Allen Bradley SLC 500 Programmable Controller System Selection Guide

Allen Bradley SLC 500 Programmable Controller System Selection Guide

In the field of industrial automation, the selection of programmable controllers directly affects the performance, reliability, and scalability of the system. The Allen Bradley SLC 500 series under Rockwell Automation, as a family of rack based small programmable controllers, has become an ideal solution for various industrial applications due to its excellent cost-effectiveness, rich selection of I/O modules, flexible communication configuration, and powerful programming software support. This selection guide aims to help engineers and technicians comprehensively understand the components, specifications, and selection process of the SLC 500 system, ensuring the construction of the optimal control system that meets specific application requirements.

Overview of SLC 500 System

The Allen Bradley SLC 500 is a rack based programmable controller family that includes a processor, discrete, analog, and special function I/O modules, as well as peripheral devices. The SLC 500 family offers powerful functionality and flexibility, with a wide range of communication configurations, features, and memory options. In conjunction with the RSLogix 500 ladder programming software, the system provides a flexible editor, point and click I/O configuration, powerful database editor, as well as diagnostic and troubleshooting tools to help users save project development time and maximize productivity.

Core advantages:

Powerful cost-effectiveness: The SLC 500 programmable controller provides excellent value at an economical price and is suitable for a wide range of application areas, including material handling, HVAC control, high-speed assembly operations, small process control, simple motion control, and SCADA systems.

Modular design: modular processors, power supplies I/O、 Memory options and communication interfaces make the system configurable and scalable. Users can configure the number of I/O points, memory capacity, and communication network as needed, and can expand the system at any time by adding I/O, memory, or communication interfaces.

Advanced instruction set: including indirect addressing, advanced mathematical computing capabilities, and computational instructions.

Wide range of I/O options: Choose from over 60 modules to control discrete, analog, and temperature signals. Encompass partners also offer third-party special modules to meet specific application requirements.

Industrial grade products: designed to withstand vibrations, thermal limits, and electrical noise in harsh industrial environments.

Windows programming software: RSLogix 500 programming software maximizes productivity by simplifying program development and troubleshooting.

System Configuration and Architecture

1. Local system

A modular hardware SLC 500 control system includes at least one processor module and one I/O module, installed in a 1746 rack with power supply. The system can be configured with one, two, or three local racks, with a maximum total of 30 local I/O or communication modules. Extend the backplane signal line of one rack to another rack through rack interconnect cables to achieve the connection of multiple local racks.

2. Distributed systems

More complex systems can use:

Distributed I

Multiple controllers connected via network

Multiple platform I/O distributed in multiple locations and connected through multiple I/O links

Select the appropriate processor based on the requirements of the onboard communication port of the processor. Optional modules can be added to provide additional communication ports for the processor. For I/O locations far from the processor, ControlNet, DeviceNet, or Universal Remote I/O Link can be selected. Both local and remote racks require communication interface modules.

3. System layout

Plan the system by determining the required number of I/O, network configuration, and component layout for each location. Decide whether each rack has its own controller or adopts a networked solution. The SLC 500 processor offers multiple memory sizes (1K to 64K) and can control up to 4096 inputs and 4096 output signals. Except for SLC 5/01, all modular processors are capable of controlling remote I/O. By adding I/O scanner modules, these processors can control/monitor remote I/O through ControlNet, DeviceNet, and universal remote I/O links.

SLC 500 processor series

The SLC 500 processor is a single slot module installed in the leftmost slot of the 1746 I/O rack. For I/O positions far from the processor, the I/O adapter is a single slot module installed in the leftmost slot of the I/O rack. The SLC 500 modular system provides independent power and must be installed directly on the left end of the 1746 I/O rack.

Processor model and specifications

Specification SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05

Memory size (words) 1K/4K 4K 8K/16K/32K 16K/32K/64K 16K/32K/64K

Backplane current @ 5V 90 mA 350 mA 500 mA 1000 mA 1000 mA

Backplane current @ 24V 0 mA 105 mA 175 mA 200 mA 200 mA

Digital I/O maximum 3940 4096 4096 4096 4096

Local rack/slot maximum 3/30 3/30 3/30 3/30 3/30 3/30

Onboard communication DH-485 slave station DH-485 and RS-232 DH+and RS-232 Ethernet and RS-232

Programming instruction count 51 72 107 107 107

Typical scanning time 8 ms/K 4.8 ms/K 1 ms/K 0.9 ms/K 0.9 ms/K

Execution time (XIC) 4 μ s 2.4 μ s 0.44 μ s 0.37 μ s 0.37 μ s

Clock/Calendar Accuracy None ± 54 seconds/month @ 25 ° C ± 54 seconds/month @ 25 ° C ± 54 seconds/month @ 25 ° C

Processor features:

SLC 5/01: Provides a basic instruction set, 1K or 4K memory, suitable for simple control applications.

SLC 5/02: Provides more complex instructions, enhanced communication, faster scan times, and extensive diagnostic capabilities.

SLC 5/03: Built in RS-232 channel, capable of connecting external smart devices without the need for additional modules.

SLC 5/04: Equipped with DH+port, providing high-speed communication between SLC 5/04 and direct connection with PLC-5 controller. There is also an SLC 5/04P option specifically designed for the plastic industry, which includes the ERC2 algorithm.

SLC 5/05: It has the same functionality as SLC 5/04, but uses standard Ethernet communication instead of DH+. The Ethernet communication speed is 10Mbps or 100Mbps, providing a high-performance network for program upload/download, online editing, and peer-to-peer communication.

Processor accessories:

Memory modules: 1747-M1 (1K EEPROM), 1747-M2 (4K EEPROM), 1747-M13 (64K Flash EPROM)

Adapter socket: 1747-M5 (for SLC 5/01/02), 1747-M15 (for SLC 5/03/04/05)

Program Storage Device (1747-PSD): Simplify program development, backup, and upgrade for SLC 5/03 and above processors

Lithium battery module (1747-BA): provides backup power for RAM, with a battery life of approximately 2-5 years

I/O module series

The SLC 500 system provides over 60 types of I/O modules, including digital, analog, and special function modules, to meet various control requirements.

1. Digital I/O module

The digital I/O module has 4, 8, 16, or 32 channels to choose from, providing multiple I/O voltages (including AC, DC, and TTL). The combination module also has 2 input/2 output, 4 input/4 output, and 6 input/6 output options.

Main features:

4. The terminals of the 8, 12, and 16 channel modules have self elevating pressure plates and can accept two 14 AWG (2 mm ²) wires

The LED indicator light at the front of the module displays the status of each I/O point

32 channel I/O module equipped with 40 pin MIL-C-83503 connector and detachable wiring connector (1746-N3)

The output modules include solid-state AC, solid-state DC, and relay contact types

The high current solid-state output modules (1746-OBP16, 1746-OVP16, 1746-OAP12) have a common terminal with a fuse indication

The 1746-OB16E, 1746-OB6EI, and 1746-OB32E modules provide electronic protection to prevent short circuits and overloads

Type of digital input module:

DC input module for current injection: 1746-IB8, IB16, IB32 (24V DC); 1746-IC16（48V DC）； 1746-IH16（125V DC）； 1746-ITB16 (24V DC fast response)

Source current DC input module: 1746-IV8, IV16, IV32 (24V DC); 1746-ITV16 (24V DC fast response); 1746-IG16（5V DC TTL）

AC input module: 1746-IA4, IA8, IA16 (100/120V AC); 1746-IM4、IM8、IM16（200/240V AC）； 1746-IN16（24V AC/DC）

Digital output module type:

Source current DC output module: 1746-OB6EI, OB8, OB16, OB16E, OB32, OB32E (24V DC, with electronic protection); 1746-OBP8, OBP16 (24V DC high current)

DC output module for current injection: 1746-OV8, OV16, OV32 (24V DC); 1746-OVP16 (24V DC high current); 1746-OG16（5V DC TTL）

AC output module: 1746-OA8, OA16 (120/240V AC); 1746-OAP12 (120/240V AC high current)

Relay output module: 1746-OW4, OW8, OW16 (AC/DC relay); 1746-OX8 (AC/DC relay)

Combination I/O modules: 1746-IO4, IO8, IO12 (120V AC input/relay output); 1746-IO12DC (24V DC input/relay output)

2. Analog I/O module

The analog I/O module has user selectable voltage or current input, backplane isolation, detachable terminal blocks, and diagnostic feedback functions.

4-channel analog I/O module:

1746-NI4: High resolution analog input module (± 20 mA or ± 10V DC)

1746-NIO4I/NIO4V: 2 Input/2 Output Combination Module (Current/Voltage Output)

1746-FIO4I/FIO4V: Fast Response 2 Input/2 Output Combination Module

1746-NO4I/NO4V: 4-channel analog output module (current/voltage)

8-channel analog I/O module:

1746-NI8: 8-channel high-resolution analog input module

1746-NO8I/NO8V: 8-channel analog output module (current/voltage)

16 channel analog input module:

1746-NI16I/NI16V: 16 channel high-resolution analog input module (current/voltage)

3. Temperature measurement module

Thermocouple/mV input module:

1746-NT4/NT8:4/8-channel thermocouple input module, supporting J, K, T, E, R, S, B, N type thermocouples

1746-INT4:4 channel thermocouple input module, additionally supporting C and D type thermocouples

All modules provide fully integrated cold end compensation, input filter frequency selection, and fault diagnosis functions

RTD input module:

1746-NR4/NR8: 4/8-channel RTD input module, supporting platinum, nickel, copper, nickel iron RTDs and variable resistance devices (such as potentiometers), providing temperature scaling of ° C or ° F or Ohmic resistance scaling

4. Counter module

1746-HSCE high-speed counter: single and bidirectional counting channels, supporting orthogonal, pulse/direction, or up/down counter inputs, with 4 onboard open collector electrode outputs

1746-HSCE2 multi-channel high-speed counter: Two sets of ± A, ± B, and ± Z input channels, capable of monitoring up to two orthogonal, differential line drivers or incremental encoders

5. Process control module

1746-BLM blow molding module: 4 independent PID control axes, each channel with a pair of discrete I/O for channel synchronization, with a cycle update time of 100 microseconds

1746-BTM barrel temperature module: 4-zone self-tuning PID heating/cooling temperature control, PID algorithm and tuning auxiliary process algorithm are executed on the module

6. Motion control module

1746-HSTP1 stepper control module: a single axis stepper controller that can provide pulse train output up to 250 kHz

1746-HSRV servo control module: a single axis closed-loop servo controller that executes blocks independently of processor scanning time, with encoder feedback up to 300 kHz

7. Positioning module

1746-QV open-loop speed module: suitable for simple hydraulic applications, can accelerate and decelerate hydraulic cylinders, using up to 7 extension and 7 retraction sections

1746-QS synchronous axis module: 4-axis closed-loop servo positioning control, using internal logic to synchronize multiple axes

8. BASIC language module

1746-BAS/BAS-T: Add data collection and report generation capabilities to SLC systems, with two configurable channels that can connect devices such as printers, operator interface terminals, modems, etc

Network communication options

The SLC 500 family offers a variety of communication modules and devices, supporting different networks including EtherNet/IP, ControlNet, DeviceNet, DH+, DH-485, universal remote I/O, and serial networks.

NetLinx Open Network Architecture

Rockwell Automation's NetLinx open network architecture strategy utilizes open network technology to achieve seamless integration from top to bottom. NetLinx based networks - DeviceNet, ControlNet, and EtherNet/IP - all use the Common Industrial Protocol (CIP), share a common language, and a set of common communication services.

Network Selection Guide

Recommended network communication modules/devices for application requirements

High speed data transmission between information systems/large number of controllers/Internet/intranet connection/program maintenance EtherNet/IP SLC 5/05 processor; 1761-NET-ENI/ENIW Ethernet interface

High speed transmission of time critical data between controllers and I/O devices/deterministic and repeatable data delivery/media redundancy or intrinsic safety options ControlNet 1747-KFC15 message module; 1747-SCNR scanner module; 1747-ACN15/ACNR15 adapter module

Low level devices directly connected to controllers/more diagnostics/reduced wiring and startup time DeviceNet 1747-SDN scanner module; 1761-NET-DNI interface module

Factory level and unit level data sharing/program maintenance DH+SLC 5/04 processor

Unit level data sharing/program maintenance DH-485 1747-KE interface module; 1747-AIC isolated link coupler; 1761-NET-AIC Advanced Interface Converter; 1747-UIC USB Converter

Connection between controller and I/O adapter/distributed control universal remote I/O 1747-SN scanner; 1747-BSN backup scanner; 1747-ASB adapter; 1747-DCM direct communication module

Modems/ASCII device communication serial SLC 5/03/04/05 processors; 1747-KE interface module

Rack and power supply

1. Rack options

The SLC modular rack offers four sizes of slots: 4, 7, 10, and 13, which can be selected according to the requirements of modular hardware components. Each rack requires its own power supply, installed on the left side of the rack. Up to 3 racks can be connected using rack interconnect cables.

Catalog Number Description

1746-A4 4-slot rack

1746-A7 7-slot rack

1746-A10 10 slot rack

1746-A13 13 slot rack

1746-C7/C9/C16 rack interconnect cable

1746-N2 card slot filler

2. Power options

Catalog Number Line Voltage 5V Current Capacity 24V Current Capacity User Current Capacity

1746-P1 85-132/170-265V AC 2 A 0.46 A 0.2 A @ 24V

1746-P2 85-132/170-265V AC 5 A 0.96 A 0.2 A @ 24V

1746-P3 19.2-28.8V DC 3.6 A 0.87 A -

1746-P4 85-132/170-250V AC 10 A 2.88 A 1 A @ 24V

1746-P5 90-146V DC 5 A 0.96 A 0.2 A @ 24V

1746-P6 30-60V DC 5 A 0.96 A 0.2 A @ 24V

1746-P7 10-30V DC isolated 12V input: 2A; 24V input: 3.6A 12V input: 0.46A; 24V input: 0.87A-

Precautions for power selection:

Each rack must have a power supply

Overload may cause power shutdown or premature failure

Consider future system expansion

Calculate the total current demand using a power load worksheet

The power supply can withstand short-term power outages (20ms to 3s, depending on the load)

Programming software and tools

1. RSLogix 500 programming software

The RSLogix 500 ladder diagram programming package provides unparalleled productivity and industry-leading user interface, compatible with programs created using the Rockwell Software DOS programming package.

Main functions:

Flexible editing function: The online editor allows for modifications to the application during runtime; The test editing function can test the modification effect before permanent integration; Drag and drop editing allows for quick movement or copying of instructions

Point and click I/O configuration: allocate modules to slots by clicking or dragging them from the complete list; Advanced configuration of special and simulation modules is easy to access

Powerful database editor: Symbol group editor can build and classify symbol groups; The symbol selector list can be assigned addresses or symbols by clicking on them

Diagnostic and troubleshooting tools: advanced diagnosis to quickly locate problem areas; Customize data monitor to simultaneously view bit, timer, counter, input and output status

On demand assistance: Comprehensive online help provides instruction references and step-by-step instructions for common tasks

RSLogix 500 software package:

9324-RL0300ENE: RSLogix 500 Standard Edition (SLC 500 and MicroLogix series)

9324-RL0100ENE: RSLogix 500 Beginner Edition (basic features, some advanced features disabled)

9324-RL0700NXENE: RSLogix 500 Professional Edition (including VBA scripts RSLogix Emulate 500、RSNetWorx for ControlNet/EtherNet/IP/DeviceNet）

2. RSLinx software

RSLinx is a complete communication server that provides factory level device connectivity for various software applications. Support multiple software applications to communicate simultaneously and connect to various devices on multiple networks.

3. RSNetWorx software

RSNetWorx is a configuration tool for controlling networks:

RSNetWorx for ControlNet: Schedule network components and automatically calculate network bandwidth

RSNetWorx for DeviceNet: Configure DeviceNet I/O devices and create scan lists

RSNetWorx for EtherNet/IP: Configuring EtherNet/IP devices using IP addresses or host names

4. RSLogix Simulate 500 software

Simulate one or more SLC 500 processors to test all ladder logic programs before debugging and startup.

System selection process

Step 1: Select the I/O module

Consider module current and voltage requirements, electronic protection, and input/output isolation

Consider using interface modules or pre wired cables

Step 2: Select communication module/device

Determine network communication requirements and select necessary communication modules/devices

Including appropriate communication cables

Consider software requirements (such as RSNetWorx)

Step 3: Select SLC 500 processor

Based on memory I/O、 Speed, programming requirements, and communication options

Consider memory modules and adapter sockets

Step 4: Select SLC 500 rack

Choose a rack with sufficient slots and consider future expansion

Using a slot filler to protect unused slots

Choose interconnecting cables when necessary

Step 5: Select SLC 500 power supply

Calculate the power load of the entire system

Reserve additional capacity for system expansion

Use a power load worksheet to ensure sufficient power supply

Step 6: Select programming software

Select the most suitable RSLogix 500 software package based on application requirements

Consider PC requirements

If necessary, choose other software packages (such as RSNetWorx)