Jodicon

984-6801685
and 984-7801785
System Planning and Installation
GM-0984401

Rev. A

December, 1989
MODICON, Inc., Industrial Automation Systems
One High Street
North Andover, Massachusetts 01845

Guide

Preface
This guide describes the PC-O984-680/685 and PC-0984-780/785 Programmable
Logic Controllers and their available options, together with procedures for system
planning and installation.
Throughout this manual, the terms Programmable Controller,Programmable Logic
Controller,and PC have been abbreviated to icontroller for the sake of brevity. For
clarity and your convenience, the Models PC-0984-680, -685, -780, and -785 are
referred to in context as the 984-680 (or 780) or simply 685 or 785, etc. Chapter 1
deals specifically with the Models 680 and 685; Chapter 2, with the Models 780 and
785. Since the remaining chapters 3-6 discuss components and functions common to
all four devices, the 680/685/780/785 is referred to simply as the controlleror the
984 in these four chapters. Any topic unique to a particular device is clearly noted.

Note This manual describes system planning and installation informationfor the
Modicon 680, 685, 780, and 785 controllers, exclusive of Modbus PlusRv
communications(in the case of the 685 and 785). Information regarding the Model 685
and 785 controllers in connection with a Modbus Plusm network, including DIP switch
settings and network system configuration, is found in GM-MBPL-001, Rev. A, Modicon
Modbus Plus Network Planning and Installation Guide.

The information in this document is subject to change without notice and should not be
construed as a commitment by Modicon, Inc., who assumes no responsibilityfor any
errors that may appear in this document. No part of this document may be reproduced
in any form or by any means, electronic or mechanical, including photocopying,without
the express written permission of the publisher, Modicon, Inc. All rights reserved.
The following are trademarks of Modicon, Inc.:
884
984-680
P190

984
984-780
Modbus

680
780
984-685
984-785
Modbus Pius

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

trademark of International Business Machines, Inc.
Figure 22 is Copyright 0 1989 by lntettace Control Technologies, Inc., Route 625,
Gainesville, VA 22065. Reprinted by permission.
0 Copyright 1989, Modicon, Inc.

GM-0984-W

Preface

iii

Objectives
This manual will help you plan, configure, mount, wire, connect, check out, and
troubleshoot your 984 slot-mount controller system, including 984/800 Series Remote
I/O. After reading this book:
A Control Engineer will be able to identify and physically plan the location and
mounting of system components.
A Plant Electrician/Installer will be able to install, power-up, and check out the
system.
A Maintenance Technician will be able to recognize, locate, identify, and resolve or
report system failures.

How To Use This Manual

Chapter 1 describes the 984-680/685 controller system and its functions.
Chapter 2 describes the 984-780/785 controller system and its functions.
Chapter 3 offers informationfor planning your installation with local I/O.
Chapter 4 is an installation procedure for your controllerwith local I/O.
Chapter 5 offers informationfor planning your Remote I/O configuration and installation.
Chapter 6 is a collection of topical installation procedures for your Remote I/O.
Appendix A gives system specifications including Remote I/O cable and accessories.
Appendix 6 describes post-installation Remote I/O cable checking techniques and
procedures.
Appendix C gives Error Codes, Customer Service/Technical Support telephone
numbers, and modbus cable connector pinouts.

Related
GM-0984-001
GM-0984-IBM
ML-P1 90-USE
GM-T984-001
GM-HIBM-002

iv

Preface

Documents
Rev
Rev
Rev
Rev
Rev

I3
B
C
A
A

P190 ProgrammingGuide
IBM Programming Guide
984-68O/P190 PC System User Manual
984-68O/P190 PC System Tape Loader
IBM Load/Record Verify Users Guide

GM-O984-501

Minimum

Revision

Levels

The minimum prom revision levels for the 984-780 and 785 slot-mount controller
options are:
Option
D908
S908
5911

Exec Part Number

AS-9592-000
AS-E908-031
AS-S945-022

Rev. Level
C
E
E

Min. Prom Number

1002
1004
1004

The minimum revision levels for programmingsoftware diskettes and tapes are:

GM-0984401

Part Number

Version

Description

IBM
Disks

PG-DIBM-904
PG-DIBM-902
PG-DIBM-984
PG-DIBM-592
PG-DIBM-905
PG-DIBM-593

5.1
4.0
4.2
3.2
3.1
2.1

Configurator
Traffic Cop
Programmer
Load/Record/Verify
Ladder Lister
ASCII Programmer

P190
Tapes

PG-T984-304
PG-T984-302
PG-T984-301
PG-T984-305
PG-T190-401
PG-T984-003

3.0
3.0
2.1
2.0
2.1
2.0

Configurator
Traffic Cop (2 tapes)
Programmer
Utility
P190 Tape Loader
ASCII Programmer

Preface

Incomhg

Inspection

Guidelines

Guidelines for Inspection

o Before you do anything, verify your shipment is complete and undamaged. If the
shipment is incomplete or damaged, notify the carrier and your distributor.
0 Remove everything from its packing and check for physical defects or damage. If the
equipment is physically defective or damaged, notify your Modicon representative.

Note

Save shipping materials until installation is complete.

Sending Something Back?

o Whenever possible, use the original packing materials supplied by Modicon.
o All equipment should be firmly packed so that it cannot move around in its shipping
container.
o All equipment should be protected against impact during shipment.
o All equipment should be clearly marked with its Return Authorization Number (RA#).

vi

Preface

Table of Contents

Introducing Your 680/685 Controller ......................

984-680/685 Programmable Controller .............................

Power Supply Function (AC and DC) ...........................
MemoryFunction ..........................................
Central Processing Unit (CPU) Function .........................
Remote Input/Output (RI/O) Processor Option ....................
Communications Processing Function ..........................
Mainframe Status Indicators .....................................
Mainframe Controls ............................................

2
7
8
9
9
9
10
10

......................

13

984-780/785 Programmable Controller, ............................

Power Supply Function (AC and DC) ............................
Memory Function ..........................................
Central Processing Unit (CPU) Function .........................
Remote input/Output (RI/O) Processor Option ....................
CommunicationsProcessing Function ..........................
Mainframe Status Indicators .....................................
Mainframe Controls ............................................

14
19
20
21
21
21
22
22

Chapter 1

Chapter 2

Chapter 3

Introducing Your ?80/785 Controller

Planning Your Controller and Local l/O Installation ..........

Planning.. ...................................................
Overview .................................................
Space Requirements ........................................
Primary Power Lines ........................................
Environmental Requirements .................................
Mounting Hardware Requirements .............................
Housing Installation Options .....................................
Panel or Bulkhead Mounting ..................................
RackMounting ............................................
Grounding Your Installation ......................................
Primary Power Cable (AC/DC) ...................................
How to Configure Modbus 1, Port 1 Manually ........................

Chapter 4

Installing Your Controller and Local I/O ...................

Installation Procedure with Local I/O ...............................

GM-9994401

25
26
26
26
26
27
27
27
27
28
30
30
32

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Table of Contents

vii

Chapter 5

Planning for Your Remote I/O Installation

..................

Planning for 984 Controllers with 800 Series Remote I/O ...............
Overview .................................................
RI/O Site Location Tradeoffs ..................................
Planning Your Remote I/O Cable Installation .........................
Good Cable installation Practices ..............................
Cabling Requirements .......................................
RI/O Cable Topologies .......................................
Planning Your Cable System Diagram ...........................
Drafting the Cable Diagram ...................................
Grounding Your Installation ........................................
Drop Cable to J890N892 Termination ...............................

Chapter 6

Installing Your Remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Your 800 Series Remote I/O Housings ......................

Panel/Bulkhead Mounting .....................................
RackMounting .............................................
Panel/Bulkhead Mounting ........................................
RackMounting ................................................
Connecting Your Field Wiring .....................................
Power Supply Installation ........................................
AC Input Power Wiring ..........................................
I/OModulelnsertion ............................................
Your S908 RIOP Installation Options ...............................
Remote I/O Cable ..............................................
Verify Your Remote I/O Installation .................................

Appendix A

984-6801685 Specifications

.................,.,........

Mainframe Specifications ........................................

Electrical Characteristics .....................................
Circuit Characteristics .......................................
Environmental Characteristics .................................
Physical Characteristics ......................................
Built-in Power Supply ...........................................
External Power Issue Specifications ................................

Appendix B

984-78OJ785 Specifications

............................

Mainframe Specifications ........................................

Electrical Characteristics .....................................
Circuit Characteristics .......................................
Environmental Characteristics .................................
Physical Characteristics ......................................
Built-in Power Supply ...........................................
External Power Issue Specifications ................................

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Table of Contents

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42
42
43
43
43
44
45
47
48
50

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54
54
54
55
59
63
65
69
69
70
72
74

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76
76
77
78
78
78

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80
80
80
81
82
82
82

GM-0984-501

Appendix C

Cable Hardware Specifications and Cable Checkout . . . . . . .

Qualified Remote I/O Cable Manufacturers ..........................

CableConnectors .............................................
Cable Terminator ...........................................
In-line Terminator ..........................................
RG-6/U Male F Connector ...................................
FIG-G/U Male BNC Connectors ................................
RG-11/U Male F Connector ..................................
RecommendedTools ........................................
Introductionto RIO Cable Checkout ...............................
Cable Checkout Test Equipment ...............................
Cable Checkout Procedures ..................................
Post-Installation Network Integrity Test .............................
Transmission Loss Measurements Tests ........................
Testing for Cable Shield-to-Ground Shorts by Meter ...............
OscilloscopeTesting ........................................
Troubleshooting Noise Problems ..................................
Analyzing Signal Shapes on an Oscilloscope .....................

Appendix D

Troubleshooting

.....................................

StoppedErrorCodes.. .........................................
Customer Service & Technical Assistance ..........................

83
84
86
86
86
87
87
87
88
89
89
90
90
94
95
96
98
99

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Table of Contents

ix

Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45

Table of Contents

984 Model 680/685 ProgrammableController .............

984-680/685 Primary Housing Backplane (H819-209) ......
RIOP (S908) Module (S908-110) ......................
984-680/685 Controller in Primary Housing (Ii81 9-209) ....
984 680/685 Power Supply Connections .................
984-680/685 CPU Board - Right Side View ..............
984-680/685 Controller- Front Panel ...................
984 Model 78Oi785 ProgrammableController .............
984-780/785 Primary Housing Backplane (H819-209) ......
RIOP (S908) Module (S908-110) .....................
984-78Oi785 Controller in Primary Housing (H819-209) ...
984 780/785 Power Supply Connections ................
984-780/785 CPU Board - Right Side View ............
984-78Of785 - Front Panel ..........................
H819 Housing Panel/Bulkhead Mounting Dimensions .....
H819 Housing Rack Mounting Dimensions ..............
984-680/685-780/785 Primary Power Input Connections . .
DIP Switch Settings for Modbus Port 1 .................
Typical Configurationfor Local Drop ...................
Recommended,Allowed, and Illegal Topologies ..........
Example of Cable System Diagram ....................
Centralized (Star) Grounding with Some Typical Mistakes . .
Drop Cable to In-Line 75 Ohm Terminator to J89O/J892 ...
TerminatingLinear and Splitter Networks ...............
Remote I/O H819 Panel/Bulkhead Mounting Dimensions ...
H819 Remote I/O Housing Footprint ...................
Attach Housing to Mounting Surface ...................
Connecting Cables within Each Drop ..................
H819 Rack Mount Dimensions .......................
Attaching Rack Mounting Flange to Housing .............
Rack Mounting Your Housing ........................
Field Wiring to Terminal Strip .........................
P810 Power Supply Insertion ........................
P810 Power Supply Terminal Strip ....................
P800 Power Supply Terminal Strip ....................
P884 Power Supply Terminal Strip ....................
984 800 Series I/O Module Installation .................
S908 Exec Pack Installation .........................
Preparing COAX Shield Prior to Connector Installation .....
Trimming Dielectric and Installing Connector ............
Pulse Reflectionsfrom Impedance Mismatch ............
TDR Measurement for Closely Spaced Taps .............
TDR Printout- Normal Network Profile .................
TDR Reading for Long Cable Run ....................
Measuring for Shield-to-Ground Shorts ................

3
4
5
6
7
8
11
15
16
17
18
19
20
23
28
29
31
33
37
46
47
49
50
51
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56
57
58
60
61
62
64
66
67
68
68
70
71
72
73
91
92
93
94
95

GM-O984-501

Figures (continued)
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52

Scope Test Points - Typical Cable System .............

Normal Envelope .................................
Normal Signal ....................................
Cable Attenuation .................................
Impedance Mismatch ..............................
Unterminated Cable ...............................
Modbus Cable Pinouts .............................

97
99
100
101
102
103
108

Tables
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table

Gh4-99~501

2
3
4
5
6
7
8
9
10
II

Model 680/685 Controllers- Modicon End-User Part Numbers

Model 780/785 Controllers- Modicon End-User Part Numbers
DIP Switch Baud Rate Settings (Left to Right) . . . . . . . . . . . .
Calculate Losses from Sample Cable Diagram (Figure 15) . .
Recommended l/2 in CATV Cable (Up to 15,000 ft) . . . . . . .
Recommended RG-G/U Coaxial Cable (up to 5,000 ft) . . . . .
Recommended RG-11/U Coaxial Cable (up to 8,000 ft) . . . .
Recommended Line Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Line Splitter . . . . . . . . . . . . . . . . . . . . . . . . :,
Summary of Transmission Losses . . . . . . . . . . . . , . . . . . . .
Stopped Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
24
34
47
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84
85
86
86
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