Instruction Manual

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INSTRUCTION MANUAL

MICRO-DCI



53MC5000 PLC AND PRINTER INTERFACES

PN24627A

Rev. 1

Summary of content (124 pages)

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INSTRUCTION MANUAL MICRO-DCI 53MC5000 PLC AND PRINTER INTERFACES PN24627A Rev.
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MicroMod Automation, Inc. The Company MicroMod Automation is dedicated to improving customer efficiency by providing the most ost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation. We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support.
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Contents Table of Contents PREFACE Preface-i 1.0 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 OVERVIEW . . . . . . . . . . . DDI-A/B HARDWARE DESCRIPTION FIELD UPGRADE INFORMATION FOR RS-232/485 ITB SPECIFICATIONS . MODEL NUMBER BREAKDOWN . . 1-1 . . . . . . . . . . EXISTING . . . . . . . . . . . . . . PCS . . . . . . . . . . UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 INSTALLATION 2.1 2.2 2.3 2.4 2.
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53MC9015 53MC5000 PLC and Printer Interfaces 5.0 OPTO 22 MODE 5-1 5.1 PURPOSE . . . . . . . . . . . . . . . . . . . 5.2 PCS DATABASE MAP FOR OPTO 22 MODE . . . . . 5.2.1 PCS DATABASE MAP DIGITAL LOCATIONS 5.2.2 PCS DATABASE MAP ANALOG LOCATIONS 5.3 CONTROL BYTES FOR OPTO 22 . . . . . . . . . 5.4 OPTOMUX COMMANDS . . . . . . . . . . . . . 5.5 ANALOG I/O NUMBERS . . . . . . . . . . . . . 5.5.1 READ ANALOG COMMAND . . . . . . . . 5.5.2 READ ANALOG INPUTS COMMAND . . . . 5.
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Contents 7.6 FAULT ISOLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 8.0 KOYO MODE 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 PURPOSE . . . . . . . . . . . . . . . INSTALLATION CONFIGURATIONS . . . . RS-232/485 ITB-PLC CABLES . . . . . . PCS MEMORY MAP FOR KOYO OPERATING KOYO HEADER BLOCK COMMAND BYTE . CONTROL BYTES FOR KOYO . . . . . . SET-UP PROCEDURE . . . . . . . . . . FAULT ISOLATION AIDS . . . . . . . . . 8-1 . . . . . . . . . MODE . . . . . . . . . . . . . . . . . . . . . . . . .
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53MC9015 53MC5000 PLC and Printer Interfaces List of Tables Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 1-1. RS-232/485 ITB (686B720) Specifications . . . 4-1. Allen-Bradley Commands Used . . . . . . . 4-2. APB Setup Bytes for Allen-Bradley . . . . . . 4-3. PLC Control and Status Bytes for Allen-Bradley . 4-4.
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Contents List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure FIGTOC 1-1. DDI-A and DDI-B Channels . . . . . . . . . . . . . . . 1-2. 53MC5000 Standard Rear Terminal Board ITB Configurations 1-3. 53MC5000 Cord Set Connector Board ITB Configurations . . 2-1.
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Preface PREFACE This manual should be used in conjunction with Instruction Bulletin 53MC5000, MICRO-DCI Process Control Station, Revision 2 (formerly titled Instruction Bulletin 53MC5000, MICRO-DCI Modular Controller, Revision 1). It is assumed the reader is familiar with the information presented in that document to install and operate the 53MC5000 Process Control Station. BOOK OVERVIEW Section 1, Introduction - This section provides preliminary information to acquaint the user with the product.
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Section 1. Introduction 1.0 INTRODUCTION 1.1 OVERVIEW The 53MC5000 Process Control Station (PCS) DDI-A1 Printer/PLC option and the DDI-B2 Printer/PLC option each provide the capability to transfer logical bit indicators and floating point variables to or from a Programmable Logic Controller (PLC). The DDI-A/B Printer/PLC options also provide the capability to send serial output PCS datalog information to a printer.
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53MC9015 53MC5000 PLC and Printer Interfaces SLOTS 5 4 3 2 1 MAIN BOARD POWER SUPPLY + DDI-A DDI-B DDI-A AND DDI-B AUXILIARY PROCESSOR BOARDS (APBs) FIRMWARE IS REV 1 OR HIGHER. (SEE SECTION 9, TABLE 9-1, TO REMOVE AND INSTALL AN APB.) FIRMWARE IS REV.
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Section 1. Introduction • An available Expansion board slot for the DDI-A APB (slot 3) and/or the DDI-B APB (slot 1). To determine the Expansion board option card complement, display slot location datapoints B095 through B099 (for slots 1 through 5 respectively). Option card codes are 128 = MicroLink, 129 = APB, 1 = 6DI/4DO, 2 = Single Channel Analog Input, 3 = Multi-Channel Analog I/O, 4 = 16DI/DO, and 5 = HART Modem.
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53MC9015 53MC5000 PLC and Printer Interfaces 1.5 MODEL NUMBER BREAKDOWN A model number breakdown with supporting Figures 1-2 and 1-3 is provided in the pages that follow: TYPE NO. 53MC SERIES NO.
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Section 1.
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Figure 1-2.
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5 MODNUML 1-7 Figure 1-3. 53MC5000 Cord Set Connector Board ITB Configurations Section 1.
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Section 2. Installation 2.0 INSTALLATION 2.1 53MC5000 PROCESS CONTROL STATION INSTALLATION The PCS instruction bulletin described in the Preface of this book should be referenced for the installation procedure. 2.2 MOUNTING THE RS-232/485 ITB The RS-232/485 ITB is designed for snap-mounting into non-conductive, 2.9 inch (74 mm) wide PVC track that is either surface direct mounted (wall mounted) or mounted on DIN rail (32 or 35 mm) with adapters. This ITB is not provided with an enclosure.
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Figure 2-1.
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Section 2. Installation 2.3 RS-232/485 ITB CABLE CONNECTIONS An RS-232/485 ITB can be connected to either the DDI-A channel (Process Control Station J5) or the DDI-B channel (Process Control Station J9), but not both. As shown in Figure 2-2, the DDI-A cable with 20 pin connectors is installed in J5 of the RS-232/485 ITB and J5 of the 53MC5000 Process Control Station. The DDI-B cable with modular connectors is installed in J4 of the RS-232/485 ITB and J9 of the 53MC5000 Process Control Station. 2.
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53MC9015 53MC5000 PLC and Printer Interfaces GROUNDING Installations are expected to have access to a high quality, noise-free point of earth reference.
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Figure 2-2. Signal and Power Connections Section 2.
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Section 3. Product Description 3.0 PRODUCT DESCRIPTION 3.1 DDI-A AND DDI-B MEMORY MAPS As shown in Figures 3-1 and 3-2, there are two identical memory maps in the 53MC5000 PCS, one for the DDI-A option and one for the DDI-B option. Each memory map has a set of contiguous Ltype datapoints and a set of contiguous C-type datapoints. There are 512 L-type datapoints (32 words or 64 bytes) and 64 C-type datapoints (64 words). In operations involving both L and C data, the L data is transferred first.
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53MC9015 53MC5000 PLC and Printer Interfaces 3.2.
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Section 3. Product Description 3.5 PCS FLOATING POINT-TO-INTEGER CONVERSION In the PCS, floating point numbers are converted to 16 bit unsigned integers before being written to the PLC.
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53MC9015 53MC5000 PLC and Printer Interfaces W O R D B Y T E S 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 DDI-A L-TYPE CONTIGUOUS DATAPOINTS 0 LSB 1 2 3 4 5 6 0,1 2,3 4,5 6,7 8,9 10,11 12,13 14,15 16,17 18,19 20,21 22,23 24,25 26,27 28,29 30,31 32,33 34,35 36,37 38,39 40,41 42,43 44,45 46,47 48,49 50,51 52,53 54,55 56,57 58,59 60,61 62,63 L1536 L1552 L1568 L1584 L1600 L1616 L1632 L1648 L1664 L1680 L1696 L1712 L1728 L1744 L1760 L1776 L1792 L1808 L1824 L1
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Section 3.
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53MC9015 53MC5000 PLC and Printer Interfaces Figure 3-3.
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Section 3. Product Description 3.6 DDI-A AND DDI-B CHANNEL SETUP The DDI-A/B channels each have up to 25 B-type control datapoints that are used for communications setup, read/write operations, and status. Seventeen of these B-type datapoints are configured for each DDI channel by the user to define the PCS-PLC data transfer operations, e.g., starting PLC high/low memory addresses, data quantity transferred each transaction, communications baud rate, etc.
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53MC9015 53MC5000 PLC and Printer Interfaces APB Setup Bytes Title Mode Baud Rate Set-Up DDI-A B290 B292 B293 DDI-B B456 B458 B459 PLC Control and Status Bytes Title Self Address Setup Error Scan Time Scan Overruns Counter DDI-A B670 B684 B685 B686 DDI-B B646 B660 B661 B662 PLC Read Control Bytes PLC Write Control Bytes Title DDI-A DDI-B PLC Address B664 B640 Starting PLC Memory B665 B641 Address Low Starting PLC Memory B666 B642 Address High Number of L LocaB667 B643 tions to Read Number of C Loca
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Section 3. Product Description 3.7 SCAN TIME The Scan Time is a time period from 100 to 25,500 ms that the user selects by entering a value from 1 to 255 into datapoints B685 (DDI-A) and B661 (DDI-B). The read and write data exchanges occur between the PCS and PLC during this time interval; therefore, the purpose of the Scan Time is to set the data update rate for the PCS. The PLC scan cycle runs asynchronously to the internal F-TRAN scan cycle.
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53MC9015 53MC5000 PLC and Printer Interfaces Each character has 11 bits (start, 8 data bits, parity, and stop bit) and at 9600 baud, 1 character time is 1.15 ms (9600/11 = 872 characters; 1 second/872 = 1.15 ms per character). It is true that the 1.15 ms character time used in the overhead calculation is also affected by the baud rate; however, for conservative calculations this number should remain constant for all baud rates at 9600 or above. Baud rates lower than 9600 should double the 1.
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Section 4. Allen-Bradley Mode 4.0 ALLEN-BRADLEY MODE 4.1 PURPOSE The Allen-Bradley interface application permits data transfers between the Process Control Station (PCS) and an addressed Allen-Bradley Programmable Logic Controller (PLC). Allen-Bradley DF-1 Protocol with Data Table and Allen-Bradley PLC-2 Data Table Addressing modes are supported. 4.2 DATA TABLE ADDRESSING Data Table Addressing is the oldest Allen-Bradley addressing mode supported by the PCS AllenBradley PLC Interface.
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53MC9015 53MC5000 PLC and Printer Interfaces 53MC5000 PCS RS-232/485 ITB 1747-KE SLC-5/02 Figure 4-1. Typical Point-to-Point Installation (SLC-5/02 Shown) 53MC5000 PCS RS-232/485 ITB 1770-KF2 PLC-5 (TO BE READ) PLC-5 (TO BE WRITTEN) ALLEN-BRADLEY DATA HIGHWAY Figure 4-2. Typical Allen-Bradley Data Highway Installation 53MC5000 PCS RS-232/485 ITB ALLEN-BRADLEY DH-485 NETWORK 1770-KF3 1747-KA SLC-5/02 (TO BE READ) 1747-KA SLC-5/02 (TO BE WRITTEN) Figure 4-3.
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Section 4. Allen-Bradley Mode RS-232/485 ITB, J1 (FEMALE DB-9 CABLE END) ALLEN-BRADLEY (MALE/FEMALE, DB-25/15 CABLE END) RxD (IN) TxD (OUT) GND 2 3 7 4 5 2 3 5 7 8 TxD RxD GND RTS CTS Figure 4-4. RS-232/485 ITB J1 to Allen-Bradley PLC Cable 4.5 ALLEN-BRADLEY COMMANDS The Allen-Bradley commands used by the PCS interface application are summarized in Table 4-1 as follows: Table 4-1.
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53MC9015 53MC5000 PLC and Printer Interfaces 4.6 CONTROL BYTES FOR ALLEN-BRADLEY The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write Control Bytes are presented in Tables 4-2 through 4-5. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.) Table 4-2.
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Section 4. Allen-Bradley Mode Table 4-4. Allen-Bradley PLC Read Control Bytes Title PLC Address Starting PLC Memory Address (Low) Starting PLC Memory Address (High) Number of L-Words to Read Number of C-Words to Read PLC Error Code* (Reply Status) Definition B640 B641 Set By User User Default 0 0 B642 User 0 B667 B643 User 0 B668 B644 User 0 B671 B647 Software 0 B672 B648 Software 0 B673 B649 Software 0 It is the address of the PLC to be accessed.
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53MC9015 53MC5000 PLC and Printer Interfaces Table 4-5. Allen-Bradley PLC Write Control Bytes Title PLC Address Starting PLC Memory Address (Low) Starting PLC Memory Address (High) Number of L-Words to Write Number of C-Words to Write Write Command Definition B650 B651 Set By User User Default 0 0 B652 User 0 B677 B653 User 0 B678 B654 User 0 B679 B655 User 0 B681 B657 Software 0 B682 B658 Software 0 B683 B659 Software 0 It is the address of the PLC to be accessed.
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Section 4. Allen-Bradley Mode 4.7 SET-UP PROCEDURE The PLC documentation must be referenced to install and configure the PLC; however, examples are given in this section of KF2 communication switch selections, initialization command selections for the KF2, and KF3 initialization switch selections. 1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS. 2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS. 3.
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53MC9015 53MC5000 PLC and Printer Interfaces PLC Control and Status Bytes (Table 4-3) Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time. PLC Read Control Bytes (Table 4-4) PLC Address (B664, B640) - This is a decimal value of the PLC address. Starting PLC Memory Address High and Low Bytes (B665, B641, B666, B642) - Also, see Section 3.4 to ensure these values are properly calculated. Number of L-Words to Read (B667, B643) - Can not exceed 32.
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Section 4. Allen-Bradley Mode 2 of 2 Table 4-6.
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53MC9015 53MC5000 PLC and Printer Interfaces STATION NUMBER ASYNCHRONOUS LINK FEATURES NETWORK LINK COMMUNICATION RATE RS-232-C/RS-422-A ASYNCHRONOUS LINK COMMUNICATION RATE NETWORK LINK SELECTION SW8 SW1 SW2 SW3 SW4 SW5 SW6 SW7 ON OFF RS-232C FULL DUPLEX STATION NUMBER 015 BCC ERROR CHECKING EVEN PARITY NO EMBEDDED RESPONSES DETECT AND IGNORE DUPLICATE MESSAGES 9600 BAUD 57,600 BITS PER SECOND (KF2 MODULE’S NETWORK LINK) PEER COMM LINK PASS ANY RECEIVED DIAGNOSTIC COMMANDS TO THE ATTA
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Section 4. Allen-Bradley Mode 4.8 FAULT ISOLATION AIDS Table 4-7 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation. Table 4-7. Fault Isolation Aids Environmental/Power See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS Instruction Bulletin for PCS environmental and power specifications. PCS Setup Errors Setup Errors 1 through 4 (Table 4-3) - Violating memory map restrictions.
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Section 5. OPTO 22 Mode 5.0 OPTO 22 MODE 5.1 PURPOSE The OPTO 22 interface application performs data transfers between the Process Control Station (PCS) and a system of OPTOMUX boards (stations) over the OPTO 22 serial I/O communication system. 5.2 PCS DATABASE MAP FOR OPTO 22 MODE The PCS database map for the OPTO 22 mode depicts the way the data from the actual boards of the OPTO 22 serial I/O communication system is stored in the PCS memory.
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53MC9015 53MC5000 PLC and Printer Interfaces BOARD NUMBER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BOARD NUMBER 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0 L1536 L1552 L1568 L1584 L1600 L1616 L1632 L1648 L1664 L1680 L1696 L1712 L1728 L1744 L1760 L1776 0 L1792 L1808 L1824 L1840 L1856 L1872 L1888 L1904 L1920 L1936 L1952 L1968 L1984 L2000 L2016 L2032 1 L1537 L1553 L1569 L1585 L1601 L1617 L1633 L1649 L1665 L1681 L1697 L1713 L1729 L1745 L1761 L1777 1 L1793 L1809 L1825 L1841 L1857 L1873 L1889 L1905 L1921
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Section 5.
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53MC9015 53MC5000 PLC and Printer Interfaces 5.2.1 PCS DATABASE MAP DIGITAL LOCATIONS In Figures 5-1 and 5-2, each of the board’s 16 digital modules map into 16 L-datapoints as shown. In addition to the rules given in Section 5.2, the user must specify the same number of PLC modules for every even and odd board for digital board addresses 0-15 and 16-31. Control bytes are dedicated to this function as shown in Figure 5-3.
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Section 5.
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53MC9015 53MC5000 PLC and Printer Interfaces 5.2.2 PCS DATABASE MAP ANALOG LOCATIONS As shown in Figures 5-1 and 5-2, the PCS can accomodate 64 C-values on eight contiguous analog boards (32 through 39) maximum. Any combination of contiguous boards and modules can be used, providing boards x modules does not exceed 64. It should be noted that even though there may be unused modules on an analog board, there are no unused corresponding C-locations in the PCS database.
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Section 5. OPTO 22 Mode BOARD ADDRESS 0 1 2 3 CONTIGUOUS ANALOG BOARDS 32 - 39 MODULE NUMBER 4 5 6 7 8 9 10 11 12 13 14 15 NUMBER OF ACTIVE CONTIGUOUS BOARDS B675/B651 NUMBER OF ANALOG MODULES PER BOARD DDI-A B676 [DDI-B B652]. (E.G., IF B676 [OR B652] = 12, THEN 12 MODULES PER BOARD AND MAXIMUM POPULATION OF 60 MODULES ON 5 BOARDS [BOARDS X MODULES CAN NEVER EXCEED 64].
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53MC9015 53MC5000 PLC and Printer Interfaces 5.3 CONTROL BYTES FOR OPTO 22 The OPTOMUX APB Setup Bytes, PLC Control and Status Bytes, Digital I/O Control Bytes, and OPTOMUX Analog I/O Control Bytes are presented in Tables 5-1 through 5-4. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.) Table 5-1.
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Section 5. OPTO 22 Mode Table 5-2. OPTOMUX PLC Control and Status Bytes Title Definition Communic Communications Error Codes are as follows: ations 255 = Timeout Error 254 = Checksum Error Code* 253 = Bad Message 252 and 251= PCS Hardware Malfunction 240-247 = OPTO 22 Error Codes 00-07 (See the appropriate OPTO 22 documentation for complete definitions.
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53MC9015 53MC5000 PLC and Printer Interfaces Table 5-3. OPTOMUX Digital I/O Control Bytes Title Communication Mode - A minimum of one word (16 Lvalues) is transferred even if only one L-value is used as an active indicator of a process event. 0 = No data exchange 1 = Reads only - (PCS ⇐ board).
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Section 5. OPTO 22 Mode Table 5-4. OPTOMUX Analog I/O Control Bytes Title Watchdog Delay on Outputs (PCS ⇒ board) of Each Board Address 32-39: 0 - Watchdog timer disabled 1 - After 10 seconds, write zero scale. 2 - After 1 minute, write zero scale. 3 - After 10 minutes, write zero scale. 4 - Watchdog timer disabled. 5 - After 10 seconds, write full scale. 6 - After 1 minute, write full scale. 7 - After 10 minutes, write full scale. Communication Mode 0 = No data exchange 1 = Reads only - (PCS ⇐ board).
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53MC9015 53MC5000 PLC and Printer Interfaces 5.4 OPTOMUX COMMANDS The PCS OPTO 22 interface application uses three command sequences: Initialization, Read, and Write, to communicate with the OPTOMUX boards. During the Initialization sequence the PCS sends to the OPTOMUX boards a Reset; control byte values (e.g., B667/B643, which contain the number of even board output modules); watchdog times (e.g., Watchdog Delay, B671/B647); and analog input probe type identifiers (e.g.
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Section 5. OPTO 22 Mode 5.6 SUPPORTED OPTOMUX CONFIGURATIONS As shown in Figure 5-5, typical OPTOMUX installation configurations that are supported by the PCS are multidrop connection and cascade (daisy chain) connection. 17 16 53MC5000 PCS 18 RS-232/485 ITB • • • 00 02 01 Typical Multidrop Connection 53MC5000 PCS RS-232/485 ITB 00 01 02 ••• 39 Typical Cascade (Daisy Chain) Connection Figure 5-5. Typical Installation Configurations 5.
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53MC9015 53MC5000 PLC and Printer Interfaces 5.8 SCALING The minimum value from an OPTO 22 module will be interpreted by the PCS as a -81910 or 0 and the maximum value will be interpreted by the PCS as a 327610 . The range of values from -81910 to 327610 is equivalent to a range from 0 to 409510 . The values 0 to 3276 or -819 to 3276 must be scaled to a 0 - 100% process range.
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Section 5. OPTO 22 Mode 5.9 SET-UP PROCEDURE The OPTOMUX documentation must be referenced to install and configure the OPTOMUX boards. 1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS. 2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS. 3. Figure 5-6 provides an illustration of the RS-485 four wire-to-OPTOMUX board connection. 4. See Section 2 of this book for the required power connections to the RS-232/485 ITB. 5.
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53MC9015 53MC5000 PLC and Printer Interfaces Read Analog Command (B678, B654) - Enter the ASCII code for the type of analog reads to be performed. Enter the code as determined from step 5 for the following two datapoints: Analog Input Type for Board Addresses 32, 33, 36, 37 (B679, B655). Analog Input Type for Board Addresses 34, 35, 38, 39 (B680, B656). Samples to Average (Read Input Average Data command) (B681, B657) - 0 disables sampling. It affects all analog inputs. Enter the appropriate number.
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Section 5. OPTO 22 Mode 5.10 FAULT ISOLATION AIDS Table 5-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation. Table 5-5. Fault Isolation Aids Environmental/Power See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS Instruction Bulletin for PCS environmental and power specifications. PCS Setup Errors PCS Setup Error 2 (Table 5-2) - Bad B Value. Setup Error 10 - Scan Time at 0.
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Section 6. MODBUS RTU Mode 6.0 MODBUS RTU MODE 6.1 PURPOSE The Modbus Remote Terminal Unit (RTU) interface application permits data transfers between the Process Control Station (PCS) and an addressed Modbus Programmable Logic Controller (PLC). The Modbus RTU binary protocol, with a given command set for initialization, write, read, and diagnostics is supported by the PCS. All of the Modbus command messages are followed by a Longitudinal Redundancy Check (LRC).
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53MC9015 53MC5000 PLC and Printer Interfaces 6.3 RS-232/485 ITB-PLC CABLES A custom RS-232 cable is required for point-to-point connection from the RS-232/485 ITB J1 to the PLC. The recommended cable for this PLC application is illustrated in Figure 6-3. In the figure, one end of the cable has a nine pin male plug that connects to J1 of the RS-232/485 ITB and the other end has a 25 pin male or female plug as required by the PLC.
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Section 6. MODBUS RTU Mode 6.4 PCS MODBUS MASTER OPERATION In Modbus master operation, the PCS initiates the read and write commands to the PLC. 6.4.1 PCS MODBUS MASTER MEMORY MAP The DDI-A and DDI-B PCS memory maps for Modbus master operation are laid out similar to those shown in Figures 3-1 and 3-2, except the L-values are stored on the byte boundary instead of a word boundary.
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53MC9015 53MC5000 PLC and Printer Interfaces 6.4.8 WRITING C-VALUES Write Function Code 16 - Preset [Write] Multiple Holding Registers.) Writing C-values causes the addressed information to be accessed from the PCS C-memory area at word boundaries. The information is accessed starting at n locations from the bottom of the Cstack, where n is the number of words to be transferred. The last word in the stack is the last word to be transferred.
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Section 6. MODBUS RTU Mode 6.4.11 WRITING L- AND C-VALUES TOGETHER Write Function Code 16 - Preset [Write] Multiple Holding Registers. Because this command is word oriented, only an even number of L-bytes can be transferred to the PLC. If an attempt is made to transfer an odd number of L-bytes, the next lower even number will be used. To facilitate transferring L- and C-values together, the L-bytes and C-words are first moved from the PCS to the PLC C-value memory segment.
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53MC9015 53MC5000 PLC and Printer Interfaces 6.4.12 PCS MODBUS MASTER COMMANDS The PCS Modbus RTU interface application uses Initialization, Read, and Write Modbus messages to communicate with the PLC. During InItialization, the PCS sends a Restart Communications Option function to the PLC.
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Section 6. MODBUS RTU Mode 2 of 2 Table 6-1. PCS Modbus Master Commands Function Code 16 Data Title Type L and Preset [Write] Multiple C Registers Description This command places specific binary values into a series of consecutive holding registers. It can also be used to write L-and C-values together to the PLC. The L- and C-values are first written to the PLC holding register memory segment. The L-values are written in first at the top of the holding register memory segment, followed by the C-values.
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53MC9015 53MC5000 PLC and Printer Interfaces The Diagnostic command is implemented at the PCS with the Modbus Write Control Bytes (see Table 6-5). The control bytes in the table that are necessary to initiate a Diagnostic command are the PLC Address, Diagnostic Code Low, Diagnostic Code High, Diagnostic Reply Data Low, Diagnostic Reply Data High, and Function Code. Diagnostic information is returned in control bytes Diagnostic Reply Data Low and Diagnostic Reply Data High.
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Section 6. MODBUS RTU Mode Table 6-3. Control and Status Bytes for PCS Modbus Master Title Definition DDI-A Setup Error It indicates the following: 0 = No Error, 1 = L-bytes to B684 read > 64, 2 = C-words to read > 64, 3 = L-bytes to write > 64, 4 = C-words to write > 64, 5 = Invalid Function Code, 6 = Write command 6 specifies more than 1 word of L or C data, 10 = Scan Time at 0. These error codes cause DDI channel operation to halt.
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53MC9015 53MC5000 PLC and Printer Interfaces 2 of 2 Table 6-4. Read Control Bytes for PCS Modbus Master Title Definition DDI-A PLC Error Code* Exception Response Codes 1-7 can be sent B671 (Exception Response from the PLC to the PCS master (see the Code) Modbus documentation for complete definitions.) 01 - Illegal Function: Does not exist as a valid function code. 02 - Illegal Data Address: Not an allowable address. 03 - Illegal Data Value: The fetch quantity requested is not allowed.
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Section 6. MODBUS RTU Mode 1 of 2 Table 6-5. Write Control Bytes for PCS Modbus Master Title PLC Address Definition B650 Set By User Default 0 B675 B651 User 0 B676 B652 User 0 B677 B653 User 0 B678 B654 User 0 B679 B655 User 0 B681 B657 Software 0 It is the address of the PLC to be accessed. B674 Starting PLC Memory The two byte PLC memory address that Address Low (or states where to start writing data into the Diagnostic Code Low) PLC memory.
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53MC9015 53MC5000 PLC and Printer Interfaces 2 of 2 Table 6-5. Write Control Bytes for PCS Modbus Master Title Definition Communications Error* 0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum (CRC) - a checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates unexpected data was found in the reply from the PLC. 252 and 251 = PCS hardware malfunction.
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Section 6. MODBUS RTU Mode PLC Read Control Bytes (Table 6-4) (Cont) Function Code (B669, B645) - This code defines the type of value to be read from the PLC (e.g., coil, status, holding register, input register) PLC Write Control Bytes (Table 6-5) PLC Address (B674, B650) - This is a decimal value of the PLC address. Starting PLC Memory Address Low and High Bytes (B675, B651, B676, B652) - Also, see Section 3.4 to ensure these values are properly calculated.
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53MC9015 53MC5000 PLC and Printer Interfaces Table 6-6. PCS Modbus Master Fault Isolation Aids 2 of 2 RS-232/485 ITB Activity Indicators Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g.
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Section 6. MODBUS RTU Mode 6.5.2 PCS MODBUS SLAVE COMMANDS The commands that the PCS Modbus slave responds to are listed in Table 6-7 as follows: Table 6-7.
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53MC9015 53MC5000 PLC and Printer Interfaces 6.5.3 PCS MODBUS SLAVE CONTROL BYTES The APB Setup Bytes, Control and Status Bytes, and applicable Error Code Bytes for Modbus slave operation are provided in Tables 6-8 through 6-10. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.) Table 6-8.
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Section 6. MODBUS RTU Mode Table 6-10. Error Code Bytes for PCS Modbus Slave Title Exception Response Code* Definition DDI-A Exception Response Codes 1-3 are sent B671 from the PCS slave to the Modbus master. 01 - Illegal Function: Does not exist as a valid function code. 02 - Illegal Data Address: Not an allowable address for the specified slave location (L address over L2047 or C address over C767).
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53MC9015 53MC5000 PLC and Printer Interfaces 6.5.4 PCS MODBUS SLAVE SET-UP PROCEDURE The Modbus PLC documentation must be referenced to install and configure the PLC. 1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS. 2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS. 3.
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Section 6. MODBUS RTU Mode 6.5.5 PCS MODBUS SLAVE FAULT ISOLATION AIDS Table 6-11 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation. Table 6-11. Modbus Slave Fault Isolation Aids Environmental/Power See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS Instruction Bulletin for PCS environmental and power specifications.
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Section 7. Siemens S5 Mode 7.0 SIEMENS S5 MODE 7.1 PURPOSE The Siemens interface application permits data transfers between the Process Control Station (PCS) and a Siemens Programmable Logic Controller (PLC) via the 3964 protocol. The PCS supports the following commands for both read and write operations: 1. D - Data Block 2. A - Absolute Address The PCS supports the following commands for read-only operations: 3. Z - Counter Locations 4. E - Input Bytes 5. A - Output Bytes 6.
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53MC9015 53MC5000 PLC and Printer Interfaces 7.3 RS-232/485 ITB-PLC CABLE A custom RS-232 cable is required for connection from the RS-232/485 ITB J1 to the PLC. The recommended cable for this PLC application is illustrated in Figure 7-2. In the figure, one end of the cable has a 9 pin female connector for J1 of the RS-232/485 ITB and the other end has a 25 pin male or female plug as required by the PLC. The typical maximum cable length for this RS-232 connection is 50 feet (15.2 m).
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Section 7. Siemens S5 Mode 7.4 CONTROL BYTES FOR SIEMENS The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write Control Bytes are presented in Tables 7-1 through 7-4. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.) Table 7-1.
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53MC9015 53MC5000 PLC and Printer Interfaces 1 of 2 Table 7-3. Siemens PLC Read Control Bytes Title Starting PLC Memory Address (Low) Starting PLC Memory Address (High) The two byte PLC memory starting address. B665 For Command 1, the low byte is the Data Word (DW) number and the high byte is the B666 Data Block (DB) number. For commands 26, the high and low bytes form a 16 bit unsigned binary integer. For command 2, it is a PLC memory address.
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Section 7. Siemens S5 Mode 2 of 2 Table 7-3. Siemens PLC Read Control Bytes Title Definition Error Count* This byte is a running total of PLC Error Codes and non-zero Communications Error Codes. *User can reset by writing zeros into the datapoints. DDI-A B673 DDI-B B649 Set By Software Default 0 Default 0 Table 7-4.
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53MC9015 53MC5000 PLC and Printer Interfaces 7.5 SET-UP PROCEDURE The Siemens PLC documentation must be referenced to install and configure the PLC. 1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS. 2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS. 3. Figure 7-2 in this section provides information to fabricate a custom RS-232 cable required to connect J1 of the ITB to the PLC. 4.
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Section 7. Siemens S5 Mode 7.6 FAULT ISOLATION AIDS Table 7-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation. Table 7-5. Fault Isolation Aids Environmental/Power See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS Instruction Bulletin for PCS environmental and power specifications. PCS Setup Errors Setup Errors 1 through 4 (Table 7-2) - Violating memory map restrictions.
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Section 8. Koyo Mode 8.0 KOYO MODE 8.1 PURPOSE The Koyo interface application permits data transfers between the Process Control Station (PCS) and an addressed Koyo Programmable Logic Controller (PLC) or a Koyo vended PLC for companies such as General Electric, GE Fanuc, Texas Instruments, and Siemens (e.g., Series One, Series One PLUS, Series One Junior, Series 305, Series 405, SIMATIC® TI305, and SIMATIC® TI405 PLCs). Data transfers are via the Koyo DirectNET communications protocol. 8.
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53MC9015 53MC5000 PLC and Printer Interfaces 8.3 RS-232/485 ITB-PLC CABLES For point-to-point installations, a custom RS-232 cable is required to connect the RS-232/485 ITB J1 to the PLC. The required cable pin connections vary depending on the Koyo PLC model number. In Figure 8-2 only the RS-232/485 ITB J1 connector end is illustrated; because of the various Koyo PLC model numbers, the PLC documentation should be referenced to determine the required connector type for that cable end.
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Section 8. Koyo Mode 8.5 KOYO HEADER BLOCK COMMAND BYTE The two command codes that are used in the read/write byte of the Koyo DirectNET header block are 30 for read and 38 for write. 8.6 CONTROL BYTES FOR KOYO The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write Control Bytes are presented in Tables 8-1 through 8-4. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective.
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53MC9015 53MC5000 PLC and Printer Interfaces Table 8-3. Koyo PLC Read Control Bytes Title PLC Address Starting PLC Memory Address (Low) Starting PLC Memory Address (High) Number of L-Words to Read Number of C-Words to Read Memory Type Communications Error Code* Definition B640 B641 Set By User User Default 0 0 B642 User 0 B667 B643 User 0 B668 B644 User 0 B669 B672 B645 B648 User Software 0 0 B673 B649 Software 0 It is the address of the PLC to be accessed.
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Section 8. Koyo Mode Table 8-4. Koyo PLC Write Control Bytes Title PLC Address Starting PLC Memory Address (Low) Starting PLC Memory Address (High) Definition DDI-A B650 B651 Set By User User Default 0 0 B652 User 0 B677 B653 User 0 B678 B654 User 0 B679 B682 B655 B658 User Software 0 0 B683 B659 Software 0 It is the address of the PLC to be accessed. B674 The two byte PLC memory address that B675 states where to start writing data into the PLC memory.
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53MC9015 53MC5000 PLC and Printer Interfaces 6. At the PCS, configure all of the appropriate DDI channel datapoints set by the user as follows: PCS APB Setup Bytes (Table 8-1) Mode (B290, B456) - 0 (to ensure interface is off.) Baud Rate (B292, B458) - Set to match the PLC. Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC. PLC Control and Status Bytes (Table 8-2) Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.
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Section 8. Koyo Mode 8.8 FAULT ISOLATION AIDS Table 8-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation. Table 8-5. Fault Isolation Aids Environmental/Power See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS Instruction Bulletin for PCS environmental and power specifications. PCS Setup Errors Setup Errors 1 through 4 (Table 8-2) - Violating memory map restrictions.
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Section 9. Printer Interface 9.0 PRINTER INTERFACE 9.1 PURPOSE When configured to printer interface mode, the DDI-A/B channel(s) can output serial data under control of the resident standard format datalog program or user generated free format datalog programs executing in the Process Control Station (PCS). The standard format datalog program generates datalog printout data streams and is the only PCS resident program designed to use the printer interface.
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53MC9015 53MC5000 PLC and Printer Interfaces 53MC5000 CONTROLLER TO PARALLEL PRINTER PARALLEL OR ● SERIAL-TOPARALLEL CONVERTER ✉ ✉ ✉ TB3 J4 DDI-A SERIAL J5 J5 J1 TO SERIAL PRINTER SERIAL I/F RS-232/485 ITB J1 (FEMALE DB-9 CABLE END) RxD RS-232/485 ITB 686B720U01 3 TxD COM (GND) 5 GND TB2 ✉ 1 R✉ 2 R+ ✉ 3 T✉ 4 T+ ✉ 5 SH J8 J4 J9 J6 J7 TB1 ✉1 ✉2 ✉3 ✉4 ✉5 ✉6 ✉7 ✉8 ✉9 ✉ 10 ✉ 11 ✉ 12 ✉ 13 ✉ 14 ✉ 15 ✉ 16 ✉ 17 ✉ 18 ✉ 19 ✉ 20 ✉ 21 ✉ 22 ● ● ● ● ● TB2 ✉ ✉ ✉ ✉ ✉ TB1 ✉ 1 ✉ 2 TO PARALLEL PRI
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Section 9. Printer Interface 9.4 STANDARD DATALOG The standard datalog format allows up to 16 Status Display Module (SDT) datapoints and 24 Parameter Module (PAR) datapoints to be logged. The number of SDT datapoints to be included in the datalog is specified by the value of datapoint B328 (maximum is 16, one for each SDT datapoint in the standard datalog). The number of PAR datapoints to be included in the datalog is specified by the value of datapoint B329 (maximum is 24, one for each datapoint pair).
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53MC9015 53MC5000 PLC and Printer Interfaces A008 - UNIT TAG NAME B259:B258 HOURS:MINUTES B260 - B261 - B262 DAY - MONTH - YEAR A071 - SDT1 POINT 8 NAME A070 - SDT1 POINT 7 NAME A069 - SDT1 POINT 6 NAME A068 - SDT1 POINT 5 NAME A067 - SDT1 POINT 4 NAME A066 - SDT1 POINT 3 NAME A065 - SDT1 POINT 2 NAME A064 - SDT1 POINT 1 NAME A062 - SDT0 POINT 8 NAME A061 - SDT0 POINT 7 NAME A060 - SDT0 POINT 6 NAME A059 - SDT0 POINT 5 NAME A058 - SDT0 POINT 4 NAME A057 - SDT0 POINT 3 NAME A056 - SDT0 POIN
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Section 9.
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53MC9015 53MC5000 PLC and Printer Interfaces 9.4.1 STANDARD DATALOG DISPLAY Standard display program 33 provides a convenient way for an operator to trigger the standard datalog via the faceplate push buttons. This display is invoked by either directly configuring datapoint B005 to a 33 or by adding a 33 to the display list. (Instructions to add a display to the display list are provided in Table 5-15, System and Miscellaneous Module of IB53MC5000, Revision 2, PCS.
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Section 9. Printer Interface 9.5.1 TRIGGERING BACKGROUND DATALOGS FROM FCS To trigger a standard datalog with datapoint L073 or a free format datalog with datapoint L074 from an FCS wirelist, configure either Parameter Loader A or B to pulse L073 [L074] to a 1. For example, to trigger the standard datalog when the CCI0 input goes from 0 to 1, a typical wirelist would be as follows: B127 B128 B129 B130 B131 B132 B133 B134 = = = = = = = = 0 96 5 0 x 0 71 97 CCI0 (L000) is wired to the A input of Logic A.
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53MC9015 53MC5000 PLC and Printer Interfaces 9.6 FREE FORMAT DATALOG Although the DDI-A/B channel options each provide resident standard datalog capabilities and the standard datalog display, users can write F-TRAN programs to generate datalogs tailored to their needs. These user written datalogs are called free format datalogs. Like the standard datalog, free format datalogs can be triggered as a background operation or as part of a display program.
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Section 9. Printer Interface 9.6.1 FREE FORMAT DATALOG EXAMPLE 1 This is a free format datalog F-TRAN program for a batch report. The report output is illustrated in Figure 9-5.
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53MC9015 53MC5000 PLC and Printer Interfaces \***** PRINT MATERIALS HEADER *****\ PRINT "MATERIALS" PRINT ’CR’ PRINT ’LF’ PRINT " " PRINT " " PRINT "TARGET " PRINT " " PRINT " " PRINT "MEASURED" PRINT ’CR’ PRINT ’LF’ \***** PRINT TOTAL ADDITIVE A *****\ PRINT "ADDITIVE A" PRINT6 ADD_A_TAR PRINT " " PRINT " " PRINT6 ADD_A_ACT PRINT ’CR’ PRINT ’LF’ \***** PRINT TOTAL ADDITIVE B *****\ PRINT "ADDITIVE B" PRINT6 ADD_B_TAR PRINT " " PRINT " " PRINT6 ADD_B_ACT PRINT ’CR’ PRINT ’LF’ \***** PRINT MIXING TIME *****
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Section 9. Printer Interface * * * * * * * * * BATCH REPORT * * * * * * * * * BATCH NUMBER TIME DATE 102 4: 37: 46 2/ 0/ 0 RECIPE NUMBER 0 PRODUCT NAME Unknown Formula MATERIALS ADDITIVE A ADDITIVE B MIX TIME COOK TEMPERATURE COOK TIME COOL TEMPERATURE COOL TIME EMPTY TIME TARGET 1000.0 1000.0 60.000 250.00 120.00 0.0 180.00 90.000 MEASURED CHANGE ME CHANGE ME ***** END OF BATCH REPORT ***** Figure 9-5.
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53MC9015 53MC5000 PLC and Printer Interfaces 9.6.2 FREE FORMAT DATALOG EXAMPLE 2 This is a free format datalog F-TRAN program for an hourly report. The report output is illustrated in Figure 9-6.
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Section 9. Printer Interface * * * * * * * * * HOURLY REPORT * * * * * * * * * TIME 4: 37: 46 DATE FLOW FLOW FLOW FLOW RATE RATE RATE RATE 14/ 6/ 94 A (GPM) B (GPM) C (GPM) D (GPM) 250.00 150.00 75.000 37.500 ***** END OF REPORT ***** Figure 9-6.
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Section 10. Parts Replacement 10.0 PARTS REPLACEMENT 10.1 PARTS REPLACEMENT The parts replacement procedure to access the DDI-A and DDI-B APB boards is provided in Table 10-1; see Figure 10-1. WARNING ALWAYS REMOVE POWER BEFORE ATTEMPTING TO INSTALL, DISASSEMBLE, OR SERVICE THE CONTROLLER. FAILURE TO REMOVE POWER MAY RESULT IN SERIOUS PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. Table 10-1.
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53MC9015 53MC5000 PLC and Printer Interfaces Table 10-1. Parts Replacement 2 of 2 Step Procedure 13 To install the front display panel: Reconnect the ribbon cable to the display J5 socket. Insert the display bottom tabs into the cabinet notches and push the front of the display to latch it in place. 10.2 TECHNICAL ASSISTANCE When replacing parts, should technical assistance be required, contact a MicroMod Automation Inc. office.
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Figure 10-1. Illustrated Parts Breakdown Section 10.
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53MC9015 53MC5000 PLC and Printer Interfaces APB JUMPER CONFIGURATION FOR DDI-A AND DDI-B PLC/PRINTER OPTIONS • • J2 T- • • J1 R- • • J4 T+ • • J3 R+- READING LINE 5 OF THE TABLE BELOW: IF THE CONTROLLER WERE CONFIGURED WITH THE PRINTER/PLC DDI-A OPTION AND MicroLink B COMMUNICATIONS OPTION, THEN THE EXPANSION BOARD WOULD HAVE AN APB OPTION CARD IN SLOT 3, AN MLAC OPTION CARD IN SLOT 2, AND AN MLBC OPTION CARD IN SLOT 1.
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Appendix A. Base 2/8/10/16 Table APPENDIX A: BASE 2/8/10/16 TABLE A numbering system is called a base. Numbers in the binary system are to the base 2; numbers in the octal system are to the base 8, etc. The base of a number is usually indicated as a subscript after the last digit of the number (e.g., 110100002 indicates this is an eight digit binary number and not a decimal number in the ten-millions).
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53MC9015 53MC5000 PLC and Printer Interfaces 1 of 2 Table A-1.
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Appendix A. Base 2/8/10/16 Table 2 of 2 Table A-1.
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The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice, or to make engineering refinements that may not be reflected in this bulletin. Micromod Automation assumes no responsibility for errors that may appear in this manual. © 2004 MicroMod Automation, Inc. Printed in USA MicroMod Automation, Inc. 75 Town Center Drive Rochester, NY USA 14623 Tel. 585-321-9200 Fax 585-321-9291 www.micromodautomation.