....................... 89 Opcode Assignments for Other Functions........................... 90 How to Handle Opcode Conflicts................................. 91 Extra Opcodes Available in 24 Bit CPUs............................ 92 Chapter 7 Ladder Logic Overview................... 95 The Structure of Ladder Logic..................................... 96 Ladder Logic Segments......................................... 96 Ladder Logic Networks......................................... 96 Ladder Logic Elements and Standard Instructions.................... 98 Additional Ladder Logic Instructions..............................