QTS-CLX-PVX PROVOX® Module User Manual
Page ii QTS-CLX-PVX September 2009 Because of the variety of uses for the products described in this publication, those responsible for the application and use of these products must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
QTS-CLX-PVX MODULE OVERVIEW 1 Part Number 2 Module Features 2 Power Requirements 3 Other Requirements 3 Package Contents 3 INSTALLATION 4 Prevent Electrostatic Discharge 4 Prepare the Chassis for Module Installation Determine Module Slot Location Insert the Module in the Chassis 4 4 5 Replacing a Module 6 Cabling and Termination 7 Software Installation 7 SUMMARY OF OPERATIONS 8 IMPORTANT CONSIDERATIONS 9 CONFIGURING THE MODULE IN RSLOGIX 5000 10 Module Configuration Adding the
QTS-CLX-PVX Page iii Configuring from a PROVOX Control I/O Bus 16 Mapping the I/O Data What gets mapped 18 19 Uploading and Downloading Configurations 19 Saving a Configuration File 20 Opening a Configuration File 20 Clearing the Configuration 20 The Configuration Signature 21 Aliases 21 ACCESSING I/O DATA 23 Required Connections 23 Data Updates 23 Discrete Data 23 Analog Data Format 23 Diagnostic Data 25 USING MONITOR MODE FOR MIGRATION 28 TROUBLESHOOTING 29 ControlLogix Mo
Page iv QTS-CLX-PVX September 2009 APPENDIX:CLXPVXCFG 33 APPENDIX: CONFIGURATION FILE FORMAT 35 SPECIFICATIONS 38 QTS-CLX-PVX ControlLogix Module 38 SUPPORT 39 WARRANTY 40
QTS-CLX-PVX Module Overview The QTS-CLX-PVX connects a ControlLogix controller to a PROVOX® Control I/O bus. The QTS-CLX-PVX is intended to be used to migrate PROVOX systems to ControlLogix controllers. You can retain the PROVOX I/O as the first step in the migration. The module can act as a monitor or as a master on the Control I/O bus. You select the mode by downloading different firmware to the module.
Page 2 QTS-CLX-PVX September 2009 does not support Control I/O card redundancy The QTS-CLX-PVX communicates with the ControlLogix processor using scheduled connections. You configure the module as a Generic Module in RSLogix 5000 with: 250 16-bit words of scheduled input data 248 16-bit words of scheduled output data 250 16-bit words of status input data The Windows configuration program supplied with the module maps Control I/O bus data to the scheduled data.
QTS-CLX-PVX Page 3 The module is shipped in monitor mode, with a blank configuration. Watchdog and Jabber Inhibit A watchdog timer is implemented in the module’s hardware. If the firmware does not kick the watchdog within the timeout period the watchdog times out and generates a fatal error (see page 31) with error code D1. In master mode, the module stops scanning and stops communicating with the ControlLogix. A jabber inhibit timer is implemented in the module’s hardware.
Page 4 QTS-CLX-PVX September 2009 Installation Prevent Electrostatic Discharge The module is sensitive to electrostatic discharge. ATTENTION: Electrostatic discharge can damage integrated circuits or semiconductors if you touch backplane connector pins.
QTS-CLX-PVX Page 5 You can use multiple modules in the same chassis. Insert the Module in the Chassis The ControlLogix module is designed to be installed or removed while chassis power is applied. WARNING! ATTENTION: When you insert or remove the module while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.
Page 6 QTS-CLX-PVX September 2009 Figure 2 Inserting the Module Replacing a Module If you are replacing an existing module with an identical one, and you want to resume identical system operation, you must: install the new module in the same slot. run the configuration program and download the appropriate configuration to the module. check that it has the correct firmware, scanner or monitor version.
QTS-CLX-PVX Page 7 Cabling and Termination WARNING! Connecting the module disrupts bus traffic! Connect the module at a time when it is safe to do so. Connect the QTS-CLX-PVX like any other device on the Control I/O bus. The bus cable is 75-ohm RG-6, for example Belden 9290 Terminate both ends of the primary and secondary I/O bus using 75 ohm resistors attached to the physical ends of the bus. There should be two and only two terminators on each bus.
Page 8 QTS-CLX-PVX September 2009 Summary of Operations The following is a short summary of the steps typically followed. Refer to the appropriate manual section for details.
QTS-CLX-PVX Page 9 Important Considerations The operation of the QTS-CLX-PVX is different in several important ways from that of a standard ControlLogix module and in some ways from a PROVOX controller. It is essential that you be aware of the following: the QTS-CLX-PVX in master mode write changes in the ControlLogix output data table to PROVOX outputs even in program mode.
Page 10 QTS-CLX-PVX September 2009 Configuring the Module in RSLogix 5000 You configure the module in RSLogix 5000 to set how much scheduled data to transfer and how often to transfer it. The terms input and output are relative to the ControlLogix. In master mode, the ControlLogix sends output data to the QTS-CLX-PVX, which then transmits it as output data on the PROVOX Control I/O bus. The QTS-CLX-PVX sends PROVOX input data to input data in the ControlLogix.
QTS-CLX-PVX Page 11 4. RSLogix 5000 displays the New Module dialog box. 5. Assign the module a Name and optionally a Description. 6. Set the Comm Format to Data – INT – With Status. 7. Set the Slot to match the slot number of the QTS-CLX-PVX module in the chassis.
Page 12 QTS-CLX-PVX September 2009 8. Set the Connection Parameters as shown above. Click OK. 9. Next set the RPI. 10. Click OK to accept the module Selecting an RPI. The module supports RPIs from 0.2 to 750.0 ms. The default RPI is 5 ms. Select an RPI appropriate to the I/O bus scan time and to your process. It makes no sense to use an RPI that is much faster than the bus or process update time. Typical RPIs are from 100 to 150 ms.
QTS-CLX-PVX Page 13 RSLinx When you right click on the module in RSLinx and select Properties, RSLinx displays the following: Parameter Value Device Name CLX-PVX-MON (Monitor) CLX-PVX-MAS (Master) Vendor 832 (Quest Technical Solutions) Product Type 12 Product Code 1052 (Monitor) 1051 (Master) Revision depends on firmware Serial Number depends on module RSLinx Properties To use the Windows utility programs, you must have RSLinx software, version 2.54 or later, with an activation.
Page 14 QTS-CLX-PVX September 2009 Configuring the I/O ClxPvxCfg Software The QTS-CLX-PVX module is supplied with a Windows configuration tool, ClxPvxCfg.exe.
QTS-CLX-PVX Page 15 The QTS-CLX-PVX Module Properties dialog appears. Enter the Module Name. It can be up to 15 characters long. It should follow the rules for naming ControlLogix aliases; it should contain only alphanumeric characters and the underscore. Click OK to accept the name. The name is displayed on the 4-character display and is used by ClxPvxCfg to build aliases for ControlLogix data. The default name assigned when you perform an autoconfiguration is Auto_Scan.
Page 16 QTS-CLX-PVX September 2009 updating firmware), the configuration is unaffected. Click Apply to download the firmware. When the firmware download is successful, the module displays the following message and shows the version of firmware downloaded. Click OK to clear the message, then click Done.
QTS-CLX-PVX Page 17 2. Use the Actions/Start Auto Configuration menu command or use Auto Configuration toolbar command to start an auto-configuration cycle. WARNING! Resetting the PROVOX controller disrupts the running system! Reset the controller only at a time when it is safe to do so. 3. Reset the PROVOX master. The QTS-CLX-PVX captures the configuration data the master sends out and passes it to the configuration program, which analyzes it and builds the tree. 4.
Page 18 QTS-CLX-PVX September 2009 Note: If the ControlLogix processor previously had a connection open to the QTS-CLXPVX module when the autoconfiguration timed out, that connection remains open, even though there is now no configuration on the module. However, if the module has no configuration, itwill not accept new connections. WARNING! If the configuration in the PROVOX controller changes, you must repeat this procedure to capture the new configuration.
QTS-CLX-PVX Page 19 addresses for data. Failure to do so will result in writing incorrect data and may result in injury or death. If the QTS-CLX-PVX is in master mode and data mappings change, make sure you clear the output data table for the module in the ControlLogix processor before you connect the QTS-CLX-PVX to the Control I/O bus. What gets mapped Master Mode PROVOX inputs (AI, DI) are mapped to ControlLogix inputs (path:I).
Page 20 QTS-CLX-PVX September 2009 If the ControlLogix processor with the connection to the QTS-CLX-PVX is in run mode when you download, the following message is displayed. TIP In master mode, to do the equivalent of a PROVOX reset, download the configuration to the module. Saving a Configuration File To save a configuration to disk, select File/Save or File/Save As. Opening a Configuration File To open a configuration file, select File/Open..
QTS-CLX-PVX Page 21 This does not change the configuration in the module; the configuration in the module changes only when you download. The Configuration Signature The configuration signature is displayed at the root of the tree. It can be used to determine if there are differences between a configuration file and the configuration in the module. Open the configuration file and note the configuration signature. Now upload the configuration from the module and compare the configuration signatures.
Page 22 QTS-CLX-PVX September 2009 Use the Select File Name button to enter the file location. If you are using monitor mode to develop your application, check the Create Temp Array Alias Tags checkbox. You should also create an array of 250 INTs with name TempPvxOutputArray in the ControlLogix. Click OK to create the alias file.
QTS-CLX-PVX Page 23 Accessing I/O Data Required Connections In master mode, the QTS-CLX-PVX does not begin scanning the I/O bus until all ControlLogix connections to the module are present. If the connection is later closed, the QTS-CLX-PVX continues scanning the bus. Inputs do not update in the ControlLogix while the connection is closed and outputs do not update. In monitor mode, the module does not wait for ControlLogix connections.
Page 24 QTS-CLX-PVX September 2009 Number, percent High byte, hex Low byte, hex Number, hex 113.97% 71 F8 71F8 Modules like thermocouples linearize the inputs to percent of range, 1 to 5V. Add-on instructions for RSLogix 5000 to convert between PROVOX percent and ControlLogix real numbers are available from the downloads area of the Rockwell Automation support website http://samplecode.rockwellautomation.
QTS-CLX-PVX Page 25 Example 1: To convert 74.5%, first convert 74 to hexadecimal 4A and store it in the upper byte. Multiply .5 by 256 to get 128 = 80 hex and store it in the lower byte. The result is 4A80 hex. Example 2: To convert -1.75%: Since the number is negative and the fractional part is non-zero, first add 256 to -1 to get 255 and subtract 1. Put 254 = FE hex in the upper byte. The fractional part is .75. Subtract it from 1 to get .
Page 26 QTS-CLX-PVX September 2009 Channel Status Bits In master mode, PROVOX channel status bits for each channel are mapped to ControlLogix status inputs. Use the aliases created by ClxPvxCfg to access the channel status bits. Diagnostic Counters In both monitor and master mode, the module maintains diagnostic counters that can be used to diagnose bus problems. Use the aliases generated by the configuration program to access the diagnostic counters.
QTS-CLX-PVX Page 27 Master Diagnostic Counters Name Description StatPrimTxGood Number of good packets sent on primary channel StatPrimRxGood Number of good packets received on primary channel StatPrimAbortErr Number of abort packets on primary channel StatPrimNoiseErr Number of error packets caused by noise on primary channel StatPrimFrameErr Number of packet frame errors on primary channel StatPrimCrcErr Number of packets with CRC errors on primary channel StatPrimPacketLenErr Number of sho
Page 28 QTS-CLX-PVX September 2009 Using Monitor Mode for Migration You can use monitor mode on the QTS-CLX-PVX to migrate existing PROVOX applications to ControlLogix. In monitor mode, the QTS-CLX-PVX captures live inputs and outputs from the PROVOX bus. You first create an array of 250 INTs with name TempPvxOutputArray in the ControlLogix. The configuration program creates aliases for PROVOX inputs and outputs and for dummy outputs in the temporary array.
QTS-CLX-PVX Page 29 Troubleshooting ControlLogix Module LEDs The module has three status LEDs to indicate the state of internal operations. The LEDs are labeled NET, CLX and OK. NET LED – Control I/O Bus Status The NET LED shows the status of I/O communication. The NET LED states are the same for master and monitor modes.
Page 30 QTS-CLX-PVX September 2009 OK LED – Module Health The OK LED indicates module health. A red LED indicates that module startup diagnostics have failed or a major module fault has occurred. Green indicates that the module has passed all power-up diagnostics and is functioning normally. All LEDs Red If all three LEDs are solid red and the 4-character display shows something like M#66, this indicates that a fatal error has occurred. Refer to page 31 for information on clearing fatal errors.
QTS-CLX-PVX Page 31 If the module has no PROVOX configuration, it refuses connection requests from the ControlLogix processor and returns an error. The Debug Log The firmware on the module maintains a log of informational and diagnostic messages that can be useful in determining the cause of configuration and I/O bus problems. To view the log, run the program LogMon from the Start Menu. Fatal Errors Fatal errors occur when the firmware on the module encounters an unexpected condition.
Page 32 QTS-CLX-PVX September 2009 Updating the Firmware The module firmware is updated using the configuration program. Select Actions/Set Module Mode. To update the firmware, set the mode to match the firmware already loaded in the module. Set Module Mode uses the firmware files (*.qtf) in the same directory as ClxPvxCfg.exe. The configuration program displays the version after the firmware has been downloaded. The module displays the firmware and version currently loaded on the 4-character display.
QTS-CLX-PVX Page 33 Appendix:ClxPvxCfg ClxPvxCfg is the configuration program for the QTS-CLX-PVX module. It is an offline configuration program; you must upload or download configuration data.
Page 34 QTS-CLX-PVX Menu Item September 2009 Description Right Click on Module Edit Module Properties Change module name Auto-allocate CLX Addressing see above Change Module Mode see above Right click on card Delete Card Delete a card from the configuration Also clears all ControlLogix addresses View Card Properties Display cofiguration data for a card
QTS-CLX-PVX Page 35 Appendix: Configuration File Format Configuration files for the QTS-CLX-PVX are text files. The following information is provided for reference only. It is recommended to use the auto-configuration capabilities of the gateway, as this reduces the risk of introducing configuration errors through manually creating or editing configuration files.
Page 36 QTS-CLX-PVX Card Type September 2009 Value, Hex Value, Decimal 16 22 PCI_CARD_TYPE State is used with card redundancy, which is not supported. Always set the value to 9. Priority defines the card priority, 1,2 or 4 CfgMask, IpMask and OpMask define which channels are configured, which channels are inputs and which channels are outputs, respectively.
QTS-CLX-PVX Page 37 Channel Type Value, Hex Value, Decimal AI_CHANNEL_RTD_148_212 37 55 AI_CHANNEL_RTD_100_600 38 56 AI_CHANNEL_RTD_32_392 39 57 AI_CHANNEL_RTD_32_1112 3a 58 AI_CHANNEL_RTD_100_500 3b 59 AI_CHANNEL_RTD_32_300 3c 60 AI_CHANNEL_RTD_SPEC 3d 61 AO_CHANNEL_TYPE_CODE 02 2 ChanParam is an array of 16 bytes containing any channel parameters Input Copy Table and Output Copy Table define where the input and output data for the card are copied to or from in the ControlLogix.
Page 38 QTS-CLX-PVX September 2009 Specifications QTS-CLX-PVX ControlLogix Module Parameter Specification Module Location ControlLogix chassis Function ControlLogix module for PROVOX Control I/O bus Maximum Backplane Current Load 675 mA @ 24VDC and 5 mA @ 5.
QTS-CLX-PVX Page 39 Support How to Contact Us: Sales and Support Sales and Technical Support for this product are provided by ProSoft Technology. Contact our worldwide Sales or Technical Support teams directly by phone or email: Asia Pacific +603.7724.2080, asiapc@prosoft-technology.com Europe – Middle East – Africa +33 (0) 5.34.36.87.20, Europe@prosoft-technology.com North America +1.661.716.5100, support@prosoft-technology.com Latin America (Sales only) +1.281.298.9109, latinam@prosoft-technology.com.
Page 40 QTS-CLX-PVX September 2009 Warranty Quest Technical Solutions warrants its products to be free from defects in workmanship or material under normal use and service for three years after date of shipment. Quest Technical Solutions will repair or replace without charge any equipment found to be defective during the warranty period. Final determination of the nature and responsibility for defective or damaged equipment will be made by Quest Technical Solutions personnel.
