Archives

Backup System Overview
System Composition: Consists of two identical hardware components, including the PLC-5 Processor Module, 1785-BCM Module, 1785-BEM Module (optional), power supply and local chassis. Suitable for a variety of PLC-5 processor models, such as 1785-L11B, 1785-L20B, etc.
Operating Principle: One system serves as the primary system to control the remote I/O and the other serves as the backup system. During normal operation, the primary system sends remote input and data table data to the standby system via HSSL. In case of failure, the standby system takes over control within 50 ms to ensure continuous operation.
Module Functions: 1785-BCM module realises high-speed communication between main and backup processors, provides 4K word buffer, automatic transmission of remote inputs and block transmission of read values, remote programming capability, etc. 1785-BEM module is used to extend the backup channel and is suitable for PLC-5/40, PLC-5/60 and other processors.

Hardware Components
1785-BCM Module: with status indicators, 1771-WG wiring arm, multiple communication link ports, customer relays and switch assemblies, etc. Communication links include HSSL, Data Highway Plus, and Remote I/O. Switch assemblies are used to configure communication modes, etc.
1785-BEM Module: Includes status indicators, 1771-WG wiring arm, two communication ports, customer relays, and switch assemblies. Works in conjunction with the 1785-BCM module to extend the backup capabilities of the processor’s communication channels.

Installation Steps
Determine power requirements: Calculate current requirements based on module and processor type and select an appropriate power supply, such as the 1771-P4S. Separate power supplies are required for the primary and backup processors and are connected to different power sources.
Setting Switches: Set the I/O chassis switches, 1785-BCM module switches for configuring communication modes, etc., and 1785-BEM module switches for setting channel configurations.
Installation and Connections: Insert the module into the specific slot in the I/O chassis and connect communication links such as HSSL, Remote I/O and Data Highway Plus networks, taking care to use the correct cables and terminating resistors when connecting.

System Operation
Data Transfer: Remote input data is transferred automatically via HSSL and data table data is transferred via Block Transfer Commands (BTR and BTW). The transfer process involves system status words, block identifiers, etc., and requires attention to the relevant settings during programming.
System startup and operation: When starting up the system, first supply power to the main system, load the programme and test it, then supply power to the backup system and test it, and finally switch the processor to RUN mode. During operation, it is necessary to pay attention to mode switching, editing and programming.

Programming and Diagnosis
Programming Methods: There are two programming methods, one is to transfer one data block at a time and the other is to transfer multiple data blocks at a time. Different methods are applicable to different scenarios, and the behaviour and effects of multiple commands should be considered when programming.
Troubleshooting: Faults are diagnosed through the status indicators and bits of the system status word of the 1785-BCM module. Different indicator statuses and bit values indicate different fault types, which can be handled accordingly.
Reference Information and Sample Programs: The appendices provide answers to frequently asked questions, data transfer time formulas, and sample programs. The sample program shows the concrete implementation of the two programming methods, which helps understanding and application.

Performance Advantages
High-speed communication capability: The high-speed serial link (HSSL) of the 1785-BCM module supports high-speed data transmission between the main and backup processors at a rate of up to 1.2 Megabaud, which can quickly synchronise remote input data and data table data to ensure system real-time performance. In industrial production lines, where equipment operation data changes in real time, the HSSL can transmit data from the main system to the standby system in a timely manner, allowing the standby system to respond quickly and take over control, reducing the risk of system failure due to data transmission delays. The module can execute block transfer commands, and the block transfer queuing mechanism of the PLC-5 processor allows multiple block transfer operations to be performed within the same programme scan, thus improving the data transfer efficiency. For example, in a complex control system with a large amount of data, it can quickly complete the transmission and processing of a large amount of data to meet the system’s requirements for data processing speed.

Reliable backup mechanism: The backup system can be quickly switched over when the main system fails, with a switchover time of less than 50 ms, and the remote I/O outputs remain in their final state during the switchover, reducing the impact on the production process. In industries such as chemical production where continuity is critical, this fast and reliable switchover mechanism prevents production interruptions due to main system failures and reduces economic losses. During normal operation of the primary system, data is continuously transmitted to the standby system, including remote input and data table data, to ensure that the standby system data is consistent with the primary system. When switchover occurs, the standby system can be put into operation immediately without waiting for data updates, ensuring stable system operation.

Flexible Configuration and Expansion: The communication ports of 1785-BCM module can be configured as Data Highway Plus or Remote I/O mode to adapt to different network requirements. Users can choose the communication mode flexibly according to the actual application scenarios to meet diversified industrial control needs. For systems using processors such as PLC-5/40, PLC-5/60, etc., the 1785-BEM module can be added to provide backup for the two additional channels of the processor, which enhances the backup function of the system and improves the overall reliability of the system. When upgrading or expanding the production line of an enterprise, the system configuration can be easily adjusted .

Good compatibility: 1785-BCM series B modules are compatible with series A modules, and communication between different series of modules can be achieved by setting switch components SW1 and SW2 to protect users’ original investment. When upgrading the system or replacing some components, there is no need to replace the equipment in a large scale, which reduces the cost. The module is compatible with a variety of PLC-5 processors (e.g. PLC-5/15, PLC-5/20, etc.), which is suitable for control systems of different sizes and needs, improving the versatility and applicability of the module .

Convenient Diagnosis and Maintenance: 1785-BCM and 1785-BEM modules are equipped with status indicator lamps, which visually display system operation status and fault information. Users can quickly determine whether the system is running normally through the indicators, and detect faults in time, such as hardware faults, communication faults, etc., so as to facilitate rapid positioning and problem solving. More detailed system status and fault information can be obtained through the relevant bits of the system status word and auxiliary diagnostic/status word, providing powerful support for fault diagnosis and troubleshooting. In complex industrial control systems, it can help technicians accurately determine the cause of the fault and shorten the troubleshooting time .

Document Overview and Important Information: Provides an overview of the installation and troubleshooting of the Enhanced PLC-5 Programmable Controller. Emphasises the differences between solid-state and electromechanical equipment, reminds the user to ensure the safety and suitability of the equipment for the application, and states that Rockwell Automation is not responsible for consequential damages and that unauthorised copying of the contents is prohibited.

Controller Overview
Models and Panel Components: The 1785-L11B, -L20B, and other models have front panel indicators for battery, processor run/fail, and force, as well as communication ports and programming terminal connections, and configurations vary slightly from model to model.
System Components: In addition to the controller, a complete system requires components such as a lithium battery (1770-XYC), I/O chassis (1771-A1B, etc.), power supply (1771-P4S, etc.), and a personal computer.

System Hardware Installation
Preparation before installation: Pay attention to static electricity protection during operation, avoid plugging and unplugging modules or connecting/disconnecting cables under electric current to prevent the danger caused by electric arc.
Component Installation and Configuration: Install the I/O chassis (refer to 1771-IN075), configure the I/O chassis (set the backplane switch and power supply configuration jumpers, etc.), install the power supply (according to the corresponding instructions for the different module choices), install the PLC-5 Programmable Controller (set the address, interface, and install the batteries, etc.), and install the I/O modules (refer to the corresponding module instructions).
Powering up the system and connecting to a PC: Power up the system and clear the memory according to the position of the key switches; connect to a PC and refer to the relevant manuals and documents.

Controller Troubleshooting
Indicator diagnosis: judge the fault by the colour and status of BATT, PROC and other indicators, e.g. BATT red light indicates low battery, different status of PROC corresponds to different faults or normal operation.
Communication Channel Troubleshooting: Judge the faults according to the channel mode and indicator status, e.g. in Remote I/O Scanner mode, green light indicates normal link, green blinking may be an adapter fault.

Controller Specifications
General specifications: different models have different backplane currents, communication ports and relay boxes have specific isolation voltages, operating temperature 0 – 60°C, storage temperature -40 – 85°C, relative humidity 5 – 95% non-condensing, as well as vibration, shock, electromagnetic compatibility and other indicators.
Other specifications: Supports multiple communication modes, different models differ in maximum user memory, number of I/O channels, etc., e.g., 1785-L11B has a maximum user memory of 8K words and 1 DH+/remote I/O channel; 1785-L80B has a maximum user memory of 100K words and 4 DH+/remote I/O channels.

Performance Advantages
Optimised Functionality: The Enhanced PLC-5 programmable controller supports a wide range of communication protocols, such as DH+, Remote I/O, etc., which allows for easy data interaction with different devices and more complex system integration, which is difficult for many traditional controllers to achieve. It also has a real-time clock/calendar function, which can accurately record the time of events, providing strong support for the traceability and management of the production process, which is often lacking in traditional controllers.

Significantly improved performance: In terms of processing speed, Enhanced PLC-5 programmable controllers are much faster, able to quickly process a large number of complex control logic to meet the high demand for real-time performance in modern industry. Taking the automobile manufacturing line as an example, it can analyse and process many sensor data in a short time, and control the movement of the robotic arm in time to ensure efficient production, compared with the slower processing speed of traditional controllers, which may lead to low production efficiency. In terms of storage capacity, the Enhanced PLC-5 programmable controller has a larger user memory, which can store more programmes and data to meet the needs of complex control systems, while traditional controllers have limited memory, making it difficult to cope with complex control tasks.

Enhanced communication capability: The controller supports a variety of communication methods, not only can communicate with the host computer to achieve remote monitoring and management, but also with other intelligent devices to form a network to achieve data sharing and collaborative work, which greatly expands the scope of its application, while the traditional controller communication methods are relatively single, which restricts the scalability and flexibility of the system.

Convenient to use and simplified maintenance: Enhanced PLC-5 programmable controller has a self-diagnostic function, can monitor its own operating status in real time, once a fault is found, it can be fed back to the user in time through the indicator or communication interface, which is convenient to quickly locate and eliminate the fault, compared to the traditional controller’s fault diagnostic function is weaker, which increases the difficulty of maintenance and the cost of time. Its programming is relatively simple, the use of programming language in line with industrial standards, such as ladder diagrams, etc., easy for engineers to understand and master, reducing the threshold of programming, while the programming of traditional controllers may be more complex, requiring professional programming knowledge and skills.

1784-PKTx Series Overview: Allen-Bradley’s 1784-PKTx series of PCI communication cards includes the 1784-PKTX, 1784-PKTXD, and 1784-PKTS models. This series utilises PCI and plug-and-play technology to connect PCs or PC-based controllers to Data Highway Plus, Data Highway 485 or remote I/O networks, reducing the number and type of PC interfaces required to support Allen-Bradley control systems.

Model Feature Differences
1784-PKTS: Single-channel card, supports RIO scanning only.
1784-PKTX: Single-channel card, supports DH+, RIO scanning, and DH-485. has two physical communication ports associated with a single protocol channel, and can be configured as a human-machine interface (MMI) running on a DH+ or DH-485 network, or as a scanning module on a remote I/O network.
1784-PKTXD: Dual-channel card that supports DH+, RIO scanning, and DH-485 on the first channel and DH+ and RIO scanning on the second channel. Each channel can support unique A-B communication protocols and can operate independently at the same time. On-board LEDs provide network interface diagnostics.

System and Environmental Requirements
System Requirements: Can be used directly under Windows 95 and Windows NT operating systems, other operating systems need to create their own drivers. Remote I/O driver development can use 6001-RIO, including binary files and sample C code; DH + or DH-485 driver development can use RSLinx PKTx driver, 1784-DP4 contains the relevant binary files and sample C code.
Environmental Requirements: Operating slot temperature 0 – 60°C (32 – 140°F), non-operating slot temperature -40 – 85°C (-40 – 185°F), 5 – 95% relative humidity and non-condensing, withstand some vibration and shock, PKTXD power consumption 800ma @ 5Vdc (4.0W).

Specification
Hardware parameters: 1784-PKTX has 1 channel, CH 1A (3-pin Phoenix) for DH + or remote I/O, CH 1C (6-pin Phoenix) for DH-485; 1784-PKTXD has 2 channels, CH 1A is the same as CH 1A of the 1784-PKTX, CH 1C is for DH-485, Ch2 (3-pin Phoenix) is for DH-485. CH 1A is the same as CH 1A of the 1784-PKTX, CH 1C is for DH-485, Ch2 (3-pin Phoenix) is for DH+ or remote I/O; the 1784-PKTS supports remote I/O only, CH 1A (3-pin Phoenix) runs remote I/O. The bus communication is native PCI (2.3 compliant) with 1 diagnostic/status LED per channel on each card. a maximum of 4 modules may be mounted in the system, which can be set via jumpers on the card.
Electrical parameters: Isolation voltage tested at 500Vac for 60 seconds, PKTXD power consumption 4.0W (800ma @ 5Vdc). Various electrical compatibility indicators are available, such as ESD immunity (4kV contact discharge, 8kV air discharge), radiated RF immunity (10V/m, 1kHz sine wave 80% AM, 30MHz – 1000MHz).
Environmental parameters: Operating temperature 0 – 60°C (32 – 140°F), storage temperature -40 – 85°C (-40 – 185°F), relative humidity 5 – 95% non-condensing. Withstands some vibration (2g @ 10 – 500Hz) and shock (operational shock 30g, non-operational shock 50g).
Communication parameters: DH+ network, maximum line length 10,000 ft. (3048 m) at 57.6K bit/s, 5,000 ft. (1,524 m) at 115.2K bits/s, 2,500 ft. (762 m) at 230.4K bits/s; DH-485 network, maximum line length 4,000 ft. (762 m) at 1200-19,200 bits/s. (1,219 m) at 1200 – 19,200 bits/s; DH-485 network, 4,000 ft. (1,219 m) at 1200 – 19,200 bits/s; Remote I/O network, 10,000 ft. (3,048 m) at 57.6K bit/s, 5,000 ft. (1,524 m) at 115.2K bit/s, 2,500 ft. (762 m) at 230.4K bit/s.

Performance Features
Versatile functions: Supports a variety of network connections to connect PCs with PLC controllers, SLC processors, and other devices for programming and data acquisition. With remote I/O scanning function, 1784-PKTXD dual-channel can support different protocols at the same time to enhance the flexibility of connection.
Strong compatibility: Hardware is adapted to PCI-compatible PCs; software, DH+ and DH-485 drivers are included in RSLinx for Windows 98 or later, and drivers can be written for other operating systems with specific tools.
Plug-and-play and auto-configuration: Following the PCI bus specification and the Plug-and-Play BIOS specification, the PCI BIOS automatically assigns IRQs and base memory addresses, reducing the need for manual configuration by the user.
Complete diagnostic function: Through the LED indicators on the card, you can visually judge the network connection and device working status, such as whether the channel is online, whether it receives tokens, and whether there are errors.

1784-PKTx Network Card Introduction
Models and Functions: 1784-PKTx series includes two types of PCI network cards, 1784-PKTX and 1784-PKTXD. 1784-PKTX has 1 channel, which can be used in DH + or DH-485 network; 1784-PKTXD has 2 channels, of which channel 1 supports DH + and/or DH-485, and both of them are equipped with remote I/O scanning function, and can be connected to PC and PLC controller to achieve programming and data acquisition. The 1784-PKTXD has 2 channels, of which channel 1 supports DH + and/or DH-485, both have remote I/O scanning function, and can be connected to PC, PLC controller and SLC processor for programming and data acquisition.

Compatibility: PCI-compatible PCs are required, and different operating systems have different support for the card; for Windows 98 or higher, the DH+ and DH-485 drivers are included in RSLinx; other operating systems need to write their own drivers using the 1784-DP4; Remote I/O, regardless of the system, need to write drivers using the 6001-RIO – RIO Tool Kit. Remote I/O systems of any kind require the 6001-RIO – RIO Tool Kit.

Hardware Configuration
IRQ Assignment: The PCI BIOS automatically assigns IRQs to the PKTx cards, each time a card is added or removed and the computer is restarted, the BIOS may assign a different IRQ, which needs to be checked each time the system is booted, and which is verified by most application software, such as the Plug and Play driver for RSLinx.

Base Memory Address: Although IRQs and base memory addresses are assigned automatically, there is a base memory address jumper (JP2) on the PKTx card that defaults to a 32-bit location. This may need to be set on non-Windows 95 or later systems. This jumper limits the base memory address to two ranges, depending on the operating system the PC is running.

Multi-Card Setup: Up to four PKTx cards can be installed in the system. The card is uniquely identified by setting the JP3 jumper, which has CID0 and CID1, with different combinations corresponding to different Card IDs, as shown in the table below:

Installation Steps
Pre-installation Preparation: Before installing the PKTx card, make sure you have set the appropriate jumpers, avoid static damage, touching a grounded object to discharge, wearing a grounded wrist strap, etc.

Insert the card: Locate the PCI bus slot on your computer and insert the PKTx card according to the computer manufacturer’s instructions.
Install the driver: Start the computer, Windows will detect the PKTx card and start the ‘New Hardware Wizard’, insert the RSLinx CD, select Search for Driver, specify the location of the driver (different paths for different systems), and complete the driver installation. If the installation fails, please contact Rockwell Technical support.

Network Connection
Connection Network Type: The PKTx card can connect to DH+, DH-485, and Remote I/O networks. Be sure to use the correct cable and terminating resistor before connecting.
DH+ Network Connection: Single or multiple devices can be connected with the 1784-CP12 cable for the original PLC-5 controller or the 1784-CP13 cable for the Enhanced model. Terminating resistors are required at both ends of the network, either 82Ω or 150Ω depending on the device’s communication rate.
DH-485 Network Connection: Multiple SLC controllers or a single SLC processor can be connected. 1747-AIC Link Coupler is required to connect multiple SLC controllers, and 1784-CP14 cable is required to connect a single SLC processor, and terminating resistors are also required at both ends of the network.
Remote I/O connection: Build a custom cable using Allen-Bradley 1770-CD or approved cable, select 82Ω or 150Ω terminating resistor depending on the remote I/O link.

Interpreting Status LEDs
DH + Status LEDs: Off to indicate channel is not online; blinking green to indicate it is the only node on the network; always green to indicate it is online and receiving tokens; blinking red to indicate a duplicate node; always red to indicate a self-test failure.
DH-485 Status LED: similar to DH + Status LED, blinking red indicates parity error.
Remote I/O Scan Mode LED: off indicates channel is not online; blinking green indicates at least one but not all adapters in the scan list are not responding; constant green indicates all adapters are responding; blinking red indicates all adapters are not responding; constant red indicates self-test failure.

Specification parameters: covering the maximum line length, communication rate, electrical characteristics, environmental adaptability and other parameters, such as the DH + at different rates of the maximum line length is different (57.6K bit/s at 10,000 ft., 115.2K bits/s at 5,000 ft., 230.4K bits/s at 2,500 ft.), with a variety of electrical (5,000 ft. at 115.2K bits/s, 2,500 ft. at 230.4K bits/s), a wide range of electrical compatibility specifications, and operating temperatures from 0 – 60°C.

Product Overview: The Stratix 8000 and 8300 Ethernet Managed Switches are designed for use in harsh industrial environments, connecting servers, routers, PLCs, and other network devices. They are available in models such as the 1783-MS06T (4 10/100BASE-T Ethernet ports and 2 dual-purpose ports) and 1783-MS10T for the Stratix 8000 series, and the 1783-RMS06T and 1783-RMS10T for the Stratix 8300 series. There are also expansion modules 1783-MX08T (8 10/100BASE-T copper Ethernet ports), 1783-MX08F (8 100BASE-FX fibre-optic Ethernet ports), and a variety of SFP modules.

Preparation for installation: Before installation, make sure that the installation environment meets the requirements, the ambient temperature is between -40°C and 60°C, and there is enough space around the equipment to ensure that the airflow is not blocked. Prepare tools such as a ratcheting torque screwdriver and specific copper grounding wire.

Installation Procedure:
Connection of expansion modules (optional): 1 – 2 expansion modules can be installed, with specific combination limitations, remove the side panels before installing and fixing.
Mounting the switch: DIN rail, wall or panel mounting is available; DIN rail mounting requires attention to grounding and DIN rail type; wall or panel mounting requires specific bolts and washers.
Mounting SFP Modules (optional): wear an ESD wrist strap during operation and be aware of module compatibility.
Grounding: Use 5.3 mm 2 (10 AWG) grounded copper wire to connect to the ground screw on the front panel of the switch.
Connecting the DC Power Supply: The power supply must comply with the CE Low Voltage Directive and UL limits, observing positive and negative polarity and torque requirements when connecting.
Connecting the power supply and relay connectors: Insert the connectors and tighten the screws, taking care to isolate the voltages if more than one power supply is used.
Connecting external alarms (optional): connect up to two external alarm devices, use specific wires and pay attention to voltage and torque requirements.

Configuration Management:
Express Setup: Used to set the initial IP address, requires specific device and network configuration.
Configuration Management Methods: Configuration and management can be performed through the Device Manager web interface, RSLogix 5000 software, and other methods.
Reset Operation: The switch can be restored to the factory default settings, after which it needs to be reconfigured.
Troubleshooting: Faults such as POST failure, port connection problems, etc. can be determined by the status indicators on the front panel of the switch. Troubleshooting can also be assisted by obtaining statistical information through the browser interface, command line interface, or SNMP workstation.

Product Specifications
Electrical specifications: The input voltage range is 18-60V DC and the maximum input current is 1A, which can adapt to power fluctuation within a certain range and provide power protection for the stable operation of the switch. The alarm relay is rated at 30V DC max. and 1A max. and can be used to connect external alarm devices to issue an alarm in time when the system is abnormal. For isolation voltage, the switch base and expansion modules have specific isolation requirements between different ports, such as 75V (continuous) basic insulation type between DC power port and ground, Ethernet port, alarm port, and between Ethernet port and expansion backplane, and have been tested at 1000V AC 60s, which guarantees electrical isolation between different circuits and improves the system security .

Physical Specifications: The dimensions of the switches and expansion modules are clearly defined, taking the 1783-MS10T and 1783-MX08T as examples, which facilitates space planning and layout during equipment installation. A variety of port types, including 10/100BASE-T, 10/100/1000BASE-T copper ports and SFP module slots, as well as 100BASE-FX fibre-optic ports (only available on the 1783-MX08F expansion module), are available to meet the connectivity needs of different devices. The connecting wires have specific specifications, including IEC 60603-7-compliant RJ45 connectors and at least Category 5e cables for Ethernet connections, 0.5-0.8 mm 2 (20-18 AWG) copper wires for DC power and alarm connections, and 3.3-5.3 mm 2 (12-10 AWG) copper wires for functional ground connections, ensuring the reliability of the electrical connections. Ensures reliable electrical connections.

Environmental specifications: Operating temperature range of – 40°C to 60°C and non-operating temperature range of – 40°C to 85°C provide a wide range of temperatures for stable operation in a variety of climatic and industrial environments. Relative humidity requirements of 5% to 95% non-condensing, even in humid environments. The product is IP20 rated, which provides a degree of protection for the internal circuitry by preventing the ingress of solid foreign objects larger than 12mm. There are also standards for vibration and shock, such as 2g @ 10-500Hz for vibration, 20g for operating shock, and 30g for non-operating shock, providing strong resistance to environmental interference.

Performance Features
Port auto-negotiation and self-adaptation: The ports are equipped with the functions of auto-negotiation of link speed (10 Mbps or 100 Mbps) and duplex setting (full-duplex or half-duplex), which can automatically match the optimal network connection parameters with the connected devices without manual configuration, thus improving the convenience and compatibility of device connection. Some models of dual-purpose ports, in the SFP module port and RJ45 port at the same time there is a connection, the SFP module port has priority, this design makes the network connection more flexible, according to the actual needs of the choice of different connection methods.

Multiple Configuration and Management Methods: Provides multiple configuration and management methods, including Device Manager web interface, RSLogix 5000 software, Cisco Network Assistant, Command Line Interface (CLI) and SNMP management application. Users can choose the appropriate way according to their own needs and technical level, which is convenient for initial setup, daily management and troubleshooting of the switch. The Express Setup function allows users to quickly set up the initial IP address of the switch, enabling the switch to be connected to the network for subsequent management and simplifying the configuration process during initial use.

Fault Detection and Indication: The status indicators on the front panel can visually reflect the working status of the switch, including power status (PWR A, PWR B indicators), EtherNet/IP module status (EIP Mod indicator), network status (EIP Net indicator), setup status (Setup indicator), and port status (Port indicator, etc.). By observing the colours and flashing status of the indicators, users can quickly determine whether the switch is working properly and find and locate faults in time, such as POST failure, port connection problems, etc. The switch will perform POST at startup. The switch will perform POST (power-on self-test) at startup, if POST fails, the system status indicator will turn red, which indicates that there is a fault in the device and it needs to be checked and repaired accordingly.

Preparation before installation:
Safety and environment: the use of equipment has special conditions, the application of hazardous areas need specific protection, should be installed in the enclosure in line with the requirements of the industrial environment for pollution degree 2, belongs to the A class of industrial equipment, installation and operation of professional personnel in accordance with the norms. The equipment is sensitive to static electricity, and anti-static measures should be taken during operation.

Networking and Grounding: For use in linear or star networks, ensure that Ring Supervisor mode is not enabled; in DLR networks, consider whether the tap acts as a ring manager. The product should be mounted on a well-grounded surface, recommended DIN rail in galvanised yellow chromate steel, fixed at approximately 200mm intervals.
Installation procedure:

Mounting method: Panel mount or DIN rail mount is optional, 2.54cm gap should be left on each side of 1783-ETAP module; 7.62cm gap should be left on the bottom of 1783-ETAP1F and 1783-ETAP2F module, 2.54cm gap should be left on the other sides, and the bending radius of the fibre optic cables should be at least 5.08cm.

Wiring operation: Provide 24V DC power through the DC connector, follow the relevant electrical safety standards, and connect no more than two wires per terminal. When connecting the RJ45 port, follow the steps to connect the device and the network; when connecting the optical fibre ports of the 1783-ETAP1F and 1783-ETAP2F, be careful to avoid looking directly at the optical ports.

Software and Configuration:
Software Requirements: RSLinx Classic 2.56.00 or higher, Studio 5000 Logix Designer 21.00.00 or higher software is required.

IP Settings: The default IP address of 169.254.1.1 can be used or configured through RSLinx Classic software, Studio 5000 Logix Designer application, or obtained from a DHCP or BOOTP server.
DIP Switch Settings: DIP switches can be used to select IP setting method, enable Ring Supervisor mode, restore factory default settings, etc.

Status Monitoring and Diagnostics:
Status Indicators: The status indicators of 1783-ETAP, 1783-ETAP1F, and 1783-ETAP2F have similar meanings; different statuses of OK indicator indicate different working conditions, and LINK1 and LINK2 indicators reflect the link status.
Web Interface Diagnostics: The tap supports a web interface that provides diagnostic information, including module resource utilisation, network settings, Ethernet statistics and ring statistics.

Performance Features
Port Auto-negotiation: By default, each port of the 1783-ETAP module is able to auto-negotiate the link speed (10 Mbps or 100 Mbps) and duplex setting (full duplex or half duplex), which enables the module to quickly adapt to different network environments and establish a stable connection without the need for users to manually carry out complex settings, improving the ease of use and compatibility of the device. The module supports a variety of network configuration methods.

Supports multiple network configuration methods: The module supports multiple network configuration methods, users can either use the default IP address 169.254.1.1, by connecting the module directly to the computer and setting the IP address on the same subnet (e.g., 169.254.1.2) in the computer’s Local Connection Properties to communicate; or through the RSLinx Classic software, Studio 5000 Logo, or the RSLinx Logo. IP settings can also be made using RSLinx Classic software, Studio 5000 Logix Designer application.

General information about the modules:
Product Family: Part of the Digital I/O product family, which consists of AC input/output, DC input/output, and relay contact output modules.

System Compatibility: Each module has specific compatibility with different models of 1771 I/O chassis and processors, and the way data tables are used varies by module.
Status Indicators and Keypads: Status indicators on the front panel of the module indicate input or output status, and some have additional indicators; plastic keypads ensure that the module is properly installed in the I/O slot.

Power Requirements and Layout: Modules draw power from the backplane of the 1771 I/O chassis, and the total current should be calculated to prevent overloading. Module layout should be considered to reduce electromagnetic interference and thermal effects, and analogue inputs and low voltage DC modules should be located away from AC or high voltage DC modules.

Product Specifications
Input Module Specifications: Input voltage range is wide, such as 1771-IA series C and 1771-IA2 modules rated input voltage is 120Vac @47 – 63Hz, 125V dc, and 1771-IAD series D module is 120V ac@ 50/60Hz, 125V dc, which varies from module to module according to its own characteristics. As for the input current, the current value varies with different voltages, like 6.83mA at 120Vac 50Hz for 1771-IA series C. The input signal delay also varies from module to module. The input signal delay also varies from module to module, ranging from a few milliseconds to tens of milliseconds. In addition, each input module has a different number of input channels, such as 8 channels, 16 channels, 32 channels, etc., to meet different application requirements.

Output Module Specifications: Output voltage ranges vary from 92 – 138V ac @ 47 – 63Hz for 1771-OA Series B Modules to 184 – 250V ac @ 47 – 63Hz for 1771-OMD Series B Modules. Output current ratings also vary, such as 1.5A per output (up to 6A total) for 1771-OA Series B modules and 2A per output (up to 6A total) for 1771-OD Series C modules. The output modules also have different inrush current, load current minimum, on-state voltage drop, off-state leakage current, and other parameters that determine the performance of the modules under different load conditions.

Performance Features
Electrical isolation and protection: All modules are equipped with electrical-optical isolation to effectively protect the backplane circuits, module logic circuits and the entire system from electrical transients. Some output modules are also equipped with surge suppression circuits, such as metal-oxide varistors (MOVs) and RC networks at the output terminals, to suppress high-voltage transients and limit the magnitude of voltage transients, thus prolonging the service life of the equipment.

Status Indication and Troubleshooting: The front panel of each module is equipped with status indicators, which clearly show the ON/OFF status of inputs or outputs, and some modules are also equipped with additional indicators such as blown fuses and thyristor failures, which are convenient for users to discover and troubleshoot in time, quickly identify system problems and improve system maintenance efficiency.
Flexible Failure Mode Selection: Some of the digital AC modules allow users to select the failure mode by configuring jumpers, and inputs or outputs can be set to remain in the last state or reset to off in case of a failure, which enhances the flexibility and reliability of the system, and meets the needs of different application scenarios for fault handling.

Application Scenarios
Industrial automation production line: In industrial production, various types of sensors (e.g. proximity switches, limit switches, etc.) and actuators (e.g. motor starters, solenoid valves, etc.) can be connected to achieve precise control of the production process. In the automobile manufacturing line, it is used to monitor and control the position and movement of the robot arm to ensure the accurate assembly of parts; in the material conveying system, it is used to control the starting and stopping of the conveyor belt motor to realise the automatic transport of materials.

Mechanical equipment control: It is applicable to the electrical control of various mechanical equipment, such as injection moulding machines, CNC machine tools and so on. In the injection moulding machine, it controls the opening and closing of the mould, the execution of the injection action, and the monitoring of the running status of the equipment; in the CNC machine tool, it receives the operating instructions and controls the operation of the motor to achieve the precise movement of the tool and the automation of the machining process.

Automated Warehousing System: In automated warehousing equipment, such as stacker cranes, shuttle cars, etc., it is used to control the movement and positioning of the equipment, as well as the gripping and placing operations of the goods. By cooperating with sensors, the precise operation of the equipment can be realised, and the working efficiency and accuracy of the storage system can be improved.

Preparation before installation:
Static protection: touch a grounded object when handling the module, wear a wrist strap, avoid touching the backplane connectors and internal circuitry components, and place in a static-shielding bag when not in use.

Directive Compliance: CE-marked, compliant with EU EMC and Low Voltage Directives and meets relevant standards.
Power Calculation: The module draws power from the 1771 I/O chassis backplane at a maximum current of 650mA (3.25W), which is required to calculate the total power in the chassis to prevent overloading.
Installation Procedure:

Jumper Setting: Each input channel has jumpers for filter/high speed operation, +5V or + 12 – 24V operation, 6 in total, which can be set independently. High-speed mode is suitable for encoders and other devices, and filter mode is used for electromechanical switch inputs (frequencies greater than 100Hz are not detected).
Module Installation: It can be installed in other slots except the leftmost slot, and different addressing modes have different requirements for module groups. The keyed strips are mounted on the backplane between 24 – 26, 28 – 30. To install, disconnect power, insert and secure the module, and connect the 1771-WN wiring arm.
Wiring Connections: Disconnect power before connecting I/O devices, shield sensor cables and ground only at the chassis end.
Grounding: Using Belden 9182 cable, follow the steps for cable handling and grounding, taking care to install a washer and nut when connecting the grounding conductor.

Module Configuration:
Operating modes: 6 modes: Counter mode, Encoder X1 mode, Encoder X4 mode, Cycle/Rate mode, Rate/Measurement mode, Continuous/Rate mode. For example, the counter mode is used to read pulses from up to 4 devices such as encoders; the encoder mode is used to process orthogonal pulses.
Gate/Reset Inputs and Stored Counts: Gate/Reset inputs can scale pulses, there are 4 stored counting modes that can be triggered on rising or falling edges, and stored counts can be updated by related events in specific modes.
Output Settings: Outputs can be connected to any counter input, have on and off presets, and represent frequency values in Rate Measurement mode (up to 500,000Hz).
Status and diagnostics:

Data Acquisition: The PLC processor acquires the module status and input data through the BTR instruction, which transfers up to 26 words and returns 18 words when the programmed BTR is zero.
Troubleshooting: The module returns diagnostic information in word 1 of the BTR file, including power supply, data update, and error codes. The status indicator can indicate the working status of the module, such as ACTIVE light indicates that the module receives power and operates normally, while FAULT light indicates that the module needs to be investigated according to the steps.

Specification
Electrical Performance Parameters: The maximum input frequency of the module varies depending on the mode of operation, up to 1MHz in counter mode (single channel), 250kHz in encoder mode (2-channel quadrature), 500kHz in cycle/rate, rate/measurement, and continuity/rate modes, and 100Hz in filtering mode for processing electromechanical switching inputs. Input voltages of 5V or 12 – 24V are supported and can be selected by the user according to actual requirements.

Outputs are available from 5 – 24V (customer supplied) with output currents of 2A per channel and all outputs can be switched on simultaneously without derating. Output control is flexible, any number of outputs can be assigned to any of the 4 counter channels, and each output also has an ‘on’ preset and an ‘off’ preset respectively.
Environmental Adaptation Parameters: In terms of operating temperature, the module has an operating temperature range of 0 – 60°C (32 – 140°F), a storage temperature range of – 40 – 85°C (- 40 – 185°F), and a relative humidity requirement of 5 – 95% (non-condensing). These parameters define the environmental conditions under which the module can work stably. Users should ensure that the ambient temperature and humidity are within the specified range when using the module in order to avoid any degradation of performance or failure of the module due to environmental factors.

Other Parameters: The module occupies one slot in the 1771 Series A or B I/O chassis and has a programmable maximum count value of 0 – 999,999. The BTW processing time is 5.5ms in the worst case (binary and with configuration changes) and 1.5 – 2.9ms typical. The electrical isolation of the module is good, with 1500V between inputs and backplane, outputs and backplane, and 300V between isolated channels. in addition, the module is certified, e.g. with CE marking, in compliance with EU directives, and with CSA certification for use in Class I Division 2, Groups A, B, C, D, or in non-hazardous locations.

Function Overview: Precise, high-speed control of 1 or 2 linear closed-loop axes, integrating the machine control capabilities of a programmable controller with the high performance of a hydraulic system that responds quickly to positional commands and load changes in as little as 2ms update time.

Performance Advantages:
High accuracy: better than 0.001‘ resolution over 60’ and 0.002‘ positioning repeatability over 180’ axes.
Device Compatibility: Directly connects to a wide range of linear displacement transducers from Temposonics, Balluff, Norstat, and servo valves from Moog, Pegasus, and other brands.
Reduced Wear and Tear: Controlled acceleration and deceleration rates of change reduce system shock, equipment wear and maintenance costs.
Simplifies development: Simulation mode facilitates PLC programme development and testing without sensors or hydraulic equipment.

Application Scenarios: Ideal for sawmills, injection control, composite layering, amusement rides, and other scenarios where position monitoring or control is required, especially for systems with hydraulic cylinders up to 180 inches long that require fast loop updates and bi-directional control.
Interfaces and Connections:
Analogue outputs: for control of servo valves or servo motor controllers with outputs ranging from ±1.0 – ±100mA or ±0.1 – ±10V, using 12-bit D/A converters.

Discrete I/O: 7 digital inputs per axis (e.g. hardware startup, pointing control, etc.) and 2 digital outputs (e.g. position arrival, loop fault indication).
Specification Parameters:
| Module Location | 1771 General Purpose I/O Chassis, One Slot Occupied | Cooling | Typical 12.5mm
| Thermal | 12.0 watts (179 BTU/hr) typical, 18.0 watts (278 BTU/hr) maximum | Electrical Isolation | 1500 watts (179 BTU/hr) typical, 18.0 watts (278 BTU/hr) maximum
| Electrical Isolation | 1500V RMS (transient) | Environmental Conditions | Operating Temperature
| Environmental Conditions | Operating Temperature 0 – 60°C, Storage Temperature – 40 – 85°C, Relative Humidity 5 – 95% non-condensing
Sampling Period | 2ms per loop | Wiring Arm | 40 terminals
| Wiring Arm | 40 Terminal 1771-WN, Wire Gauge 14 gage stranded wire (max), 3/64 inch insulation (max), Category 2| | Power Requirements | Back Panel
| Power Requirements | Backplane current 1.6A max, 1.1A typical (+5Vdc); Sensor Interface +5Vdc 5% @ 300 mA(max); Analogue Interface +15Vdc +5% @ 540 mA(max), -15Vdc ±5% @ 360 mA(max); Discrete Inputs +15Vdc(min) +24Vdc(max) @ 50 mA(max); Discrete Inputs +15Vdc(min) +24Vdc(max) @ 50 mA(max); Discrete Inputs +15Vdc(min) +24Vdc(max) +50 mA(max) mA(max); Discrete Output + 30Vdc @ 400 mA(max) with 1.6Vdc @ 100mA max dropout (requires + 11.6Vdc(min) for compatibility with discrete inputs)

Applications
Sawmill: Precision and efficiency in log cutting is critical in the production process of a sawmill. 1771-QB modules are connected to a linear displacement sensor to monitor the saw blade position in real time. When cutting different sizes of wood, the module quickly and accurately adjusts the position, angle and depth of cut of the saw blade according to a preset programme. The precise control of the hydraulic system ensures that the saw blade operates stably and accurately cuts the logs into boards of the required size. This not only improves wood utilisation and reduces waste, but also greatly improves sawing efficiency, making the production process more efficient and stable.

Injection moulding and reaction injection moulding (RIM): In injection moulding and RIM processes, the precise control of the mould has a direct impact on the quality of the product. 1771-QB module controls the mould closing, injection and ejection movements of the injection moulding machine. By cooperating with linear displacement sensors, it accurately monitors the position and movement of the mould to ensure a tight fit during mould closing and prevent plastic leakage; during injection, it accurately controls the injection volume and speed to ensure the dimensional accuracy and quality stability of the product; and during the ejection phase, it accurately controls the ejection position and speed to avoid product damage.

Composite Material Processing: In composite material processing, such as the lay-up process of composite materials, it is necessary to accurately control the position and trajectory of the lay-up equipment. 1771-QB module connects with the drive system of the lay-up equipment, and realises the accurate control of the lay-up equipment by receiving the positional information fed back from the sensors. It is able to lay the material in different positions and angles according to the preset programme, ensuring uniformity and accuracy of the layers and improving the quality and performance of the composite products.

Amusement Rides and Flight Simulators: In amusement rides and flight simulators, the motion of the equipment needs to be accurately controlled in order to provide passengers with a realistic experience. 1771-QB modules control the moving parts of the amusement rides and flight simulators, and according to the preset motion programs, combined with the real-time positional information fed back from the sensors, it achieves fast and accurate positional control. In roller coasters and other amusement rides, the position and speed of the rail vehicles are precisely controlled to ensure safe and exciting operation; in flight simulators, various flight postures of the aircraft are simulated to provide pilots with a realistic training environment.

Module Overview:
Functionality: The 1771- OFE is an intelligent block transfer module that converts binary or quadruple BCD values supplied by the processor into analogue signal outputs. It has four independently isolated differential output channels with selectable scaling, data format, etc. It requires no external power supply and occupies only one I/O slot.
Output range: There are three versions, 1771-OFE1 is a voltage output, 1 – 5V dc, 0 – 10V dc, +10V dc can be selected through the configuration jumper; 1771-OFE2 and 1771-OFE3 are current outputs, 4 – 20mA and 0 – 50mA respectively, and the latter two are factory-set.
Communication mode: The processor transmits data to and from the module through the BTW and BTR instructions in the ladder program to send output values, set modes and receive status information.

Installation steps:
Preparation for installation: Comply with the relevant EU directives, calculate the power requirement before installation to avoid overloading the backplane and power supply of the I/O chassis.
Module Setup: Can be installed in any slot of the I/O chassis, but avoid grouping with discrete high-density modules, and keep away from AC or high-voltage DC modules. Set configuration jumpers, including the last state configuration jumper (determines the output state in the event of a communication failure) and the voltage range configuration jumper (for 1771-OFE1).
Installation and Connections: Install the keying strip, insert the module smoothly into the chassis and secure it, and connect the 1771-WH junction arm; use the 1771-WC junction arm to connect to analogue equipment with the sensor cable shielded and grounded at the chassis end only.

The module is configured:
Configuration: Configure the module using a Block Transfer Write command (BTW) with a 13-word maximum write block containing output data, data format, and scaling information.
Data format and scaling: data format can be BCD or binary, scaling function can convert data to engineering units, by setting the corresponding scaling value, the maximum scaling value is 9999, the minimum is – 9999, and the maximum must be greater than the minimum.
Default Configuration: At power-on, the module microprocessor defaults to positive data words, no scaling, and BCD data format.

Programming Points:
Programming Format: The programming format is different for different processors, PLC-2, PLC-3, PLC-5 have their own characteristics, and the module does not allow the enable bit of the read/write instruction to be set to ON at the same time.
Programming Considerations: Including block length and scaling considerations (e.g., different settings for no-channel scaling, partial-channel scaling, and full-channel scaling), block transfer boundary words (PLC-2 processor), and module update time (8 milliseconds for BCD and scaling, and 1.6 milliseconds for binary and no scaling).

Performance
Optimisation of hardware mounting and layout: Choose the location of the modules in the I/O chassis appropriately, avoiding the grouping of discrete high-density modules, and keeping them away from AC or high-voltage DC modules in order to reduce electromagnetic interference. Modules that are too close to these sources of interference may result in unstable signal transmission and affect the accuracy of the analogue output. Installing the module in a location away from the source of interference with good shielding and grounding can effectively reduce the impact of electromagnetic interference on the performance of the module and improve the quality of signal transmission .

Ensure that the sensor cable is properly connected and well shielded, and the cable shield is grounded only at the chassis end to reduce noise interference. If the shield is not properly grounded or shielded cable is not used, external noise may be coupled into the signal line, resulting in fluctuations or errors in the output signal. The use of high quality shielded cables, such as Belden 8761, and grounding in strict accordance with the specifications, can enhance the module’s anti-interference ability and ensure the stability of the output signal.

Fine adjustment of parameter configuration: According to the actual application requirements, precisely set the output range and data format of the module. Different analogue devices have different requirements for input signals, and the correct choice of output range and data format can ensure the compatibility of the module with the device and improve the output accuracy. For devices requiring 0 – 10V voltage input, setting the output range of the 1771-OFE1 module to 0 – 10V and selecting the appropriate data format (e.g., binary or BCD) can match the output of the module with the requirements of the device, avoiding data conversion errors caused by incompatible formats. Reasonable use of the scaling function to convert data to actual engineering units can improve the readability and practicality of the data.

When setting the scaling parameters, it should be ensured that the maximum scaling value is greater than the minimum scaling value, and the format of all the scaling information is consistent with the format of the module sent to the data table. For an application that measures temperature and converts it to voltage output, the temperature value can be accurately converted to the corresponding voltage signal output by precisely setting the scaling parameters, which is convenient for subsequent monitoring and control.

Improved programming strategy: Depending on the type of processor, choose the appropriate programming method and strictly follow the programming specifications. When using PLC – 2, PLC – 3, PLC – 5 and other processors, pay attention to the use of block transfer instructions and restrictions, avoid enabling the enable bit of read/write instructions at the same time to prevent data transfer errors. For the PLC-2 processor, programs should be written according to its specific programming structure to ensure correct data transfer and processing.

Optimise the settings for block length and scaling by determining whether to scale all channels and how to set the scaling values according to the actual situation. In some applications, only some channels may need to be scaled, in which case the block length and scaling parameters should be set appropriately to improve data processing efficiency. If only two channels are scaled, the appropriate block length can be set and the scaling value can be entered accurately to avoid unnecessary calculations and data transfers and to improve the system operation efficiency .
Regular calibration and maintenance: Regular calibration of the module ensures the accuracy of its output.

The calibration process includes preparatory work (e.g. switching off the power, connecting the test equipment, etc.) and calibration operations for each channel. For the voltage output version of the module, the output voltage is calibrated by adjusting the potentiometer; for the current output version of the module, the corresponding current calibration operation is also required. Regular calibration can detect and correct possible deviations of the module in time to ensure its long-term stable operation. Pay close attention to the running status of the module, through the indicator lights and diagnostic bits to timely detect faults and take appropriate measures.

When the red FAULT indicator lights up, the connection, configuration and hardware status of the module should be checked according to the fault prompts, and the faulty parts should be replaced in time to ensure that the module works normally. If the output of a channel is found to be abnormal, the cause of the fault can be determined by reading the diagnostic bit information, such as whether the data is out of range, whether the scaling is correct, etc., and then carry out targeted repair.