GuardPLC™ Controller Systems Bulletin 1753, 1754, 1755 User Manual Solid state equipment has operational characteristics differing from those of Important User Information electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual we use notes to make you aware of safety considerations. Identifies information about practices or circumstances WARNING that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Identifies information that is critical for successful IMPORTANT application and understanding of the product. Identifies information about practices or circumstances ATTENTION that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • identify a hazard • avoid a hazard • recognize the consequence GuardPLC is a trademark of Rockwell Automation. Modbus is a registered trademark of Schneider Automation, Inc. Table of Contents Preface Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . P-1 Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1 Chapter 1 Overview of Safety Controllers Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Response to Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safe States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GuardPLC 1200 System . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GuardPLC 1600 and GuardPLC 1800 System . . . . . . . . . 1-4 Distributed I/O for GuardPLC. . . . . . . . . . . . . . . . . . . . 1-5 GuardPLC 2000 System . . . . . . . . . . . . . . . . . . . . . . . . 1-6 GuardPLC 2000 Power Supply. . . . . . . . . . . . . . . . . 1-7 1755-IB24XOB16 I/O Module . . . . . . . . . . . . . . . . . 1-7 1755-IF8 Analog Input Module . . . . . . . . . . . . . . . . 1-7 1755-OF8 Analog Output Module . . . . . . . . . . . . . . 1-8 1755-HSC High Speed Counter Module . . . . . . . . . . 1-8 Communication Capabilities . . . . . . . . . . . . . . . . . . . . . . . 1-8 GuardPLC Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 ASCII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Modbus RTU Slave. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Profibus DP Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 OPC Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Chapter 2 Installation Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 European Communities (EC) Directive Compliance . . . . . . 2-1 EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 GuardPLC 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Back Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . 2-4 GuardPLC 1600, GuardPLC 1800, and Distributed I/O . . 2-4 GuardPLC 2000 Chassis . . . . . . . . . . . . . . . . . . . . . . . . 2-5 GuardPLC 2000 Controller, I/O, and Power Supply . . . . 2-7 Communication Connections . . . . . . . . . . . . . . . . . . . . . . . 2-9 GuardPLC 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 GuardPLC 1600 and GuardPLC 1800 . . . . . . . . . . . . . . . 2-10 1 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 2 Connections for Safety-Related Communication . . . . 2-10 Connections for Non-Safety-Related Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 GuardPLC Distributed I/O Modules . . . . . . . . . . . . . . . 2-12 GuardPLC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Connections for Safety-Related Communication . . . . 2-12 Connections for Non-Safety-Related Communication 2-13 Reset Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Chapter 3 Wiring Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 GuardPLC Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . 3-2 GuardPLC 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 GuardPLC 1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1753-IB16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 1753-OB16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 1753-IB20XOB8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 GuardPLC 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 1755-IB24XO16 Digital Input/Output Modules . . . . . . . 3-8 1755-IF8 Analog Input Modules . . . . . . . . . . . . . . . . . . 3-9 1755-OF8 Analog Output Modules . . . . . . . . . . . . . . . . 3-9 1755-HSC High Speed Counter Module. . . . . . . . . . . . . 3-10 General Wiring Considerations . . . . . . . . . . . . . . . . . . . . . 3-11 Safety-Related Digital Inputs. . . . . . . . . . . . . . . . . . . . . 3-11 Safety-Related Digital Outputs . . . . . . . . . . . . . . . . . . . 3-11 Safety-Related Analog Inputs . . . . . . . . . . . . . . . . . . . . 3-12 High Speed Counters . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Safety-Related Analog Outputs . . . . . . . . . . . . . . . . . . . 3-14 Power Supply Considerations . . . . . . . . . . . . . . . . . . . . . . 3-15 GuardPLC 1600/1800 Controllers and Distributed I/O . . 3-16 GuardPLC 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 GuardPLC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 GuardPLC 1600 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Safety-Related Digital Inputs. . . . . . . . . . . . . . . . . . . . . 3-17 Safety-Related Digital Outputs. . . . . . . . . . . . . . . . . . . . 3-18 GuardPLC 1800 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Safety-Related Digital Inputs. . . . . . . . . . . . . . . . . . . . . 3-19 Safety-Related Digital Outputs . . . . . . . . . . . . . . . . . . . 3-20 Safety-Related Analog Inputs . . . . . . . . . . . . . . . . . . . . 3-20 Safety Related High Speed Counter. . . . . . . . . . . . . . . . 3-22 1753-IB16 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Pulse Test Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Safety-Related Digital Inputs. . . . . . . . . . . . . . . . . . . . . 3-23 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 3 1753-OB16 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Operating Voltage Considerations. . . . . . . . . . . . . . . . . 3-24 1753-IB20XOB8 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Safety-Related Digital Inputs . . . . . . . . . . . . . . . . . . 3-26 Safety-Related Digital Outputs . . . . . . . . . . . . . . . . . 3-27 GuardPLC 1200 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Lower Terminal Block. . . . . . . . . . . . . . . . . . . . . . . 3-28 Upper Terminal Block. . . . . . . . . . . . . . . . . . . . . . . 3-29 GuardPLC 2000 Terminal Connections and Other Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 1755-IB24XOB16 Digital I/O Module . . . . . . . . . . . . . . 3-30 1755-IF8 Analog Input Module . . . . . . . . . . . . . . . . . . . 3-31 1755-OF8 Analog Output Module . . . . . . . . . . . . . . . . . 3-31 1755-HSC Counter Modules . . . . . . . . . . . . . . . . . . . . . 3-33 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Grounding Considerations for All Controllers . . . . . . . . 3-34 GuardPLC 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 GuardPLC 1600 and GuardPLC 1800 Controllers and Distributed I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 GuardPLC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Preventing Electrostatic Discharge . . . . . . . . . . . . . . . . . . . 3-35 Chapter 4 Connecting to the GuardPLC Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Connecting to the Controller via RSLogix Guard PLUS . . . . 4-1 Controller Connecting to a GuardPLC 1200 Controller . . . . . . . . . . 4-1 Connecting to a GuardPLC 1600 or 1800 Controller . . . . 4-2 Connecting to a GuardPLC 2000 Controller . . . . . . . . . . 4-2 GuardPLC Factory Defaults. . . . . . . . . . . . . . . . . . . . . . 4-2 Understanding Ethernet Addressing . . . . . . . . . . . . . . . 4-2 Configure the IP Address of Your Programming Terminal 4-3 Going Online with the GuardPLC Controller . . . . . . . . . . . 4-5 Step 1: Open RSLogix Guard PLUS . . . . . . . . . . . . . . . . 4-6 Step 2: Create a New Project . . . . . . . . . . . . . . . . . . . . 4-6 Step 3: Configure the Controller Type and SRS . . . . . . . 4-7 Step 4: Communication Settings . . . . . . . . . . . . . . . . . . 4-9 Step 5: Change Settings via MAC Address . . . . . . . . . . . 4-10 Step 6: Move the Settings Into Your Offline Project . . . . 4-11 Step 7: Use the Control Panel to Connect to the GuardPLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Step 8: Change the Controller to STOP Mode . . . . . . . . 4-14 Step 9: Reset the Controller to the Default Settings . . . . 4-14 Step 10: Ping the Controller . . . . . . . . . . . . . . . . . . . . . 4-15 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 4 Step 11: Configure the GuardPLC Controller’s IP Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Step 12: Recovering from a Controller Fault After Using the RESET Button. . . . . . . . . . . . . . . . . . . . . . . . 4-17 Configuring the Programming Terminal . . . . . . . . . . . . . . . 4-19 Specify Host SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Login Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Determining the IP Address and SRS of the Controller . . . . 4-21 Changing the SRS of the Controller . . . . . . . . . . . . . . . . . . 4-22 Changing the IP Address of the Controller . . . . . . . . . . . . . 4-22 Chapter 5 Creating Your First GuardPLC Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Start a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Project Configure the Project and Hardware . . . . . . . . . . . . . . . . . 5-3 Create Signals and Connect Them to I/O Points . . . . . . . . . 5-5 Create a Function Block Program. . . . . . . . . . . . . . . . . . . . 5-9 Save, Compile, Test, and Download the Program . . . . . . . . 5-12 Save the Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Compile the Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Run an Off-Line Simulation . . . . . . . . . . . . . . . . . . . . . 5-13 Download the Program . . . . . . . . . . . . . . . . . . . . . . . . 5-15 How to Monitor the Routine Online. . . . . . . . . . . . . . . . . . 5-17 Chapter 6 Check, Download, Start, and Test Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Checking Consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 a Routine Downloading a Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Troubleshooting the Download Process . . . . . . . . . . . . 6-3 Checking the SRS of the Controller . . . . . . . . . . . . . 6-3 Updating the SRS in the Controller . . . . . . . . . . . . . 6-3 Starting a Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Testing a Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 How a Routine Executes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Controlling a Routine . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Chapter 7 Using the Control Panel Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Resource State Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Safety Parameters Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Statistics Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 P2P (Peer-to-Peer) State Tab . . . . . . . . . . . . . . . . . . . . . . . 7-4 Distributed I/O Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 HH (High-Level High-Speed) State Tab . . . . . . . . . . . . . . . 7-6 Environment Data Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 5 OS Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Using the Multi-Control Panel . . . . . . . . . . . . . . . . . . . . . . 7-8 Control Panel Resource Menu . . . . . . . . . . . . . . . . . . . . . . 7-11 Control Panel Extra Menu . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Chapter 8 Controller Configuration and Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Controller Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Modes of Operation Recovering From A FAILURE_STOP . . . . . . . . . . . . . . . 8-4 Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Routine Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Load a Configuration and Routine (in STOP mode only). . . 8-9 Test Mode of the Routine . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Chapter 9 Monitoring and Forcing Signals Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Monitoring Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Forcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Enabling Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Starting the Force Editor . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Specifying Force Values and Force Marks. . . . . . . . . . . . . . 9-5 Force Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Starting Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Stopping Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Chapter 10 Access Management Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 How the Controller Uses Access Levels . . . . . . . . . . . . . . . 10-1 Creating User Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Chapter 11 Diagnostics Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Viewing Controller Diagnostics . . . . . . . . . . . . . . . . . . . . . 11-1 Selecting Online or Offline Diagnostics. . . . . . . . . . . . . 11-3 Filtering Diagnostic Data . . . . . . . . . . . . . . . . . . . . . . . 11-3 GuardPLC 1200 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 GuardPLC 1600 and GuardPLC 1800 Controllers and GuardPLC Distributed I/O . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 System LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Communication LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Safety-Related GuardPLC Ethernet . . . . . . . . . . . . . . 11-6 Non-Safety-Related Communication. . . . . . . . . . . . . 11-6 GuardPLC 2000 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 Controller Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 Routine Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 6 Ethernet Communication Indicators . . . . . . . . . . . . . . . 11-8 Serial Communication Indicators. . . . . . . . . . . . . . . . . . 11-9 1755-IB24XOB16 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Power Supply and Module Status . . . . . . . . . . . . . . . . . 11-9 I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 1755-IF8 Analog Input Module LEDs . . . . . . . . . . . . . . . . 11-10 1755-OF8 Analog Output Module LEDs . . . . . . . . . . . . . . 11-11 1755-HSC Combination High-Speed Counter and Output Module LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 Power Supply and Module Status . . . . . . . . . . . . . . . . 11-11 I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Chapter 12 Peer-to-Peer Communication Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Peer-to-Peer Communication Basics. . . . . . . . . . . . . . . . . . 12-1 Overview Networking Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 HH Protocol Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Token Group ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Protocol Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 RAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Link Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 TCS Direct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 TCS TOKCYC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Token Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Token Alive Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Primary Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Secondary Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Link Mode (Extern) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Response Time (Extern) . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Peer-to-Peer Protocol Parameters. . . . . . . . . . . . . . . . . . . . 12-6 Message Response Time (ReponseTime). . . . . . . . . . . . 12-7 Receive Timeout (ReceiveTMO) . . . . . . . . . . . . . . . . . . 12-8 Resend Timeout (ResendTMO). . . . . . . . . . . . . . . . . . . 12-8 Acknowledge Timeout (AckTMO) . . . . . . . . . . . . . . . . 12-9 Queue Length (QueueLen). . . . . . . . . . . . . . . . . . . . . . 12-9 Production Rate (ProdRate) . . . . . . . . . . . . . . . . . . . . . 12-9 Watchdog Time (WDZ) . . . . . . . . . . . . . . . . . . . . . . . . 12-9 Worst-Case Reaction Time (TR) . . . . . . . . . . . . . . . . . 12-10 HH Network Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Profile I: Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 Profile II: Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Using LAN Switches and Hubs . . . . . . . . . . . . . . . 12-13 The “None” Profile . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 7 Peer-to-Peer Network Profiles . . . . . . . . . . . . . . . . . . . . . 12-17 Peer-to-Peer Profile I: Fast & Cleanroom . . . . . . . . . . . 12-18 Fast & Cleanrooom Characteristics. . . . . . . . . . . . . 12-18 Peer-to-Peer Profile II: Fast & Noisy . . . . . . . . . . . . . . 12-19 Fast & Noisy Characteristics. . . . . . . . . . . . . . . . . . 12-19 Peer-to-Peer Profile III: Medium & Cleanroom. . . . . . . 12-20 Medium & Cleanroom Characteristics. . . . . . . . . . . 12-20 Peer-to-Peer Profile IV: Medium & Noisy . . . . . . . . . . 12-21 Medium & Noisy Characteristics . . . . . . . . . . . . . . 12-21 Peer-to-Peer Profile V: Slow & Cleanroom. . . . . . . . . . 12-22 Slow & Cleanroom Characteristics . . . . . . . . . . . . . 12-22 Peer-to-Peer Profile IV: Slow & Noisy . . . . . . . . . . . . . 12-23 Slow & Noisy Characteristics . . . . . . . . . . . . . . . . . 12-23 Chapter 13 Configuring Peer-to-Peer Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 Considerations for Using Peer-to-Peer . . . . . . . . . . . . . . . . 13-1 Communication Setting Peer-to-Peer Controller Properties. . . . . . . . . . . . . . 13-2 Communication Time Slice . . . . . . . . . . . . . . . . . . . 13-2 Code Generator Version . . . . . . . . . . . . . . . . . . . . . 13-4 Create a Peer-to-Peer Network. . . . . . . . . . . . . . . . . . . . . . 13-4 Create Token Group(s) . . . . . . . . . . . . . . . . . . . . . . . . 13-5 Add Controllers to Token Group(s) . . . . . . . . . . . . . . . 13-5 Configure Token Group(s) . . . . . . . . . . . . . . . . . . . . . . 13-6 Design the Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7 Create Peer-to-Peer Signals. . . . . . . . . . . . . . . . . . . . . . 13-7 Use Peer-to-Peer System Signals . . . . . . . . . . . . . . . . . . 13-7 Input System Signals. . . . . . . . . . . . . . . . . . . . . . . . 13-7 Output System Signal . . . . . . . . . . . . . . . . . . . . . . . 13-8 Design the Logic for all Controllers. . . . . . . . . . . . . . . . 13-9 Design Logic for Robot A . . . . . . . . . . . . . . . . . . . 13-10 Design Logic for Robot B . . . . . . . . . . . . . . . . . . . 13-10 Configure Peer-to-Peer Communication . . . . . . . . . . . . . . 13-11 Define Controller Connections . . . . . . . . . . . . . . . . . . 13-11 Assign HH-Network . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12 Select Peer-to-Peer Profile . . . . . . . . . . . . . . . . . . . . . 13-13 Define Peer-to-Peer Parameters . . . . . . . . . . . . . . . . . 13-13 Define The Signals to Exchange Between Each Controller Connection . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Compile and Download . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Compile Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Start Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16 Network Optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 Check Routine Timing . . . . . . . . . . . . . . . . . . . . . . . . 13-18 Reconfigure Watchdog Time . . . . . . . . . . . . . . . . . . . 13-19 Check HH Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 8 Check Peer-to-Peer Status. . . . . . . . . . . . . . . . . . . . . . 13-21 Reconfigure ResponseTime . . . . . . . . . . . . . . . . . . . . 13-22 Reconfigure Receive Timeout . . . . . . . . . . . . . . . . . . . 13-23 Chapter 14 Communicating with ASCII Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Connecting the Controller to an ASCII Device . . . . . . . . . . 14-1 Devices Connecting to a GuardPLC 1200 Controller . . . . . . . . . . 14-1 Connecting to a GuardPLC 1600 or 1800 Controller . . . . 14-2 Connecting to a GuardPLC 2000 Controller . . . . . . . . . . 14-3 Configuring the ASCII Serial Port . . . . . . . . . . . . . . . . . . . . 14-4 Connecting Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 ASCII Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6 ASCII master - request . . . . . . . . . . . . . . . . . . . . . . . . . 14-6 ASCII slave - controller response . . . . . . . . . . . . . . . . . 14-7 Data type formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 Chapter 15 Communicating with Modbus and Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Modbus RTU Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Profibus Devices Connecting the Controller to a Modbus Device . . . . . . . 15-2 Configuring the Modbus Serial Port . . . . . . . . . . . . . . . 15-2 Connecting Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 Profibus DP Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 Connecting the Controller to a Profibus DP Device . . . . 15-5 Configuring the Profibus DP Serial Port. . . . . . . . . . . . . 15-6 Connecting Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7 Configuring the Profibus Master . . . . . . . . . . . . . . . . . . 15-8 Chapter 16 Pulse Testing Wiring for Line Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 GuardPLC 1600 and 1753-IB20XOB8. . . . . . . . . . . . . . . 16-1 1753-IB16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2 Response to Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3 Configuration for Line Control . . . . . . . . . . . . . . . . . . . . . . 16-4 Required Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 Pulse Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 Chapter 17 Creating User-Defined Function Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 Creating User-Defined Function Blocks . . . . . . . . . . . . . . . 17-2 Blocks Declaring variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5 Defining Technical Units and Scaling . . . . . . . . . . . . . . 17-8 Defining I/O Positions . . . . . . . . . . . . . . . . . . . . . . . . . 17-9 How the Variables Display . . . . . . . . . . . . . . . . . . . . . . 17-9 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 9 Moving Declared Variables to the User-Defined Function Block Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-10 Generating Function Block Code . . . . . . . . . . . . . . . . . . . 17-11 Checking for Errors and Warnings . . . . . . . . . . . . . . . 17-12 Chapter 18 Using High-Speed Counters Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 Counter/Decoder Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 Counter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 Tips for Using Counters in a GuardPLC System . . . . 18-1 Counter Mode Inputs . . . . . . . . . . . . . . . . . . . . . . . 18-2 Decoder Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2 Decoder Mode Inputs . . . . . . . . . . . . . . . . . . . . . . . 18-2 Understanding Counter Module Configuration . . . . . . . . . . 18-3 Counter Mode/Manual Direction. . . . . . . . . . . . . . . . . . 18-3 Counter Mode/Direction and Reset. . . . . . . . . . . . . . . . 18-4 Decoder Mode/Gray Codes . . . . . . . . . . . . . . . . . . . . . 18-5 Chapter 19 Configuring the GuardPLC OPC Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 Select an IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 Server Adding the GuardPLC Controller and the OPC Server to the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 Configuring the GuardPLC System for OPC Communication 19-3 Configure the Communication Network . . . . . . . . . . . . 19-3 Connecting Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4 Setting the System Properties . . . . . . . . . . . . . . . . . . . . 19-6 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-6 Token Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 Generating Code for the OPC Server . . . . . . . . . . . . . . . . . 19-8 Going Online with the Controller. . . . . . . . . . . . . . . . . . . . 19-8 Using the OPC Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8 Appendix A Specifications GuardPLC 1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 GuardPLC 1600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 GuardPLC 1800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Distributed I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 1753-IB16 Input Module. . . . . . . . . . . . . . . . . . . . . . . . A-6 1753-IB20XOB8 Combination I/O Module. . . . . . . . . . . A-7 1753-OB16 Output Module. . . . . . . . . . . . . . . . . . . . . . A-9 GuardPLC 2000 Controller . . . . . . . . . . . . . . . . . . . . . . . . A-10 GuardPLC 2000 Distributed I/O Modules . . . . . . . . . . . . . A-11 1755-IB24XOB16 Digital I/O Module . . . . . . . . . . . . . A-11 1755-IF8 Analog Input Module . . . . . . . . . . . . . . . . . . A-12 Publication 1753-UM001A-EN-P - April 2004 Table of Contents 10 1755-OF8 Analog Output Module . . . . . . . . . . . . . . . . A-13 1755-HSC High Speed Counter Module. . . . . . . . . . . . A-14 GuardPLC 2000 Power Supply . . . . . . . . . . . . . . . . . . . . . A-15 Appendix B System Variables Using This Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Programming Controller Data . . . . . . . . . . . . . . . . . . . . . . B-1 I/O Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Digital I/O Module Variables (AB-DIO) for GuardPLC 1200 and 2000 . . . . . . . . . . . . . . . . . . . . . . . B-3 Analog Input Module Variables (AB-AI) for GuardPLC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 Analog Output Module Variables (AB-AO) for GuardPLC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 High-Speed Counter Variables For GuardPLC 1200 and 2000 . . . . . . . . . . . . . . . . . . . . . . . B-8 Digital Input Module Variables for GuardPLC 1600 and DIO . . . . . . . . . . . . . . . . . . . . . . B-11 Digital Output Module Variables for GuardPLC 1600, 1800 and DIO. . . . . . . . . . . . . . . . . . B-13 Counter Module Variables for GuardPLC 1800 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14 Digital (Analog) Input Variables for the GuardPLC 1800 Controller . . . . . . . . . . . . . . . . . . . . . B-16 Appendix C Replacing the Backup Battery Preventing Electrostatic Discharge . . . . . . . . . . . . . . . . . . . C-1 GuardPLC 1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 GuardPLC 2000 Power Supply . . . . . . . . . . . . . . . . . . . . . . C-2 Index Publication 1753-UM001A-EN-P - April 2004 Preface Use this manual if you are responsible for designing, installing, Who Should Use This programming, or troubleshooting control systems that use GuardPLC Manual controllers. Personnel responsible for installation, programming, operation, and troubleshooting of safety-related controllers must be familiar with relevant safety standards for Programmable Electronic Systems (PES). The manual only briefly describes the safety concept of the GuardPLC Purpose of this Manual family of controllers. Its purpose is to provide the information on installing and operating your controller system. For detailed information on the safety policy regarding GuardPLC controllers, including information on the controller’s central functions, input and output channels, operating system, application program safety and regulations for use, refer to the GuardPLC Controller Systems Safety Reference Manual, publication number 1755-RM001. The table on the following page lists documents that contain Related Documentation additional information concerning Rockwell Automation GuardPLC products. If you would like a copy, you can: • download a free electronic version from the internet: www.theautomationbookstore.com • purchase a printed manual by: – contacting your local distributor or Rockwell Automation representative – visiting www.theautomationbookstore.com and placing your order – calling 1.800.963.9548 (USA/Canada) or 001.330.725.1574 (Outside USA/Canada) 1 Publication 1753-UM001A-EN-P - April 2004 2 Preface For Read this Document Document Number In-depth information on the safety concept of GuardPLC controller GuardPLC Controller Systems Safety Reference 1755-RM001 systems Manual Information on installing 1754-L28BBB GuardPLC 1200 Controllers. 1754-L28BBB GuardPLC 1200 Installation Instructions 1754-IN001 Information on installing 1755-A6 GuardPLC 2000 I/O Chassis. 1755-A6 GuardPLC 2000 I/O Chassis Installation 1755-IN001 Instructions Information on installing 1755-L1 GuardPLC 2000 Controllers. 1755-L1 GuardPLC 2000 Controller Installation 1755-IN002 Instructions Information on installing 1755-IB24XOB16 GuardPLC 2000 Digital 1755-IB24XOB16 GuardPLC 2000 Digital Input 1755-IN003 Input Modules. Module Installation Instructions Information on installing 1755-IF8 GuardPLC 2000 Analog Input 1755-IF8 GuardPLC 2000 Analog Input Module 1755-IN004 Modules. Installation Instructions Information on installing 1755-OF8 GuardPLC 2000 Analog Output 1755-OF8 GuardPLC 2000 Analog Output Module 1755-IN005 Modules. Installation Instructions Information on installing 1755-HSC GuardPLC 2000 High Speed 1755-HSC GuardPLC 2000 High Speed Counter 1755-IN006 Counter Modules. Module Installation Instructions Information on installing 1755-PB720 GuardPLC 2000 Power 1755-PB720 GuardPLC 2000 Power Supply 1755-IN007 Supplies. Installation Instructions Information on installing GuardPLC 1600 controllers GuardPLC 1600 Controllers Installation Instructions 1753-IN001 Information on installing GuardPLC 1800 controllers GuardPLC 1800 Controllers Installation Instructions 1753-IN002 Information on installing GuardPLC 1753-IB20XOB8 I/O module GuardPLC 1753-IB20XOB8 I/O Module Installation 1753-IN003 Instructions Information on installing GuardPLC 1753-IB16 Input Module GuardPLC 1753-IB16 Input Module Installation 1753-IN004 Instructions Information on installing GuardPLC 1753-OB16 Output Module GuardPLC 1753-OB16 Output Module Installation 1753-IN005 Instructions Information on installing and uninstalling RSLogix Guard PLUS RSLogix Guard PLUS Programming Software 1753-IN006 software Installation Instructions Information on installing and uninstalling the GuardPLC OPC GuardPLC OPC Server Installation Instructions 1753-IN007 Server In-depth information on grounding and wiring Allen-Bradley Allen-Bradley Programmable Controller Grounding 1770-4.1 programmable controllers and Wiring Guidelines A description of important differences between solid-state Application Considerations for Solid-State Controls SGI-1.1 programmable controller products and hard-wired electromechanical devices An article on wire sizes and types for grounding electrical National Electrical Code - Published by the National Fire Protection equipment Association of Boston, MA. A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1 Publication 1753-UM001A-EN-P - April 2004 Chapter 1 Overview of Safety Controllers Using This Chapter For information about: See page understanding the safety concept 1-1 safe states 1-2 GuardPLC system hardware 1-3 communication capabilities 1-8 GuardPLC controllers feature a fail-safe CPU according to IEC 61508 Safety Concept (SIL3) and EN954-1 (Cat.4). Faults that cause loss of safety function are detected within the safety time you specify. Faults that cause loss of safety function only in combination with another fault, are detected at least within the multiple error occurrence time (24 hours). This results in the following requirements for the safety concept: • You specify the safety time and the watchdog time. The multiple error occurrence time is preset to 24 hours. • Even upon the detection of an error, the controller continues to react in a safety-related way. • Faulty input signals (e.g. incorrectly transmitted input values) do not affect the safe function of the controller. Faulted input signals have a “0” value. • An error in a non-safety-related module does not affect the safety of the controller. • The failure of the controller has no effect on the safety of other safety-related modules. For more information on the safety concept, see the GuardPLC Controllers Safety Reference Manual, publication 1755-RM001. 1 Publication 1753-UM001A-EN-P - April 2004 1-2 Overview of Safety Controllers Response to Faults Type of I/O error: Controller behavior: permanent If an error occurs at an I/O point, only this I/O point is considered faulty and not the entire module. In case of faulty input points, “0” is assumed to be the safe value. Faulty output channels are de-energized. If it is not possible to de-energize a single point, the entire module is considered to be faulty, the entire module is de-energized, and the corresponding error status is set. The controller reports the error to the user program. If the entire module cannot be de-energized, the controller goes to FAILURE_STOP. transient A transient error is an error that occurs in an I/O module and then disappears by itself. If a transient error occurs, the module performs a self test. If the test is successful, the status of the I/O module is set to “good” and the module’s normal function continues. In the process, the GuardPLC controller performs a statistical evaluation of the frequency of errors. The I/O module is permanently set to “faulty” if the pre-set error frequency is exceeded. In this case, the module does not resume its normal function after the error has disappeared. To resume normal function, you must cycle power or change the controller to STOP and then RUN. If an error persists for a period of time exceeding that of the multiple error occurrence time (24 hours), the I/O module is permanently set to “faulty” and does not continue normal function after the disappearance of the error. The I/O module can only resume normal function after you cycle power or STOP/START the controller. For faulty modules, the controller uses safe values (“0”, LOW). controller Upon the detection of an error, the controller goes to FAILURE_STOP and all output channels are set to the safe state (value = “0”). In some cases in which a FAILURE_STOP occurs, a power cycle will not enable normal operation. A manual reset from STOP to RUN, using RSLogix Guard PLUS, is required. CAT 4 faults typically require manual resets. An error in the user program is not considered an error of the controller. The controller also monitors the timing and consistency of the: • hardware self-tests and software self-tests of the controller • cycle of the user program • processing of the I/O signals including I/O tests • RUN cycle of the controller • transition from RUN to STOP Inputs Safe States The safe state of an input is indicated by a 0 signal being passed to the user program logic. When a fault occurs, the inputs are switched off (0). Publication 1753-UM001A-EN-P - April 2004 Overview of Safety Controllers 1-3 Outputs An output is in the safe state when it is de-energized. In the event of a fault, all outputs are switched off. This includes faults in Ethernet communication. GuardPLC 1200 System Hardware Overview The GuardPLC 1200 is a compact system consisting of a CPU, watchdog, and on-board digital I/O. The GuardPLC 1200 features 20 digital inputs, 8 digital outputs, and 2 high-speed counters. An RS-232 serial port supports ASCII communications and an Ethernet port provides safety-related communication. A user-supplied 24V dc power supply is required. See page 2-2 for power supply requirements and page 3-15 for power supply connections. Figure 1.1 GuardPLC 1200 Controller Upper Terminal Block PLC Backup Battery 1200 Compartment Port for Factory Use Only ASCII Serial Port Lower Terminal Block Ethernet dongle required Ethernet Port (on bottom of controller) RJ-45 port Publication 1753-UM001A-EN-P - April 2004 1-4 Overview of Safety Controllers GuardPLC 1600 and GuardPLC 1800 System Figure 1.2 GuardPLC 1600 Controller Digital Outputs RJ-45 Ethernet Ports (on top of controller) Voltage Supply Connection RS-485 Serial Ports (see page 1-5) RJ-45 Ethernet Ports (on bottom of controller) Digital Inputs Figure 1.3 GuardPLC 1800 Controller RJ-45 Ethernet Ports (on top of controller) Digital Inputs Digital Outputs Voltage Supply Connection RS-485 Serial Ports High Speed (see page 1-5) Counter Analog Inputs RJ-45 Ethernet Ports (on bottom of controller) The GuardPLC 1600 system features 20 digital inputs, 8 digital outputs with the addition of optional distributed Safety I/O. The GuardPLC 1800 system features 24 digital inputs, 8 digital outputs, 8 safety-related analog outputs, and 2 high speed counters, as well as optional distributed Safety I/O. The status of inputs and outputs is indicated via LEDs. A user-supplied 24Vdc power supply is required. See page 3-15 for information on power supply requirements. Each controller features four 10/100BaseT, RJ-45 connectors to provide safety-related communications via GuardPLC Ethernet to distributed I/O and other GuardPLC controllers, OLE for Process (1) Control (OPC) servers , and with RSLogix Guard PLUS programming software. The four connectors and the controller are connected via an internal Ethernet switch. (1) The OPC server is not suitable for safety-related communications. Publication 1753-UM001A-EN-P - April 2004 Overview of Safety Controllers 1-5 Three ports are located on the front of the controller, providing the following non-safety-related communication options: Serial Port Designation Function COMM1 (RS-485) Modbus RTU Slave (1753-L28BBBM or 1753-L32BBBM-8A) Profibus-DP-Slave (1753-L28BBBP or 1753-L32BBBP-8A) Read/Write COMM2 not used COMM3 (RS-485) GuardPLC ASCII Protocol (Read-only) Distributed I/O for GuardPLC Figure 1.4 GuardPLC Bulletin 1753 I/O 1753-IB20XOB8 Module 1753-IB16 Module Voltage Supply Connection Digital Inputs Voltage Supply Connection Digital Outputs Digital Inputs Ethernet Ports (on bottom of module) Digital Inputs Pulse Test Sources Ethernet Ports (on bottom of module) 1753-OB16 Module Digital Digital Voltage Supply Voltage Supply Connection Outputs Outputs Connection Digital Outputs Ethernet Ports (on bottom of module) Publication 1753-UM001A-EN-P - April 2004 1-6 Overview of Safety Controllers Three modules are available for use with the GuardPLC 1600, GuardPLC 1800, series C GuardPLC 1200 controllers and series C GuardPLC 2000 CPUs. Module status is indicated via LEDs. Catalog Description Inputs Outputs Number 1753-IB16 Input Module 16 digital (not isolated) NA 4 pulse test sources 1753-OB16 Output Module NA 16 digital (not isolated) 1753-IB20XOB8 Input/Output 20 digital (not isolated) 8 digital (not isolated) Module GuardPLC 2000 System The GuardPLC 2000 is a modular system consisting of a controller (1755-L1), which provides central CPU and communications functions, and a separate power supply and I/O residing in a GuardPLC 1755-A6 chassis. A maximum of six I/O modules may be used in a single system. The GuardPLC 2000 controller has one active RS-232 serial port for non-safety related communications. It also features an Ethernet port for configuration and safety-related communications. The lower DB9 port supports RS-232 ASCII (read-only) communications; the upper port is inactive. Publication 1753-UM001A-EN-P - April 2004 Overview of Safety Controllers 1-7 Figure 1.5 GuardPLC 2000 Controller, Power Supply, and I/O Modules GuardPLC 2000 I/O Modules GuardPLC 2000 GuardPLC 2000 Power Supply Controller 1755- 1755- 1755- 1755- 1755- 1755- 1755- 1755- PB720 L1 IB24XOB16 IB24XOB16 IF8 OF8 HSC HSC RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR 1 LS+ 111 LS+ 1 I1+ 1 O1+ 1 C- 1 C- 2 I1 222 I1 2 I- 2 O1- 2 A1 2 A1 RUN STOP 3 I2 333 I2 3 I2+ 3 O2+ 3 B1 3 B1 4 I3 444 I3 4 I- 4 O2- 4 Z1 4 Z1 PROG FAULT 5 I4 555 I4 5 I3+ 5 O3+ 5 C1 5 C1 6 I5 666 I5 6 I- 6 O3- 6 C- 6 C- FORCE Ethernet Port 7 I6 777 I6 7 I4+ 7 O4+ 7 C- 7 C- 8 I7 888 I7 8 I- 8 O4- 8 C- 8 C- 9 I8 999 I8 9 9 9 C- 9 C- GuardPLC 2000 Tx COL 10 LS+ 10 10 LS+ 10 I5+/1-10 O5+ 10 C- 10 C- 11 I9 11 11 I9 11 I- 11 O5- 11 A2 11 A2 12 I10 12 12 I10 12 I6+/2-12 O6+ 12 B2 12 B2 13 I11 13 13 I11 13 I- 13 O6- 13 Z2 13 Z2 14 I12 14 14 I12 14 I7+/3-14 O7+ 14 C2 14 C2 Backup Battery 10/100BaseT 15 I13 15 15 I13 15 I- 15 O7- 15 C- 15 C- 16 I14 16 16 I14 16 I8+/4-16 O8+ 16 C- 16 C- 17 I15 17 17 I15 17 I- 17 O8- 17 C- 17 C- Compartment 18 I16 18 18 I16 18 18 18 C- 18 C- 19 LS+ 19 LS+ 20 I17 20 I17 21 I18 21 I18 22 I19 22 I19 3V DC 23 I20 23 I20 24 I21 24 I21 LITH-BATT. 25 I22 25 I22 26 I23 26 I23 27 I24 27 I24 28 L- 28 L- 19 L- 19 L- 29 O1 29 O1 20 1 20 1 RS-232 Serial Port 24V FAULT 30 O2 30 O2 21 2 21 2 3,3V 5V 31 O3 31 O3 22 3 22 3 RESTART 32 O4 32 O4 23 4 23 4 (inactive) 33 O5 33 O5 24 L- 24 L- 1 34 O6 34 O6 25 L- 25 L- FB1 2 35 O7 35 O7 26 L- 26 L- 3 FAULT 36 O8 36 O8 27 L- 27 L- FB2 37 L- 37 L- RS-232 Serial Port L+ 38 O9 38 O9 DC 24V 39 O10 39 O10 40 O11 40 O11 L- (active) 41 O12 41 O12 42 O13 42 O13 43 O14 43 O14 44 O15 44 O15 45 O16 45 O16 PS CPU DIO DIO AI AO CO CO GuardPLC 2000 Power Supply The 1755-PB720 power supply module provides two voltages (3.3V dc and 5V dc) for the GuardPLC 2000. They are electrically isolated from the supply voltage, 24V dc. 1755-IB24XOB16 I/O Module The 1755-IB24XOB16 digital input/output module provides 24 digital inputs and 16 digital outputs. The status of each I/O signal is displayed with an LED located on the right side of the front plate connectors. Inputs and outputs are electrically isolated from the supply voltage, 24V dc. 1755-IF8 Analog Input Module The 1755-IF8 analog input module has eight inputs. These inputs can be used as either eight single-ended inputs or four differential analog inputs which are electrically isolated from the logic side of the GuardPLC. The measured input value can be either voltage or current. If you use the input module for current, you need a shunt resistor. The measured value is digitally transferred to the processor system as a value between 0 and 2000. Publication 1753-UM001A-EN-P - April 2004 1-8 Overview of Safety Controllers 1755-OF8 Analog Output Module The 1755-OF8 analog output module provides eight outputs, galvanically isolated in groups of 2 (i.e. 2 outputs per power supply). They are electrically isolated from the processor system. Each analog output can operate as a current source or a voltage source. 1755-HSC High Speed Counter Module The 1755-HSC counter module provides two counters and four digital outputs. They are electrically isolated from the processor system. The status of the four output signals is displayed with LEDs located at the right side of the front plate output connector. GuardPLC Ethernet Communication Capabilities GuardPLC Ethernet provides safe communication via Ethernet for distributed I/O and peer-to-peer communications for all GuardPLC controllers. It also provides non-safety-related communication with the OPC server. Programming and configuration of controllers is accomplished via GuardPLC Ethernet. Various GuardPLC systems can be networked together via GuardPLC Ethernet, using star or daisy-chain configurations. A programming device running RSLogix Guard PLUS can also be connected wherever required. Make sure that a network loop is not generated. Data IMPORTANT packets must only be able to reach a node via a single path. Publication 1753-UM001A-EN-P - April 2004 Overview of Safety Controllers 1-9 Figure 1.6 GuardPLC Ethernet Networking Example 12 3 4 5 6 78 9 101112 Star Configuration Daisy-Chain (Line) Configuration 12 3 4 5 6 78 9 101112 L- L- L+ L+ 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- (2A) (2A) 24 V DC RUN ERROR PROG To Programming Terminal FORCE FAULT 1753-IB20OXB8 OSL 20 DC Inputs BL 8 DC Outputs To Programming Terminal D1 D1 D1 D1 D1 LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 12 3 4 5 6 78 9 101112 GuardPLC Ethernet 3 (—) (—) 4 10/100 BaseT 12 3 4 5 6 78 9 10 11 12 12 3 4 5 6 78 9 101112 1 (—) (—) 2 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 L- L- L+ L+ 12 3 4 56 78 9 10 11 12 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- L- L- L+ L+ (2A) (2A) 24V DC DO L- 1 2 34 L- DO L- 5 6 7 8 L- (2A) (2A) RS-485 24 V DC ASCII MODBUS DIO 24 V DC RUN COMM3 COMM2 COMM1 RUN ERROR ERROR PROG PROG FORCE FORCE FAULT FAULT 1753-L28BBBM 1753-IB20OXB8 OSL 20 DC Inputs OSL 20 DC Inputs 3 (—) (—) 4 BL 8 DC Outputs BL 8 DC Outputs 12 3 4 5 6 78 9 10 11 12 D1 D1 D1 D1 D1 12 3 4 56 78 9 10 11 12 LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- D1 D1 D1 D1 D1 LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- L- L- L+ L+ 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 24V DC DO L- 1 2 34 (2A) L- DO L- 5 6 7 (2A) 8 L- GuardPLC Ethernet 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 10/100 BaseT RS-485 GuardPLC Ethernet ASCII MODBUS 3 (—) (—) 4 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 10/100 BaseT 24 V DC 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 COMM3 COMM2 COMM1 1 (—) (—) 2 RUN ERROR PROG Controller FORCE FAULT Controller 1753-L28BBBM OSL 20 DC Inputs DIO BL 8 DC Outputs D1 D1 D1 D1 D1 LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 GuardPLC Ethernet 10/100 BaseT 3 (—) (—) 4 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 DIO DIO 12 3 4 5 6 78 9 101112 12 3 4 5 6 78 9 101112 12 3 4 5 6 78 9 101112 12 3 4 5 6 78 9 101112 L- L- L+ L+ L- L- L+ L+ 12 3 4 5 6 78 9 101112 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- 12 3 4 5 6 78 9 101112 (2A) (2A) (2A) (2A) 12 3 4 5 6 78 9 101112 L- L- L+ L+ 12 3 4 5 6 78 9 101112 24 V DC 24 V DC 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- L- L- L+ L+ RUN RUN (2A) (2A) 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- ERROR ERROR (2A) (2A) PROG PROG 24 V DC FORCE FORCE RUN 24 V DC ERROR RUN FAULT 1753-IB20OXB8 FAULT 1753-IB20OXB8 ERROR OSL 20 DC Inputs OSL 20 DC Inputs PROG BL 8 DC Outputs BL 8 DC Outputs FORCE PROG FAULT FORCE D1 D1 D1 D1 D1 D1 D1 D1 D1 D1 1753-IB20OXB8 OSL 20 DC Inputs FAULT LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 1753-IB20OXB8 BL 8 DC Outputs OSL 20 DC Inputs 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 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 BL 8 DC Outputs GuardPLC Ethernet GuardPLC Ethernet D1 D1 D1 D1 D1 10/100 BaseT 10/100 BaseT LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- (—) (—) 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 (—) (—) 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 D1 D1 D1 D1 D1 1 2 1 2 LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 GuardPLC Ethernet 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 10/100 BaseT GuardPLC Ethernet 1 (—) (—) 2 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 10/100 BaseT 1 (—) (—) 2 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 DIO DIO 12 3 4 5 6 78 9 101112 12 3 4 5 6 78 9 101112 L- L- L+ L+ 24V DC DO L- 1 2 3 4 L- DO L- 7 8 9 10 L- (2A) (2A) 24 V DC RUN ERROR PROG FORCE FAULT 1753-IB20OXB8 OSL 20 DC Inputs BL 8 DC Outputs D1 D1 D1 D1 D1 LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 GuardPLC Ethernet 10/100 BaseT 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 (—) (—) 2 DIO ASCII This read-only, non-safety-related protocol can be used to extract diagnostic and status information from the GuardPLC controllers. ASCII protocol is available over the RS-232 port on the GuardPLC 1200 and GuardPLC 2000 controllers and via the RS-485 Comm 3 port on GuardPLC 1600 and GuardPLC 1800 controllers. See Chapter 14 for details on communication with ASCII devices. Modbus RTU Slave Modbus is a standard industrial non-safety-related serial protocol in which the Modbus master can communicate with a maximum of 255 slave devices. The Modbus master initiates and controls all communications on the network. Modbus RTU Slave protocol is available via the RS-485 Comm 1 port on GuardPLC 1600 and GuardPLC 1800 controllers with catalog numbers ending in “M”. Publication 1753-UM001A-EN-P - April 2004 1-10 Overview of Safety Controllers Modbus RTU Slave protocol allows both the reading and writing of data. For more information on the Modbus RTU Slave protocol, see the Modbus Protocol Specifications, available from www.modicon.com/techpubs/. Profibus DP Slave Profibus DP is a non-safety-related serial protocol, designed for high-speed data transmission between automation systems and distributed peripherals. Profibus DP slave is available via the RS-485 Comm 1 port on GuardPLC 1600 and GuardPLC 1800 controllers with catalog numbers ending in “P”. Profibus DP Slave protocol allows both the reading and writing of data. OPC Server The GuardPLC 1600, GuardPLC 1800, and series C GuardPLC 1200 and 2000 are OPC clients. An OPC server, catalog number 1753-OPC, is available from Rockwell Automation and allows PC applications to read and write data to and from the GuardPLC (non-safety-related communications only). Publication 1753-UM001A-EN-P - April 2004 Chapter 2 Installation Using This Chapter For information about: See page European Communities (EC) Directive Compliance 2-1 mounting 2-2 communication connections 2-9 reset pushbutton 2-13 If this product has the CE mark it is approved for installation within European Communities (EC) the European Union and EEA regions. It has been designed and tested Directive Compliance to meet the following directives. EMC Directive This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part: • EN 50081-2 EMC — Generic Emission Standard, Part 2 — Industrial Environment • EN 50082-2 EMC — Generic Immunity Standard, Part 2 — Industrial Environment • EN 61131-2 — Programmable Controllers, Part 2: Equipment Requirements and Tests • EN 61000-6.2 EMC — Part 6-2: Generic Standards — Immunity for Industrial Environments This product is intended for use in an industrial environment. 1 Publication 1753-UM001A-EN-P - April 2004 2-2 Installation Low Voltage Directive The power supply of the GuardPLC controllers must meet Council Directive 73/23/EEC Low Voltage, by applying the requirements of EN 61131-2 Programmable Controllers, Part 2 – Equipment Requirements and Tests, as well as one of the following: • EN 60950 — SELV (Safety Extra Low Voltage) • EN 60204 — PELV (Protective Extra Low Voltage) General Safety Open style devices must be provided with environmental and safety protection by proper mounting in enclosures designed for specific application conditions. See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Consider the following before installing your ATTENTION GuardPLC 1200/1600/1800 controller or distributed I/O: These products are grounded through the DIN rail. Use zinc-plated yellow-chromate steel DIN rails to assure proper grounding. The use of other DIN rail materials (e.g. aluminum, plastic, etc.) that can corrode, oxidize, or are poor conductors, can result in improper or intermittent grounding. GuardPLC 1200 Mounting The GuardPLC 1200 can be either snapped onto a DIN rail or mounted to a back panel using bolts. DIN rail mounting is the easiest way to attach the controller and should be used wherever possible. Publication 1753-UM001A-EN-P - April 2004 Installation 2-3 For cooling reasons: IMPORTANT • The GuardPLC 1200 must be mounted horizontally with the Ethernet socket facing down. • Select a location where air flows freely or use an additional cooling fan. • The minimum clearance around the GuardPLC 1200 must be at least 100 mm. • Do not mount the GuardPLC 1200 over a heating device. DIN Rail Mounting 1. Hook the two top latches, on the back of the GuardPLC 1200, over the top of the DIN rail. 2. If the lower latches are extended (see figure below), push them up until they lock into place. If the lower latches are not extended, press the GuardPLC 1200 into the DIN rail until they lock into place. PLC 1200 lower latch (not extended) lower latch (extended) If you need to remove the controller from the DIN TIP rail, use a screwdriver to pull down the lower latches, then lift the controller toward you. Publication 1753-UM001A-EN-P - April 2004 2-4 Installation Back Panel Mounting Do not bend the controller. Bending the controller ATTENTION will damage it. Use the four brackets on the GuardPLC 1200 to mount it onto a back panel. Top Brackets Use the following to mount the controller: PLC 1200 Top Brackets Bottom Brackets M4 screws (2) M5 screws (2) lock washer lock washer washers washers nut nut Bottom Brackets If the mounting brackets are not flat before the nuts are tightened, use additional washers as shims, so the controller does not bend when you tighten the nuts. GuardPLC 1600, GuardPLC 1800, and Distributed I/O For effective cooling: IMPORTANT • Mount the device horizontally. • Provide a gap of at least 100 mm (3.94 in.) above and below the device and at least 20 mm (0.79 in.) horizontally between devices. • Wire duct can run in the 100 mm (3.94 in.) of free space above and below the controller if it is no deeper than 40 mm (1.58 in.). If the depth is greater than 40 mm (1.58 in.), the devices must be placed on stand-offs that match the depth of the duct. If stand-offs are not used, you must provide a gap of at least 80 mm (3.15 in.) between the device and the duct. • Select a location where air flows freely or use an additional fan. • Do not mount the controller or I/O module over a heating device. • Do not block the ventilation slots on the side of the device. Publication 1753-UM001A-EN-P - April 2004 Installation 2-5 GuardPLC 1600/1800 controllers and I/O cannot be panel-mounted. Mount the GuardPLC 1600/1800 controllers and distributed I/O to a DIN rail by following the steps below. 1. Hook the top slot over the DIN rail. (1) Top Slot 2. Insert a flathead screwdriver into (3) DIN Rail the gap between the housing and (2) the latch and pull the latch downward. Latch 3. Hold the latch down as you push the housing back onto the DIN rail. 4. Release the latch to lock the device onto the rail. To remove the device from the DIN rail, insert a TIP flathead screwdriver into the gap between the housing and the latch and pull the latch downward as you lift the device off of the rail. GuardPLC 2000 Chassis The GuardPLC 2000 provides two flanges with eyelets. Refer to the illustration below. Use bolts to mount the system to a back panel. To mount the chassis flanges, you will need four M8 size bolts with lock washer, washer and nut with 13 mm (max.) head diameter. The bolts must be long enough to accept the chassis at its mounting place. • Do not bend the chassis. Bending will damage ATTENTION the chassis and/or the backplane inside the GuardPLC 2000. • If the rear side of the chassis does not lie flat before the nuts are tightened, use additional washers as shims so that the chassis does not bend when you tighten the nuts. Publication 1753-UM001A-EN-P - April 2004 2-6 Installation • The chassis must be installed without any modules IMPORTANT inserted. • Disconnect the supply voltage before mounting the chassis. • The chassis must be vertically mounted with the cooling fans on the lower side. • Do not obstruct ventilation openings. • Provide a gap of at least 100 mm (3.94 in.) above and below the device and at least 20 mm (0.79 in.) horizontally between devices. Modules are shown for illustration only. The chassis must be installed without any modules inserted. 255 mm (10 in.) including flanges 236 mm (9.3 in.) width eyelet to eyelet 15.9 mm (0.63 in.) eyelet flanges 177.8 mm (7.0 in.) 285 mm 11.2 in.) Depth: 218 mm eyelet (8.6 in.) includes termination plug Publication 1753-UM001A-EN-P - April 2004 Installation 2-7 GuardPLC 2000 Controller, I/O, and Power Supply Mount the GuardPLC 2000 chassis prior to installing the controller, I/O, and power supply modules. Disconnect the power supply module, 1755-PB720, IMPORTANT from the 24V dc supply voltage before you insert the module. 1. Before you insert the module, you must detach the grounding grill. To do this, remove the grounding grill screws (see figure below). grounding grill 2. Remove the lower panel of the chassis and disconnect the fans. 3. Power Supply: Insert the power supply into the left-most slot of the chassis. Controller: Insert the controller into the slot directly to the right of the power supply module (slot 0). I/O Module: Insert the module into any unused slot from 1 to 6 (see figure on page 2-8). Keep the module in line with the guides so the module runs smoothly in the track. 4. Begin pushing the module into the chassis. If there is resistance when you push the module into the backplane, do not force the module because the pins will bend. Remove the module and start again at step 3. 5. Continue pushing the module into the chassis until the front of the module is flush with the other modules in the chassis. 6. Secure the module with the module screws on the top and bottom of the module (see figure on page 2-8). Publication 1753-UM001A-EN-P - April 2004 1755- IF8 RUN ERR I1+ 1 I- 2 I2+ 3 I- 4 I3+ 5 I- 6 I4+ 7 I- 8 9 10 I5+/1- I- 11 12 I6+/2- 13 I- 14 I7+/3- I- 15 16 I8+/4- 17 I- 18 A-B QUALITY Allen-Bradley GuardPLC 2000 QUALITY A-B Allen-Br Allen-Bradle adley GuardPLC 2000 2-8 Installation controller screw I/O module screw power supply screws Slot 0 Slot 6 Slot 2 Slot 4 Slot 5 Slot 3 Slot 1 guides power supply screws I/O module screw If you are installing other GuardPLC 2000 modules, TIP follow their Installation Instructions up to this point before you complete the next 3 steps. 7. Reconnect the fans. 8. Replace the lower panel of the chassis, sliding it over the tabs on the sides of the chassis and under the tabs on the back of the chassis. 9. Use the grounding grill screws to attach the grounding grill. Publication 1753-UM001A-EN-P - April 2004 Installation 2-9 GuardPLC 1200 Communication Connections The GuardPLC 1200 has an ASCII serial port for non-safety-related communications and an Ethernet port for safety-related communications. Connect the ASCII port to any RS-232 device that has the capability to send ASCII command strings to the controller. The controller replies with a data variable string. See Chapter 14 for more information on ASCII communications Use the following illustration to connect the ASCII and Ethernet ports. PLC 1200 Port for Factory ASCII Use Serial Port Only (use 1761-CBL-PM02 series C cable) Ethernet dongle Ethernet Port (on bottom of controller) The pin assignment of the ASCII Serial port is shown below. 2 1 4 Pin Function 3 5 6 1 24V dc 8 7 2 ground (GND) 3 request to send (RTS) 4 received data (RxD) 5 received line signal detector (DCD) 6 clear to send (CTS) 7 transmitted data (TxD) 8 ground (GND) 9 not applicable Publication 1753-UM001A-EN-P - April 2004 2-10 Installation GuardPLC 1600 and GuardPLC 1800 Connections for Safety-Related Communication The controller has four 10/100BaseT, RJ-45 connectors to provide communications via GuardPLC Ethernet to other controllers, distributed I/O or RSLogix Guard PLUS. Connectors 1 and 2 are located on the bottom side on the left. Connectors 3 and 4 are located on the top side on the left. Ethernet Ports 3 and 4 3 (—) (—) 4 L- L- L+ L+ 24V DC RS-485 ASCII MODBUS COMM3 COMM2 COMM1 GuardPLC Ethernet 10/100 BaseT 1 (—) (—) 2 Ethernet Ports 1 and 2 All four connectors and the GuardPLC processor are connected together by an internal Ethernet switch. In contrast to a hub, a switch is able to store data packets for a short period of time in order to establish a temporary connection between two communication partners for the transfer of data. In this way, collisions (typical of a hub) can be avoided and the load on the network is reduced. The switch automatically switches between transfer rates of 10 and 100 Mbit/s and between full- and half-duplex connections. This makes the full bandwidth available (full-duplex operation) in both directions. A switch enables several connections to be established at the same time and can address up to 1000 absolute MAC addresses. Auto-crossing recognizes that cables with crossed wires have been connected and the switch adjusts accordingly. Therefore, either cross-over or straight-through Ethernet cabling can be used. Star or line configurations are available. Make sure that a network loop is not generated. Data packets must only be able to reach a node via a single path. See Chapters 4 and 12 for information on programming via Ethernet and on peer-to-peer communications. Publication 1753-UM001A-EN-P - April 2004 Installation 2-11 Connections for Non-Safety-Related Communications Three 9-pin Min-D connectors are located on the front of the controller, providing the following communications: Designation Function COMM1 (RS-485) Modbus RTU Slave (1753-L28BBBM or 1753-L32BBBM-8A) Profibus-DP-Slave 1753-L28BBBP or 1753-L32BBBP-8A) COMM2 not used COMM3 GuardPLC ASCII Protocol 3 (—) (—) 4 L- L- L+ L+ 24V DC RS-485 ASCII MODBUS COMM3 COMM2 COMM1 Modbus or Profibus port ASCII port (COMM 3) (COMM 1) GuardPLC Ethernet 10/100 BaseT 3 (—) (—) 4 The three Min-D connectors are RS-485. You must IMPORTANT use an electrical interface device to connect the controller to an RS-232 device. The pin assignment of the Min-D connectors is shown in the table below. Connection Signal Function 1 --- --- 2 RP 5V, decoupled with diodes 3 RxD/TxD-A Receive/Transmit data A 4 CNTR-A Control Signal A 5 DGND Data reference potential 6 VP 5V, positive pole of supply voltage 7 --- --- 8 RxD/TxD-B Receive/Transmit data B 9 CNTR-B Control Signal B Publication 1753-UM001A-EN-P - April 2004 2-12 Installation GuardPLC Distributed I/O Modules Each module has two 10/100BaseT, RJ-45 connectors to provide safety-related communications via GuardPLC Ethernet. These two connectors and the GuardPLC DIO module are connected together by an internal Ethernet switch. L- L- L+ L+ 24V DC 24 V DC RUN ERROR PROG FORCE FAULT OSL BL GuardPLC Ethernet 10/100 BaseT 1 (—) (—) 2 Ethernet Ports 1 and 2 GuardPLC 2000 Connections for Safety-Related Communication To configure/program the GuardPLC system, the controller must be connected on an Ethernet network to the RSLogix Guard PLUS programming terminal. GuardPLC Ethernet also provides for Peer-to-Peer communication to distributed I/O and to other controllers. Tx COL Ethernet port 10/100 Base T Publication 1753-UM001A-EN-P - April 2004 Installation 2-13 Connections for Non-Safety-Related Communication Connect the ASCII port (FB2) to any RS-232 device that has the capability to send ASCII command strings to the controller. The controller replies with a data variable string. See Chapter 14 for more information on ASCII communications. pin function 1 none 2 send data 3 receive data FB1 4 none FB2 5 ground 1 6 2 7 6 none ASCII port 3 8 4 7RTS 9 5 8CTS 9 none GuardPLC 1600 and 1800 controllers and distributed I/O are equipped Reset Pushbutton with a reset pushbutton. Reset via the pushbutton is necessary: • if you forget the password to go online via the programming software, or • if you are unable to determine the IP address and SRS of the controller The pushbutton is accessible through a small round hole at the top of the housing, approximately 4 to 5 cm (1.6 to 2.0 in.) from the left rim and recessed approximately 9.5 mm (0.375 in.). Activate the reset pushbutton using an insulated pin IMPORTANT to prevent short-circuits. To reset, press and hold the pushbutton while rebooting the controller by cycling power. Hold the reset pushbutton until the PROG LED stops flashing. Pressing the Reset pushbutton during operation has no affect. After a reset, the IP address, SRS and login accounts are temporarily reset to their default settings: • IP = 192.168.0.99 • SRS = 60000.1 • login Username = Administrator • login Password = [none] Publication 1753-UM001A-EN-P - April 2004 2-14 Installation At the next power cycle, these settings will be reset to the last values stored into Flash. This means that either: • the settings prior to the reset will be restored, or • if any settings were changed after the reset, these new settings will still be in effect. Publication 1753-UM001A-EN-P - April 2004 Chapter 3 Wiring Using This Chapter For information about: See page GuardPLC Wiring Examples 3-2 General Wiring Considerations 3-11 Power Supply Considerations 3-15 GuardPLC 1600 Terminal Connections and Other Considerations 3-17 GuardPLC 1800 Terminal Connections and Other Considerations 3-18 1753-IB16 Terminal Connections and Other Considerations 3-22 1753-OB16 Terminal Connections and Other Considerations 3-24 GuardPLC 1200 Terminal Connections and Other Considerations 3-27 GuardPLC 2000 Terminal Connections and Other Considerations 3-30 Grounding 3-34 Preventing Electrostatic Discharge 3-35 The wiring diagrams in this chapter detail only the IMPORTANT wiring necessary to sense/control the I/O devices. They do not show all of the wiring necessary to achieve CAT. 3 or CAT. 4 safety circuits. For example, monitoring feedback signals is not illustrated. 1 Publication 1753-UM001A-EN-P - April 2004 3-2 Wiring GuardPLC 1600 GuardPLC Wiring Examples 24V dc + Power 24V dc + COM Supply Power COM Supply A1 A2 A1 A2 Safety Relay Safety Relay CH1 CH2 CH1 CH2 3 (—) (—) 4 12 3 4 5 6 78 9 10 11 12 PE Pulse-Tested 12 3 4 56 78 9 10 11 12 Safety Input L- L- L+ L+ 24V DC DO L- 1 2 34 L- DO L- 5 6 7 8 L- (2A) (2A) RS-485 MODBUS PROFIBUS 24 V DC COMM1 COMM2 COMM3 RUN Dry ERROR Contact PROG FORCE FAULT 1753-L28BBBM OSL 20 DC Inputs BL 8 DC Outputs D1 D1 D1 D1 D1 LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 GuardPLC Ethernet 10/100 BaseT 3 (—) (—) 4 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 + + COM COM 24V dc + Power Dry Contact COM Supply Light Curtain/ Light Curtain Safety Input Publication 1753-UM001A-EN-P - April 2004 Wiring 3-3 GuardPLC 1800 + Light Curtain/ Safety Input Light Curtain/ COM Safety Input 24V dc 24V dc + + + Dry Contact Power Power COM COM COM Supply Supply Pulse Tested Safety Input 3 (—) (—) 4 12 3 4 5 6 78 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 PE 12 3 4 56 78 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 L- L+ L+ DO L- 1 2 34 5 6 78 L- DI LS+ 1 23 4 5 67 8 L- DI LS+ 1 2 3 4 5 6 7 8 L- DI LS+ 1 2 3 4 5 6 7 8 L- 24V DC (2A) (2A) RS-485 1753-L34BBBP ASCII PROFIBUS 24 DC Inputs 24 V DC 8 DC Outputs COMM3 COMM2 COMM1 RUN 8 Analog Inputs ERROR 2 High Speed Counters PROG AI AI AI AI HSC FORCE T1 I1 L- T2 I2 L- T3 I3 L- T4 I4 L- T5 I4 L- T6 I6 L- T7 I7 L- T8 I8 L- A1 B1 Z1 L- A2 B2 Z2 L- FAULT OSL 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 BL * * * GuardPLC Ethernet 10/100 BaseT 3 (—) (—) 4 AI + - T5 I4 L- T6 I6 L- 4-wire Device Using B B Z Z A A + - External Power 53 54 55 56 57 58 + - + - 24V dc + Power - * COM Supply 4-wire Device Using Transmitter Supply + 24V dc + 24V dc COM Power Power COM + Supply 2-wire Device Supply - Using Transmitter Supply + 2-wire Device Using External Power * If current: 500 Ω If voltage: 10kΩ Publication 1753-UM001A-EN-P - April 2004 3-4 Wiring 1753-IB16 24V dc + 24V dc + + Power Power COM Supply COM COM Supply 12 3 4 5 6 78 9 101112 13 14 15 16 17 18 PE 12 3 4 5 6 78 9 101112 13 14 15 16 17 18 L- L- L+ L+ LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- 24V DC D1 D1 D1 24 V DC RUN ERROR PROG FORCE FAULT 1753-IB16 OSL 16 DC Inputs BL 4 Pulse Test Sources PO PULSE TEST LS+ 13 14 15 16 L- L- 1 23 4 L- Pulse Tested 19 20 21 22 23 24 25 26 27 28 29 30 Safety Input GuardPLC Ethernet 10/100 BaseT 19 20 21 22 23 24 25 26 27 28 29 30 (—) (—) 1 2 + Dry Contact COM Dry Contact Light Curtain/ Safety Input Publication 1753-UM001A-EN-P - April 2004 Wiring 3-5 1753-OB16 24V dc + Power COM Supply 24V dc + A1 A2 Power Safety Relay COM Supply CH1 CH2 12 3 4 5 6 78 9 101112 PE 12 3 4 5 6 78 9 101112 L- L- L+ L+ L- L- L+ L+ 24V DC 24V DC DO L- 1 2 3 4 L- DO L- 5 6 7 8 L- 24 V DC RUN ERROR PROG FORCE FAULT 1753-OB16 OSL 16 DC Outputs BL DO L- 9 10 11 12 L- DO L- 13 14 15 16 L- 13 14 15 16 17 18 19 20 21 22 23 24 GuardPLC Ethernet 10/100 BaseT 1 (—) (—) 2 13 14 15 16 17 18 19 20 21 22 23 24 24V dc + Power COM Supply A1 A2 Safety Relay CH1 CH2 Publication 1753-UM001A-EN-P - April 2004 3-6 Wiring 1753-IB20XOB8 24V dc + Power 24V dc + COM Supply Power COM Supply A1 A2 A1 A2 Safety Relay Safety Relay CH1 CH2 CH1 CH2 12 3 4 5 6 78 9 101112 PE 12 3 4 5 6 78 9 101112 L- L- L+ L+ 24V DC DO L- 1 2 3 4 L- DO L- 5 6 7 8 L- (2A) (2A) 24 V DC RUN ERROR PROG FORCE FAULT 1753-IB20OXB8 Pulse-Tested OSL 20 DC Inputs BL 8 DC Outputs Safety Input D1 D1 D1 D1 D1 LS+ 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 Dry GuardPLC Ethernet 10/100 BaseT Contact 13 14 15 16 23 24 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 (—) (—) 2 + + COM COM 24V dc + Power Dry Contact COM Supply Light Curtain/ Light Curtain Safety Input Publication 1753-UM001A-EN-P - April 2004 Wiring 3-7 GuardPLC 1200 A1 A2 Safety 24V dc + Relay Power A COM CH1 CH2 Supply B Z A1 A2 Safety Relay CH1 CH2 24V dc + Power COM Supply L+ L+ O1+ O2+ O3+ O4+ O5+ O6+ O7+ O8+ A1 B1 Z1 I- (1) (2) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 24V dc + Power COM Supply 13 57 9 11 13 15 17 19 21 23 25 27 29 L- L- PA O1- O2- O3- O4- O5- O6- O7- O8- A2 B2 Z2 I- (1) (2) Pulse-Tested PE Safety Input B Z A Dry Contact Dry Contact Not I2 I4 I6 I8 I10 I12 I14 I16 I18 I20 I- I- Used 13 57 9 11 13 15 17 19 21 23 25 + COM 24V dc + Power 2 4 6 8 10 12 14 16 18 20 22 24 COM Supply Light I1 I3 I5 I7 I9 I11 I13 I15 I17 I19 I- I- Curtain or + any Safety Input COM Light Curtain Publication 1753-UM001A-EN-P - April 2004 3-8 Wiring 1755-IB24XO16 Digital Input/Output Modules 1755- IB24XOB16 RUN ERR LS+ 1 I1 2 I2 3 Dry I3 4 Contact I4 5 I5 6 I6 7 I7 8 I8 9 24V dc LS+ + 10 Power COM I9 11 Supply I10 12 I11 13 I12 14 I13 15 + Same power I14 16 supply used by COM I15 17 GuardPLC CPU I16 18 LS+ 19 I17 20 I18 21 I19 22 I20 23 I21 24 I22 25 I23 26 I24 27 Pulse Tested Safety Input L- 28 O1 29 O2 30 O3 31 O4 32 O5 33 O6 34 A1 A2 O7 35 Safety Relay O8 36 CH1 CH2 + 24V dc Power L- 37 Supply O9 COM 38 O10 39 O11 A1 A2 40 O12 41 Safety Relay O13 42 CH1 CH2 O14 43 O15 44 O16 45 Publication 1753-UM001A-EN-P - April 2004 - + Wiring 3-9 1755-IF8 Analog Input Modules 10K Ω (current devices) 500 Ω (voltage devices) 1755- IF8 10K Ω ERR RUN single- external + + I1+ 1 ended power – I- – 2 voltage supply external + I2+ 3 power 500 Ω I- 4 supply COM external single- I3+ + 5 + power ended I- 6 – – supply 2-wire transmitters current I4+ 7 I- 8 9 10 I5+/1- external + differential + 11 I- power voltage 12 I6+/2- – supply – 13 I- I7+/3- 14 I- 15 16 I8+/4- I- 17 4-wire analog devices 18 1755-OF8 Analog Output Modules 1755- OF8 RUN ERR external O1+ + voltage + 1 power O1- – output – 2 supply O2+ 3 O2- 4 O3+ 5 O3- 6 O4+ 7 O4- 8 9 external current O5+ + + 10 power output O5- 11 – – supply 12 O6+ O6- 13 O7+ 14 15 O7- O8+ 16 O8- 17 18 Publication 1753-UM001A-EN-P - April 2004 3-10 Wiring 1755-HSC High Speed Counter Module 1755- HSC RUN ERR C- 1 24V dc A1 A1 2 + + B1 Power B1 3 – COM Z1 Supply Z1 4 C1 5 C- 6 C- 7 C- 8 C- 9 10 C- Same power 11 A2 A1 + 12 B2 B1 supply used – Z1 13 Z2 by GuardPLC 14 C2 CPU C- 15 16 C- 17 C- 18 C- L- 19 1 20 2 21 24V dc + 3 22 Power 4 COM 23 Supply 24 L- A1 A2 L- 25 L- 26 Safety Relay L- 27 CH1 CH2 Publication 1753-UM001A-EN-P - April 2004 Wiring 3-11 2 Terminals accommodate wire sizes up to 1.5 mm (16 AWG) for General Wiring 2 input/output wiring and up to 2.5 mm (14 AWG) for voltage supply Considerations connections. Safety-Related Digital Inputs The status of digital inputs is indicated via LEDs when the controller is in RUN mode. Follow the closed-circuit principle for external wiring when connecting sensors. To create a safe state in the event of a fault, the input signals revert to the de-energized state (0). The external line is not monitored, but a wire break is interpreted as a safe (0) signal. In general, the LS+ terminals, not L+ on the power supply connection, should be used to supply voltage for safety inputs. Each LS+ features individual short-circuit and EMC protection. Due to current limitations, use LS+ for only the safety inputs on the same terminal plug. Safety-Related Digital Outputs The status of digital outputs is indicated via LEDs when the controller is in RUN mode. GuardPLC outputs are rated to either 0.5A or 1.0A at an ambient temperature of 60°C (140°F). At an ambient temperature of 50°C (122°F), outputs rated at 1.0A increase to 2.0A. If an overload occurs, the affected outputs are turned off. When the overload is eliminated, the outputs are under the control of the controller and are energized based on the user program code. An output is in the safe state when it is de-energized. Therefore, outputs are switched off when a fault that affects the safe control of those outputs occurs. Publication 1753-UM001A-EN-P - April 2004 3-12 Wiring For connection of a load, the reference pole L- of the corresponding channel group must be used (2-pole connection). Although L- poles are connected internally to L- on the power supply input, it is strictly recommended to connect the L- reference poles only to their corresponding output group. EMC testing was performed in this manner. Inductive loads can be connected without a TIP protection diode on the load, because there is a protection diode located within the GuardPLC. However, Rockwell Automation strongly recommends that a protection diode be fitted directly to the load to suppress any interference voltage. A 1N4004 diode is recommended. Safety-Related Analog Inputs GuardPLC safety controllers use analog inputs for the unipolar measurement of voltages from 0 to 10V, referenced to L-. A 10 KΩ shunt is used for single-ended voltage signals. With a 500 Ω shunt resistor, currents from 0 to 20 mA can also be measured. The feeder lines should be no more than 300 m (284 ft.) in length. Use shielded, twisted-pair cables, with the shields connected at one end, for each measurement input. Unused analog inputs must be short-circuited. Place wire jumpers to ground on any inputs that are not used. AI 10 I5+/1- T1 I1 L- T2 I2 L- 11 I- 12 I6+/2- 13 I- I7+/3- 14 41 42 43 44 45 46 I- 15 16 I8+/4- wire wire I- 17 jumper 18 jumper GuardPLC 1800 1755-IF8 Publication 1753-UM001A-EN-P - April 2004 Wiring 3-13 Shielded cabling is fed in from below so that the shielding can be connected to the shield contact plate using a clip. Remove about 2 cm of the outer cable insulation so that the mesh is exposed at the point where the cable is clipped to the plate. Position the clip over the uninsulated cable shielding and push it into the slots of the shield contact plate until it fits firmly in place, as shown below. 41 42 43 44 45 46 47 48 49 50 51 52 53 5 mesh shielded cable cable clip Make sure that the mesh comes in direct contact IMPORTANT with the shield contact plate. If the mesh does not touch the plate, the cable is not grounded. High Speed Counters The GuardPLC safety controllers feature inputs for high speed counting up to 1 MHz. These counters are 24-bit, and are configurable for either 5V or 24V dc. The table below shows the maximum input frequency of the counters by controller type. Maximum Input Frequency Controller Type 100 KHz GuardPLC 1200 GuardPLC 1800 1 MHz GuardPLC 2000 (1755-HSC) The counters can be used as a counter or as a decoder for 3-bit Gray Code inputs. As a counter, input A is the counter input, input B is the counter direction input, and input Z is used for a reset. The counter inputs must be connected using shielded, twisted-pair cables for each measurement input. The shields must be connected at both ends. The input lines should be no more than 500m in length. All reference (L-, C-, or I- depending on the controller) connections are interconnected on the module in the form of common reference pole. Publication 1753-UM001A-EN-P - April 2004 3-14 Wiring Cables are clipped to the shield contact plate when connecting counter inputs. Remove about 2 cm of the outer cable insulation so that the mesh is exposed at the point where the cable is clipped to the plate. 63 64 65 66 67 68 69 70 71 72 mesh net T 4 cable clip shield contact plate Make sure that the mesh comes in direct contact IMPORTANT with the shield contact plate. If the mesh does not touch the plate, the cable is not grounded. Do not terminate unused high speed counter inputs. IMPORTANT D To ensure that counters are used in a safety-related manner (SIL3 in accordance to IEC 61508), the whole system, including connected sensors and encoders, must satisfy these safety requirements. Refer to the GuardPLC Controllers Safety Reference Manual, publication number 1755-RM001, for more detailed information. Safety-Related Analog Outputs GuardPLC safety controllers use analog outputs to transfer analog values from the user program into outputs ranging from ±10V dc to 0 to 20 mA. The relationship between the value in the user program and the output value is linear and is displayed in the following table. Logic Value Output Voltage Output Current 0 0.00V 0.0 mA 1000 10.00V 20.0 mA -1000 -10.00V na Unused current inputs must be short-circuited. Publication 1753-UM001A-EN-P - April 2004 Wiring 3-15 Shielded cabling is fed in from below so that the shielding can be connected to the shield contact plate using a clip. Remove about 2 cm of the outer cable insulation so that the mesh is exposed at the point where the cable is clipped to the plate. Position the clip over the uninsulated cable shielding and push it into the slots of the shield contact plate until it fits firmly in place, as shown below. 41 42 43 44 45 46 47 48 49 50 51 52 53 5 mesh shielded cable cable clip Make sure that the mesh comes in direct contact IMPORTANT with the shield contact plate. If the mesh does not touch the plate, the cable is not grounded. The power supply must provide a voltage between 20.4 and 28.8V dc. Power Supply You must supply enough power to drive the controller, inputs, and Considerations outputs. To operate, GuardPLC controllers typically draw less than 1A at 24V dc. They require additional power to operate the inputs and outputs connected to the controller. Consider the power draw of the I/O when specifying the size of the power supply and required fusing. The 24V dc voltage supply must feature galvanic isolation since inputs (1) and outputs are not electrically isolated from the processor. It must also meet the requirements of the Safety Extra Low Voltage (SELV – EN60950) or Protective Extra Low Voltage (PELV – EN60204) guidelines. Protect the controller with a slow-blowing fuse. IMPORTANT Before connecting the power supply, check for ATTENTION correct polarity, value and ripple. Do not reverse the L+ and L- terminals or damage to the controller will result. There is no reverse polarity protection. (1) The I/O and CPU are only isolated from one another on the GuardPLC 2000. Publication 1753-UM001A-EN-P - April 2004 3-16 Wiring GuardPLC 1600/1800 Controllers and Distributed I/O The supply voltage is connected via a 4-pin connector which 2 accommodates wire sizes up to 2.5 mm (14 AWG). You only need to connect one wire to L+ and one wire to L-. Both L+ and L- terminals are internally connected. The other terminal can be used to daisy-chain 24V dc to addtional devices. The power supply connector is rated to 10A. GuardPLC 1200 Both terminals must be used in parallel to allow the maximum current of 8A. (Each terminal maximum is 4A so both are required for 8A.) If the power supply has only one (+) lead, a short bridge jumper must be installed between L+ and L+ . (1) (2) The GuardPLC 1200 requires approximately 0.5A to TIP operate. The remaining 7.5A is used to source power for inputs and outputs. GuardPLC 2000 The GuardPLC 2000 controller features several different modules. These modules and their current draw specifications are listed in the table below. Module Current Draw at 3.3V dc Current Draw at 24V dc 1755-IB24XO16 0.3A 0.5A 1755-IF8 0.15A 0.4A 1755-OF8 0.15A 0.4A 1755-HSC 0.8A 0.1A 1755-L1 1.5A 1.0A The GuardPLC 2000 can draw up to 30A. The TIP majority of this 30A is used to source inputs and outputs. Only 1A is required to operate the CPU module. Publication 1753-UM001A-EN-P - April 2004 Wiring 3-17 Connect the power supply unit, 1755-PB720, to the 24V dc supply voltage. Refer to the GuardPLC 2000 Power Supply Installation Instructions, publication number 1755-IN007, for detailed instructions. Safety-Related Digital Inputs GuardPLC 1600 Terminal DI DI DI DI DI Connections and Other LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 Considerations 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 Digital inputs are connected to the following terminals: Terminal Number Designation Function 13 LS+ Sensor supply for inputs 1 to 4 14 1 Digital input 1 15 2 Digital input 2 16 3 Digital input 3 17 4 Digital input 4 18 L- Reference pole 19 LS+ Sensor supply for inputs 5 to 8 20 5 Digital input 5 21 6 Digital input 6 22 7 Digital input 7 23 8 Digital input 8 24 L- Reference pole 25 LS+ Sensor supply for inputs 9 to 12 26 9 Digital input 9 27 10 Digital input 10 28 11 Digital input 11 29 12 Digital input 12 30 L- Reference pole 31 LS+ Sensor supply for inputs 13 to 16 32 13 Digital input13 33 14 Digital input 14 34 15 Digital input 15 35 16 Digital input 16 36 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 3-18 Wiring Terminal Number Designation Function 37 LS+ Sensor supply for inputs 17 to 20 38 17 Digital input 17 39 18 Digital input 18 40 19 Digital input 19 41 20 Digital input 20 42 L- Reference pole Safety-Related Digital Outputs. 12 3 4 5 6 78 9 101112 12 3 4 56 78 9 10 11 12 DO L- 1 2 34 L- DO L- 5 6 7 8 L- (2A) (2A) Digital outputs are connected to the following terminals: Terminal Number Designation Function Current 1 L- Reference pole — 2 1 Digital output 1 0.5 A 3 2 Digital output 2 0.5 A 4 3 Digital output 3 0.5 A 5 4 Digital output 4 (for increased load) 2.0 A 6 L- Reference pole — 7 L- Reference pole — 8 5 Digital output 5 0.5 A 9 6 Digital output 6 0.5 A 10 7 Digital output 7 0.5 A 11 8 Digital output 8 (for increased load) 2.0 A 12 L- Reference pole — The controller has 24 digital inputs whose status is indicated via LEDs GuardPLC 1800 Terminal when in RUN mode. The digital inputs are actually analog inputs that Connections and Other provide the program with UINT values of 0 to 30V (0 to 3000), which Considerations are used to create limit values to calculate signals for the digital inputs. Default settings are: • <7V = 0 signal • >13V = 1 signal Publication 1753-UM001A-EN-P - April 2004 Wiring 3-19 The limit values are set using system variables. See page B-16 for more information on configuring these inputs. Since digital inputs are actually analog values, the TIP .USED variable must be set HI in the output signal connections dialog to activate the digital input. See step 6 on page 5-7 for an example. Safety-Related Digital Inputs 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 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 DI LS+ 1 2 3 4 5 6 7 8 L- DI LS+ 9 10 11 12 13 14 15 16 L- DI LS+ 17 18 19 20 21 22 23 24 L- Digital inputs are connected to the following terminals: Terminal Number Designation Function 11 LS+ Sensor supply for inputs 1 to 8 12 1 Digital input 1 13 2 Digital input 2 14 3 Digital input 3 15 4 Digital input 4 16 5 Digital input 5 17 6 Digital input 6 18 7 Digital input 7 19 8 Digital input 8 20 L- reference pole 21 LS+ Sensor supply for inputs 9 to 16 22 9 Digital input 9 23 10 Digital input 10 24 11 Digital input 11 25 12 Digital input 12 26 13 Digital input 13 27 14 Digital input 14 28 15 Digital input 15 29 16 Digital input 16 30 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 3-20 Wiring Terminal Number Designation Function 31 LS+ Sensor supply for inputs 17 to 24 32 17 Digital input 17 33 18 Digital input 18 34 19 Digital input 19 35 20 Digital input 20 36 21 Digital input 21 37 22 Digital input 22 38 23 Digital input 23 39 24 Digital input 24 40 L- Reference pole Safety-Related Digital Outputs 12 3 4 5 6 78 9 10 12 3 4 56 78 9 10 DO L- 1 2 34 5 6 78 L- (2A) (2A) Digital outputs are connected to the following terminals: Terminal Designation Function Current Number 1 L- Reference pole — 2 1 Digital output 1 0.5 A 3 2 Digital output 2 0.5 A 4 3 Digital output 3 0.5 A 5 4 Digital output 4 (for increased load) 2.0 A 6 5 Digital output 5 0.5 A 7 6 Digital output 6 0.5 A 8 7 Digital output 7 0.5 A 9 8 Digital output 8 (for increased load) 2.0 A 10 L- Reference pole — Safety-Related Analog Inputs The GuardPLC 1800 features 8 single-ended analog inputs. Differential analog inputs cannot be used on the GuardPLC 1800. Two- or four-wire transmitters can be used. These devices can be Publication 1753-UM001A-EN-P - April 2004 Wiring 3-21 powered from the transmitter supply terminal of the GuardPLC 1800 or from an external power supply. Unused analog inputs must be short-circuited. See IMPORTANT page 3-12. AI AI AI AI T1 I1 L- T2 I2 L- T3 I3 L- T4 I4 L- T5 I4 L- T6 I6 L- T7 I7 L- T8 I8 L- 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 The analog inputs are connected to the following terminals: Terminal Number Designation Function 41 T1 Transmitter supply 1 42 I1 Analog input 1 43 L- Reference pole 44 T2 Transmitter supply 2 45 I2 Analog input 2 46 L- Reference pole 47 T3 Transmitter supply 3 48 I3 Analog input 3 49 L- Reference pole 50 T4 Transmitter supply 4 51 I4 Analog input 4 52 L- Reference pole 53 T5 Transmitter supply 5 54 I5 Analog input 5 55 L- Reference pole 56 T6 Transmitter supply 6 57 I6 Analog input 6 58 L- Reference pole 59 T7 Transmitter supply 7 60 I7 Analog input 7 61 L- Reference pole 62 T8 Transmitter supply 8 63 I8 Analog input 8 64 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 3-22 Wiring Safety Related High Speed Counter HSC A1 B1 Z1 L- A2 B2 Z2 L- 65 66 67 68 69 70 71 72 Counters are connected to the following terminals: Terminal Number Designation Counter Function Gray Code Function 65 A1 Input A1 bit 0 (LSB) 66 B1 Input B1 bit 1 67 Z1 Input Z1 bit 2 (MSB) 68 L- Common reference pole 69 A2 Input A2 bit 0 (LSB) 70 B2 Input B2 bit 1 71 Z2 Input Z2 bit 2 (MSB) 72 L- Common reference pole The 1753-IB16 input module features 16 digital inputs and 4 pulse test 1753-IB16 Terminal sources. Connections and Other Considerations Since the 1753-IB16 is the only module/controller without digital outputs, it is equipped with four pulse test sources that can be software-configured for pulse testing of safety inputs, if required. Due to minimal current capacity, these pulse test sources cannot be used as outputs if they are not configured as pulse test sources. For information on configuring pulse test sources for line control, see Chapter 16. Pulse Test Sources Terminal Number Designation Function PO PULSE TEST 25 L- Reference pole L- 1 23 4 L- 26 1 Pulse test source 1 25 26 27 28 29 30 27 2 Pulse test source 2 28 3 Pulse test source 3 25 26 27 28 29 30 29 4 Pulse test source 4 30 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 Wiring 3-23 Safety-Related Digital Inputs DI DI DI DI LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- 12 3 4 5 6 78 9 101112 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 1011 12 13 1415 1617 18 19 2021 2223 24 Digital inputs are connected to the following terminals: Terminal Number Designation Function 1 LS+ Sensor supply for inputs 1 to 4 2 1 Digital input 1 3 2 Digital input 2 4 3 Digital input 3 5 4 Digital input 4 6 L- Reference pole 7 LS+ Sensor supply for inputs 5 to 8 8 5 Digital input 5 9 6 Digital input 6 10 7 Digital input 7 11 8 Digital input 8 12 L- Reference pole 13 LS+ Sensor supply for inputs 9 to 12 14 9 Digital input 9 15 10 Digital input 10 16 11 Digital input 11 17 12 Digital input 12 18 L- Reference pole 19 LS+ Sensor supply for inputs 13 to 16 20 13 Digital input 13 21 14 Digital input 14 22 15 Digital input 15 23 16 Digital input 16 24 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 3-24 Wiring Operating Voltage Considerations 1753-OB16 Terminal Connections and Other The 1753-OB16 is the only module/controller that has a total current Considerations capacity (16A) higher than the terminal block current limitation (10A). Therefore, it features two separate operating voltage supply connections. Each group of 8 outputs has a current capacity of 8A, and is powered by a separate voltage supply. Output groups are comprised of the following: Group 1 Group 2 12 3 4 5 6 78 9 101112 12 3 4 5 6 78 9 101112 L- L- L+ L+ L- L- L+ L+ 24V DC 24V DC DO1 L- 1 2 3 4 L- DO2 L- 5 6 7 8 L- 24 V DC RUN ERROR PROG FORCE FAULT 1753-OB16 OSL 16 DC Outputs BL DO1 L- 9 10 11 12 L- DO2 L- 13 14 15 16 L- 13 14 15 16 17 18 19 20 21 22 23 24 GuardPLC Ethernet 10/100 BaseT 1 (—) (—) 2 13 14 15 16 17 18 19 20 21 22 23 24 Group Outputs 1 1, 2, 3, 4, and 9, 10, 11,12 2 5, 6, 7, 8 and 13, 14, 15, 16 The module has 16 digital outputs (DO1 to DO16) whose status is indicated via LEDs. DO1 DO2 LS+- 1 23 4 L- LS+5L 67 8- 12 3 4 5 6 78 9 101112 1 2 34 5 6 7 8 9101112 DO1 DO2 LS+9L 10 11 12- LS+ 13 14 15 16 L- 13 14 15 16 17 18 19 20 21 22 23 24 13 14 15 16 17 18 19 20 21 22 23 24 Each output is rated for up to 1A at 60° C (140°F) or 2A at 40°C (104°F). However, each group of 8 outputs may not exceed 8A total. For heat dissipation, intersperse high-current and low-current outputs so that all the high-current outputs are not next to each other. Publication 1753-UM001A-EN-P - April 2004 Wiring 3-25 The digital outputs are connected to the following terminals: Terminal Number Designation Function 1 L- Reference pole 2 1 Digital output DO 1 3 2 Digital output DO 2 4 3 Digital output DO 3 5 4 Digital output DO 4 6 L- Reference pole 7 L- Reference pole 8 5 Digital output DO 5 9 6 Digital output DO 6 10 7 Digital output DO 7 11 8 Digital output DO 8 12 L- Reference pole 13 L- Reference pole 14 9 Digital output DO 9 15 10 Digital output DO 10 16 11 Digital output DO 11 17 12 Digital output DO 12 18 L- Reference pole 19 L- Reference pole 20 13 Digital output DO 13 21 14 Digital output DO 14 22 15 Digital output DO 15 23 16 Digital output DO 16 24 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 3-26 Wiring The remote I/O module features 20 digital inputs and 8 digital outputs 1753-IB20XOB8 Terminal whose status is indicate via LEDs. Connections and Other Considerations Safety-Related Digital Inputs DI DI DI DI DI LS+- 1 23 4 L- LS+5L 67 8- LS+9L 10 11 12- LS+ 13 14 15 16 L- LS+ 17 18 19 20 L- 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 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 The digital inputs are connected to the following terminals: Terminal Number Designation Function 13 LS+ Sensor supply for inputs 1 to 4 14 1 Digital input 1 15 2 Digital input 2 16 3 Digital input 3 17 4 Digital input 4 18 L- Reference pole 19 LS+ Sensor supply for inputs 5 to 8 20 5 Digital input 5 21 6 Digital input 6 22 7 Digital input 7 23 8 Digital input 8 24 L- Reference pole 25 LS+ Sensor supply for inputs 9 to 12 26 9 Digital input 9 27 10 Digital input 10 28 11 Digital input 11 29 12 Digital input 12 30 L- Reference pole 31 LS+ Sensor supply for inputs 13 to 16 32 13 Digital input 13 33 14 Digital input 14 34 15 Digital input 15 35 16 Digital input 16 36 L- Reference pole 37 LS+ Sensor supply for inputs 17 to 20 38 17 Digital input 17 39 18 Digital input 18 40 19 Digital input 19 41 20 Digital input 20 42 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 Wiring 3-27 Safety-Related Digital Outputs The module has 8 digital outputs (DO1 to DO8) whose status is indicated via LEDs. 12 3 4 5 6 78 9 101112 12 3 4 56 78 9 10 11 12 DO L- 1 2 34 L- DO L- 5 6 7 8 L- (2A) (2A) The digital outputs are connected to the following terminals: Terminal Designation Function Current Number 1 L- Reference pole — 2 1 Digital output 1 0.5 A 3 2 Digital output 2 0.5 A 4 3 Digital output 3 0.5 A 5 4 Digital output 4 (for increased load) 2.0 A 6 L- Reference pole — 7 L- Reference pole — 8 5 Digital output 5 0.5 A 9 6 Digital output 6 0.5 A 10 7 Digital output 7 0.5 A 11 8 Digital output 8 (for increased load) 2.0 A 12 L- Reference pole — The GuardPLC 1200 has no LS+ terminal for a safety input voltage GuardPLC 1200 Terminal source. Use the L+ supply terminal as the source for safety input Connections and Other voltage. The four reference terminals, labeled I-, should be used for Considerations the safety input voltage reference. This is a common reference for all 20 inputs. Publication 1753-UM001A-EN-P - April 2004 3-28 Wiring Lower Terminal Block Not I2 I4 I6 I8 I10 I12 I14 I16 I18 I20 I- I- Used 13 57 9 11 13 15 17 19 21 23 25 2 4 6 8 10 12 14 16 18 20 22 24 I1 I3 I5 I7 I9 I11 I13 I15 I17 I19 I- I- Terminal Number Designation Function 1 Not Used None 2 I1 Digital input 1 3 I2 Digital input 2 4 I3 Digital input 3 5 I4 Digital input 4 6 I5 Digital input 5 7 I6 Digital input 6 8 I7 Digital input 7 9 I8 Digital input 8 10 I9 Digital input 9 11 I10 Digital input 10 12 I11 Digital input 11 13 I12 Digital input 12 14 I13 Digital input 13 15 I14 Digital input 14 16 I15 Digital input 15 17 I16 Digital input 16 18 I17 Digital input 17 19 I18 Digital input 18 20 I19 Digital input 19 21 I20 Digital input 20 22 I- Reference pole 23 I- Reference pole 24 I- Reference pole 25 I- Reference pole All eight of the digital output zero-voltage reference terminals are common. Unlike the GuardPLC 1600/1800 or distributed I/O, which have an earth ground screw, the GuardPLC 1200 earth ground should be wired to the PA terminal. Publication 1753-UM001A-EN-P - April 2004 Wiring 3-29 Upper Terminal Block L+ L+ O1+ O2+ O3+ O4+ O5+ O6+ O7+ O8+ A1 B1 Z1 I- (1) (2) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 13 57 9 11 13 15 17 19 21 23 25 27 29 L- L- PA O1- O2- O3- O4- O5- O6- O7- O8- A2 B2 Z2 I- (1) (2) Terminal Number Designation Function 1 L- 24V dc return path 2 L+ 24V dc power input 3 L- 24V dc return path 4 L+ 24V dc power input 5 PA Functional ground 6 O1+ Digital output 1 7 O1- Voltage reference for digital output 1 8 O2+ Digital output 2 9 O2- Voltage reference for digital output 2 10 O3+ Digital output 3 11 O3- Voltage reference for digital output 3 12 O4+ Digital output 4 13 O4- Voltage reference for digital output 4 14 O5+ Digital output 5 15 O5- Voltage reference for digital output 5 16 O6+ Digital output 6 17 O6- Voltage reference for digital output 6 18 O7+ Digital output 7 19 O7- Voltage reference for digital output 7 20 O8+ Digital output 8 21 O8- Voltage reference for digital output 8 22 A1 Universal signal input for counter 1 23 A2 Universal signal input for counter 2 24 B1 Signal input for counting direction for counter 1 25 B2 Signal input for counting direction for counter 2 26 Z1 Reset for counter 1 27 Z2 Reset for counter 2 28 I- Signal ground for counters 1 and 2 29 I- Signal ground for counters 1 and 2 Publication 1753-UM001A-EN-P - April 2004 3-30 Wiring 1755-IB24XOB16 Digital I/O Module GuardPLC 2000 Terminal Connections and Other This module is a combination I/O module featuring 24 safety-related Considerations digital inputs and 16 safety-related digital outputs. • Inputs: The sockets with pins 2 through 9, 11 through 18, and 20 through 27 provide the 24 digital inputs I1 to I24. Pins 1, 10, and 19 are the common positive poles (LS+). Each group of 8 inputs has current limits of 100mA. • Outputs: The sockets with pins 29 through 36 and 38 through 45 provide the 16 digital outputs O1 to O16. Pins 28 and 37 are the common negative poles (L-) for the output loads. • Each output channel can be loaded with 2A, but the total load of all 16 outputs must not exceed 8A. Terminal Designation Function Terminal Designation Function Number Number 1755- IB24XOB16 1 LS+ Digital input supply 24 I21 Digital input 21 RUN ERR for inputs 1 to 8 LS+ 1 2 I1 Digital input 1 25 I22 Digital input 22 I1 2 I2 3 3 I2 Digital input 2 26 I23 Digital input 23 I3 4 I4 5 4 I3 Digital input 3 27 I24 Digital input 24 I5 6 I6 7 5 I4 Digital input 4 28 L- Reference pole for I7 8 I8 9 outputs 1 to 8 LS+ 6 I5 Digital input 5 29 O1 Digital output 1 10 I9 11 I10 12 7 I6 Digital input 6 30 O2 Digital output 2 I11 13 I12 14 8 I7 Digital input 7 31 O3 Digital output 3 I13 15 I14 16 9 I8 Digital input 8 32 O4 Digital output 4 I15 17 I16 18 10 LS+ Digital input supply 33 O5 Digital output 5 for inputs 9 to 16 LS+ 19 I17 20 11 I9 Digital input 9 34 O6 Digital output 6 I18 21 I19 22 12 I10 Digital input 10 35 O7 Digital output 7 I20 23 I21 24 13 I11 Digital input 11 36 O8 Digital output 8 I22 25 I23 26 14 I12 Digital input 12 37 L- Reference pole for I24 27 outputs 9 to 16 L- 28 15 I13 Digital input 13 38 O9 Digital output 9 O1 29 O2 30 16 I14 Digital input 14 39 O10 Digital output 10 O3 31 O4 32 17 I15 Digital input 15 40 O11 Digital output 11 O5 33 O6 34 18 I16 Digital input 16 41 O12 Digital output 12 O7 35 O8 36 19 LS+ Digital input supply 42 O13 Digital output 13 L- 37 for inputs 17 to 24 O9 38 O10 39 20 I17 Digital input 17 43 O14 Digital output 14 O11 40 O12 41 21 I18 Digital input 18 44 O15 Digital output 15 O13 42 O14 43 22 I19 Digital input 19 45 O16 Digital output 16 O15 44 O16 45 23 I20 Digital input 20 Publication 1753-UM001A-EN-P - April 2004 Wiring 3-31 1755-IF8 Analog Input Module This module features 8 single-ended analog inputs or 4 differential analog inputs. Two-wire or four-wire transmitters can be used. The devices cannot be powered from the GuardPLC module. An external power supply is required for all analog transmitters. Single-ended transmitters connect between the Ix and I- terminals. For example: pins 1 and 2, 3 and 4, 5 and 6. Differential transmitters connect between Ix and x- terminals. For example: pins 1 and 10, 3 and 12, 5 and 14. Unused channels must be short-circuited. See page IMPORTANT 3-12. All reference poles (I-) are internally connected. Terminal Number Designation Function 1755- 1 I1+ Analog input 1 IF8 2 I- Reference pole for input 1 ERR RUN 3 I2+ Analog input 2 I1+ 1 I- 2 4 I- Reference pole for input 2 I2+ 3 I- 5 I3+ Analog input 3 4 I3+ 5 6 I- Reference pole for input 3 I- 6 I4+ 7 7 I4+ Analog input 4 I- 8 9 8 I- Reference pole for input 4 9 shield connection signal ground 10 I5+/1- 11 I- 10 I5+/1- Analog input 5 12 I6+/2- 13 I- 11 I- Reference pole for input 5 I7+/3- 14 I- 15 12 I6/2- Analog input 6 16 I8+/4- 17 I- 13 I- Reference pole for input 6 18 14 I7+/3- Analog input 7 15 I- Reference pole for input 7 16 I8+/4- Analog input 8 17 I- Reference pole for input 8 18 shield connection signal ground 1755-OF8 Analog Output Module This module features 8 analog outputs. Devices cannot be powered from the 1755-OF8 module. An external power supply is required for all analog output devices. Publication 1753-UM001A-EN-P - April 2004 3-32 Wiring There are 4 reference poles for the 8 outputs. A pair of outputs share a reference pole as shown below. These outputs: Share these Reference Poles: 1 and 2 O1- and O2- 3 and 4 O3- and O4- 5 and 6 O5- and O6- 7 and 8 O7- and O8- Each group of 2 outputs is electrically isolated from the others. If an unused channel is defined as a current output IMPORTANT (software configuration set to “current output”), the output channel has to be short-circuited. Place jumpers into these outputs and tighten the screws. If an unused channel is defined as a voltage output IMPORTANT (software configuration set to “voltage output”), the unused outputs must be left open. Short-circuiting a unused voltage output may cause damage to the output. Terminal Number Designation Function 1 O1+ Analog output 1 1755- OF8 2 O1- Group 1 reference pole 3 O2+ Analog output 2 RUN ERR 4 O2- Group 1 reference pole O1+ 1 O1- 2 5 O3+ Analog output 3 O2+ 3 6 O3- Group 2 reference pole O2- 4 O3+ 5 7 O4+ Analog output 4 O3- 6 8 O4- Group 2 reference pole O4+ 7 O4- 8 9 shield connection signal ground 9 10 O5+ Analog output 5 O5+ 10 11 O5- Group 3 reference pole 11 O5- 12 O6+ Analog output 6 O6+ 12 O6- 13 13 O6- Group 3 reference pole O7+ 14 14 O7+ Analog output 7 15 O7- O8+ 16 15 O7- Group 4 reference pole O8- 17 16 O8+ Analog output 8 18 17 O8- Group 4 reference pole 18 shield connection signal ground Publication 1753-UM001A-EN-P - April 2004 Wiring 3-33 1755-HSC Counter Modules This module contains 2 high speed counters and 4 digital outputs. Although the 4 digital outputs are located on the 1755-HSC module, they cannot be driven by counter presets. The 4 digital outputs are driven by software, just as on the 1755-IB24XOB16 module. The nominal current per output is limited to ≤ 0.5A. Currents > 0.5A are regarded as overload. The overload is limited to ≤ 11A per output, or ≤ 2A if all four outputs are overloaded at the same time. With an overload of 2A, the output voltage drops to 18V. All counter common reference poles, C-, share the same path. All digital output common reference poles, L-, share the same path, but are electrically isolated from the C- pins. Terminal Number Designation Function 1755- HSC 1 C- Common reference pole 2 A1 Signal input for counter 1 RUN ERR C- 1 3 B1 Counting direction input for counter 1 A1 2 B1 3 4 Z1 Reset input for counter 1 Z1 4 C1 5 C1 no function 5 C- 6 6 C- Common reference pole C- 7 C- 8 7 C- Common reference pole C- 9 8 C- Common reference pole C- 10 11 A2 9 C- Common reference pole B2 12 10 C- Common reference pole 13 Z2 14 C2 11 A2 Signal input for counter 2 15 C- 16 C- 12 B2 Counting direction input for counter 2 17 C- 18 C- 13 Z2 Reset input for counter 2 14 C2 no function 15 C- Common reference pole 16 C- Common reference pole L- 19 1 20 17 C- Common reference pole 2 21 22 3 18 C- Common reference pole 4 23 19 L- Reference pole for digital outputs 24 L- 25 L- 20 1 Digital output 1 L- 26 L- 27 21 2 Digital output 2 22 3 Digital output 3 23 4 Digital output 4 24 L- Reference pole for digital outputs 25 L- Reference pole for digital outputs 26 L- Reference pole for digital outputs 27 L- Reference pole for digital outputs Publication 1753-UM001A-EN-P - April 2004 3-34 Wiring You must provide an acceptable grounding path for each device in Grounding your application. For more information on proper grounding guidelines, refer to the Industrial Automation Wiring and Grounding Guidelines, publication number 1770-4.1. Grounding Considerations for All Controllers • To improve EMC conditions, ground the controller. • Run the ground connection from the ground screw of the 2 controller to a good earth ground. Use a minimum of 2.5 mm (14 AWG) wire. • Keep the connection to earth ground as short as possible to minimize resistance. • Grounding is required even if the control system does not have shielded cables. • If shielded cables are used to connect the controller to the external 24V dc source, connect the shield to the grounding contact of the power supply. • No protective grounding (against hazardous shock) is required. GuardPLC 1200 Ground the GuardPLC 1200 by connecting the PA terminal to earth ground. See page 3-27 for GuardPLC 1200 terminal connections. GuardPLC 1600 and GuardPLC 1800 Controllers and Distributed I/O The controllers and I/O have a grounding screw located on the upper left of the housing and marked with the grounding symbol . This grounding screw is common to the DIN rail connection. Attach an appropriate earth ground to the grounding screw. Publication 1753-UM001A-EN-P - April 2004 Wiring 3-35 GuardPLC 2000 Ground the GuardPLC 2000 chassis and cables using the grounding screw located on the left side of the grounding grill. Ground the chassis via the grounding grill. PS CPU DIO DIO AI AO CO CO grounding grill grounding screw Preventing Electrostatic Discharge Electrostatic discharge can damage integrated circuits ATTENTION or semiconductors. Follow these guidelines when you handle the module: • Touch a grounded object to discharge static potential. • Wear an approved wrist-strap grounding device. • If available, use a static-safe workstation. • When not in use, keep the GuardPLC controller in its static-shield box. Publication 1753-UM001A-EN-P - April 2004 3-36 Wiring Publication 1753-UM001A-EN-P - April 2004 Chapter 4 Connecting to the GuardPLC Controller Using This Chapter For information about: See page connecting to the controller via RSLogix Guard PLUS 4-1 going online with the GuardPLC controller 4-5 configuring the programming terminal 4-19 login dialog 4-20 determining the IP address and SRS of the controller 4-21 changing the SRS of the controller 4-22 changing the IP address of the controller 4-22 You connect the controller to the programming terminal via an Connecting to the Ethernet port on the controller. The programming terminal must have Controller via RSLogix an Ethernet port or Ethernet communication card. Guard PLUS To directly connect the programming terminal to the controller, use a cross-over Ethernet cable. The GuardPLC 1600 and 1800 feature auto-sensing ports so that a cross-over or straight-thru cable may be used. Connecting to a GuardPLC 1200 Controller PLC 1200 Ethernet port (on the bottom of the controller) 1 Publication 1753-UM001A-EN-P - April 2004 4-2 Connecting to the GuardPLC Controller Connecting to a GuardPLC 1600 or 1800 Controller Ethernet Ports 3 and 4 3 (—) (—) 4 L- L- L+ L+ 24V DC RS-485 ASCII MODBUS COMM3 COMM2 COMM1 GuardPLC Ethernet 10/100 BaseT 1 (—) (—) 2 Ethernet Ports 1 and 2 Connecting to a GuardPLC 2000 Controller Tx COL Ethernet port 10/100 Base T GuardPLC Factory Defaults IP Address 192.168.0.99 Subnet Mask 255.255.252.0 (1) 60000 SRS (1) The SRS code is compiled with the program. It guarantees that the program can only be downloaded to a GuardPLC with a matching SRS stored in non-volatile memory. Understanding Ethernet Addressing As with any connection between devices on Ethernet, the IP address and subnet mask determine if the connection can take place. Every device on Ethernet has an IP address and subnet mask. The IP address and subnet mask are made up of four (4) octets (001.002.003.004) The IP address is made up of the Network ID (octets 001 and 002) and the Host ID (octets 003 and 004). The Network ID portion of the IP address is derived from the subnet mask. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-3 When any two devices attempt to talk on Ethernet, a check is made to see if the Network ID of both the originator and the destination address match. If they match, then the message is sent on the local network. If they do not match, then the message is sent to the Gateway to route the message to the destination. The subnet masks of all the devices on a local network should be the same. The example below illustrates how to derive the Network ID based on the GuardPLC IP address and subnet mask defaults. Determining the Network ID EXAMPLE GuardPLC Defaults: IP Address 192.168.0.99 = 11000000 . 10101000 . 00000000 . 01100011 Subnet Mask 255.255.252.0 = 11111111 . 11111111 . 11111100 . 00000000 Network ID = 11000000 . 10101000 . 000000xx . xxxxxxxx Set up the programming terminal’s IP address so that it has the same Network ID as the GuardPLC. Octets one and two have to be the same because the subnet mask octets are 255. The third subnet mask octet is 252, which means that only the last two bits can be different. If the factory default settings above are used, the allowable IP addresses for the programming terminal running RSLogix Guard PLUS are: • 192.168.0.xxx (xxx represents any value between 000-255) • 192.168.1.xxx • 192.168.2.xxx • 192.168.3.xxx Configure the IP Address of Your Programming Terminal The first time you connect to a controller, you must IMPORTANT use the factory-set IP address of 192.168.0.99 and the default SRS of 60000. After you establish communications with the controller (using the steps on the following pages), you can change the IP address and SRS to better accommodate your Ethernet network. Publication 1753-UM001A-EN-P - April 2004 4-4 Connecting to the GuardPLC Controller Change the IP address of your programming terminal running RSLogix Guard PLUS so that the GuardPLC and programming terminal can communicate on a local network. If you suspect the GuardPLC has the factory-set TIP default IP address of 192.168.0.99 and the default subnet mask of 255.255.252.0, set your programming terminal’s IP address to 192.168.0.98 with a subnet of 255.255.252.0 to establish communications. Change the IP address (via Windows 2000) by selecting Start → Settings → Control Panel → Network and Dial-up Connections. Open Local Area Connections and select Properties. Select TCPIP and Properties. Set the General TCP/IP Properties as shown below. Confirm your settings by clicking OK in both dialog boxes. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-5 The following flowchart illustrates the steps required to successfully Going Online with the go online with the GuardPLC controller. GuardPLC Controller Step 1: Open RSLogix Guard PLUS Step 2: Create a New Note: This path is not possible for Notes: Project GuardPLC 1200 and GuardPLC 2000. (1) Assume correct SRS was entered in Step 3. Step 12: Fault Recovery NO after Reset. Step 3: Configure the (2) Controller reverts back to prior settings if not controller type and SRS re-configured before the next power cycle. YES (3) If the controller was previously running and the SRS was changed in Step 5, or if the controller is new Is the (out-of-box) the only way to clear the FAULT is to FAULT LED YES download a program with a matching SRS. illuminated? Do you already know settings? NO Step 8: Change Step 4: Communication Step 9: Reset Controller Controller Mode to Settings (2) Default Settings STOP Did Do you NO communication NO YES think you know the settings read IP/SRS controller settings? successfully? Do you YES want to change these NO YES settings in the controller? Step 10: Ping the Controller Is the YES controller in RUN Step 6: Move Settings mode? into Offline Project NO Ping successful? NO Step 7: Connect to Step 5: Change Controller Using Settings via MAC YES Control Panel Address Step 11: Configure Controller IP (1) Address NO Are you online with YES the correct settings? (3) DONE The steps are described in detail below. Publication 1753-UM001A-EN-P - April 2004 4-6 Connecting to the GuardPLC Controller Step 1: Open RSLogix Guard PLUS Select Start → Programs → RSLogix Guard PLUS → RSLogixGuardPLUS. Step 2: Create a New Project Open an existing project or create a new project that contains a GuardPLC controller. 1. To create a new project, select Project → New from the main menu or click on the New icon. 2. Enter the name of the project in the Object Name field. 3. Click OK. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-7 The RSLogix Guard PLUS Hardware Management window opens. Both the Project Management and Hardware Management windows are normally open when running RSLogix Guard PLUS. Step 3: Configure the Controller Type and SRS To go online, you must specify the controller type and change the default SRS. The software defaults to an SRS of zero (0), which is the only illegal SRS value. To accept the controller type, the SRS must be (1) changed to a value between 2 and 65535. 1. Expand the project tree in the Hardware Management window until [0] Resource is visible. 2. Right-click on [0] Resource and select Properties. (1) The programming terminal defaults to 1. Publication 1753-UM001A-EN-P - April 2004 4-8 Connecting to the GuardPLC Controller 3. Specify the controller type and enter an SRS of 60000. You must use the default SRS of 60000 the first time you connect to a GuardPLC controller. 4. Click OK. The Hardware Management window should appear as shown below. Notice that the SRS has changed to 60000. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-9 Step 4: Communication Settings 1. Select Online → Communication Settings from the pull-down menu. 2. The MAC address is on the sticker on the side of a GuardPLC 1200 controller, on the label positioned over both lower RJ-45 connections on GuardPLC 1600/1800 controllers and I/O, or on the front bezel of the AB-CPU module of a GuardPLC 2000 controller. Enter the last three elements of the MAC address into the MAC Address field and click on Get. The IP address and SRS of the GuardPLC should appear in the Address PES using… fields. Publication 1753-UM001A-EN-P - April 2004 4-10 Connecting to the GuardPLC Controller Step 5: Change Settings via MAC Address 1. Enter desired settings for the IP and SRS in the Communication Settings fields indicated by the arrows below. 2. Click on the Set via MAC button. 3. The Authentication window appears. Enter the default username “Administrator” as shown below. 4. Click OK. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-11 The IP address and SRS should have changed. If successful, a prompt appears at the bottom of the window and the settings in the middle fields change. Step 6: Move the Settings Into Your Offline Project If you wish to connect using the current GuardPLC settings, move the settings into your offline project. 1. Left-click on “-> Project”. Publication 1753-UM001A-EN-P - April 2004 4-12 Connecting to the GuardPLC Controller 2. The Resource Selection window appears. Make sure Resource is selected and click OK. 3. Answer YES to the warning prompt. This moves the IP address and SRS of the GuardPLC to your offline project and overwrites the existing values. These new values will be used in the login screen to connect with the GuardPLC. Step 7: Use the Control Panel to Connect to the GuardPLC 1. Right-click on [60000] Resource. 2. Select Online → Control Panel. 3. The Login Window appears. Type [Ctrl]+[A] to fill in the default Username, Password, and Access Type. 4. Click OK. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-13 The Control Panel Online indicator will be GREEN if the controller is in RUN Mode. The Online indicator may also be yellow, white, or red based on its current state. If you are successfully online with the GuardPLC and TIP in RUN mode (Green Online indicator as shown above), you do not need to continue with the steps 8 through 12 below. However, if you are not online and in RUN mode, consult the flowchart on page 4-5, and perform the appropriate steps. Publication 1753-UM001A-EN-P - April 2004 4-14 Connecting to the GuardPLC Controller Step 8: Change the Controller to STOP Mode To change the controller to STOP mode, select Resource → Stop from the Control Panel or use the Stop icon. When in STOP Mode, the Control Panel appears as follows: Close the Control Panel. Step 9: Reset the Controller to the Default Settings In some cases, you may have to reset the GuardPLC to its default IP address and SRS. GuardPLC 1600 and 1800 controllers have a Reset button that is accessible via a small hole directly to the right of the Ethernet ports on top of the controller. The Reset button returns the IP address, SRS and Password settings to: IP Address 192.168.0.99 SRS 60000 Username Administrator Password [none] To reset the controller, hold down the RESET button, then power cycle the GuardPLC. Continue to hold down the Reset button until the PROG led stops flashing. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-15 At the next power cycle, the settings will revert back to the last configured settings. These could be the settings in place prior to the Reset operation, if you did not reconfigure them after resetting the controller. Step 10: Ping the Controller Use the Start menu to open the RSLogix Guard PLUS Command Prompt by selecting Start → Programs → RSLogix Guard PLUS → RSLogix Guard PLUS Command Prompt. Run IPCONFIG at the DOS Command prompt to verify your computer’s IP address. It must be on the same local network as the GuardPLC. Ping the GuardPLC using the command shown at the C:\> below. If the ping is successful, the IP address of the GuardPLC has been verified and the Ethernet link is operating. If the ping was not successful either the IP address, subnet mask, or Ethernet link is not correct. The picture below is the result of a successful ping. Type “exit” at the command prompt to close the Command Prompt window. Publication 1753-UM001A-EN-P - April 2004 4-16 Connecting to the GuardPLC Controller Step 11: Configure the GuardPLC Controller’s IP Address 1. Expand the project tree in the Hardware Management window until the controller COM icon is visible. 2. Right-click on COM and select Properties. 3. Edit the IP address to match the GuardPLC controller and click OK. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-17 Step 12: Recovering from a Controller Fault After Using the RESET Button After using the Reset button, the Control Panel will appear as follows if the SRS was not originally 60000 prior to the Reset. The Fault LED on the front of the GuardPLC is illuminated, and the CPU State of the Resource is STOP/INVALID CONFIGURATION. To recover from this fault: 1. Select Extra → Change System ID from the Control Panel. 2. Verify that 60000 appears in the first window with 0 in the second, as shown below. 3. Click OK. Publication 1753-UM001A-EN-P - April 2004 4-18 Connecting to the GuardPLC Controller The Fault LED should turn off, and the Control Panel should show that the CPU State has changed to STOP/VALID CONFIGURATION, as shown below. The Online indicator is white because the GuardPLC TIP is in STOP/VALID mode. This is the end of the steps related to the flowchart TIP on page 4-5. Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-19 Specify Host SRS Configuring the Programming Terminal From the Hardware Management window, you can specify the host SRS of the programming terminal. 1. Right-click on Programming Terminal and select Properties. 2. Enter the host SRS (1 to 65535) for the programming terminal. Make sure the host SRS of the programming terminal is not identical to the system ID (SRS) of any other controllers or programming terminals. In a network, as many as five programming terminals can connect to the same controller at the same time. However, only one programming terminal can have read/write access. If another controller logs in with read access, that additional user can query controller states and parameters (RUN, STOP, controller switches, etc.) with the Control Panel. The additional user can also display data values if the programming terminal has the same configuration as the controller. If there are multiple programming terminals in one network, each programming terminal must have a unique host SRS. Publication 1753-UM001A-EN-P - April 2004 4-20 Connecting to the GuardPLC Controller The Login dialog defines the communication parameters between the Login Dialog controller and the programming terminal. Field: Description: IP address the IP address of the controller on the Ethernet network. The factory-set IP address is 192.168.0.99. SRS SRS stands for “System, Rack, Slot”. The rack and slot IDs are already preset by the controller, so you only need to enter the system ID. You can enter any number from 1 to 65,535. However, the number must be unique from the programming terminal and from any other GuardPLCs on the same Peer-to-Peer Ethernet. The default (factory-set) SRS is 60000. Username your username. (default = Administrator) The Administrator assigns a username. The username is sensitive to upper and lower case characters. A username can only contain letters, numbers, and underscore characters. You can define as many as 10 usernames per GuardPLC controller. Password your password. (default = ) An Administrator assigns a password. The password is case sensitive. A password can only contain letters, numbers, and underscore characters. Access Type your access level. Login as one of these options: Administrator highest privileges manage usernames and passwords read data from controller write routines and data into controller force tags stop, start, freeze, and force a routine download an operating system change IP address and system ID reboot the controller can also login under read/write and read levels Read/Write read data from controller write routines and data into controller force tags start, stop, freeze, and force a routine can also login under read level Read lowest privileges only read data from controller As many as five users can login to the same controller at the same time; however, only one of those users can login as Administrator or Read/Write. The others must login with READ access. If you login while someone else is logged in with Administrator or Read/Write access, you automatically get READ access, regardless of the access type you select. For new controllers, and if the backup battery was removed from a GuardPLC 1200 or 2000 controller, access is available using the following system defaults: Username: Administrator Password Access Type Administrator Publication 1753-UM001A-EN-P - April 2004 Connecting to the GuardPLC Controller 4-21 The default IP address of a new controller is 192.168.0.99. The default Determining the IP Address SRS of a new controller is 60000. To check the current IP address and and SRS of the Controller SRS of a controller: 1. Select Online → Communication Settings. 2. In the MAC address field, enter the MAC address of the controller. The MAC address is on the sticker on the side of a GuardPLC 1200 controller, on the label positioned over both lower RJ-45 connections on GuardPLC 1600/1800 controllers and I/O, or on the front bezel of the AB-CPU module of a GuardPLC 2000 controller. 3. Click Get. The controller responds back with the IP address and the SRS it is currently using. This function works if the IP address of the TIP GuardPLC passes through the subnet mask of your computer. Publication 1753-UM001A-EN-P - April 2004 4-22 Connecting to the GuardPLC Controller There are two ways to change the SRS of the controller: Changing the SRS of the Controller 1. From the Control Panel, select Extra → Change System ID (SRS). Enter the SRS and click OK. 2. Or follow “Step 4: Communication Settings” on page 4-9 and “Step 5: Change Settings via MAC Address” on page 4-10. Typically, you change the SRS of the GuardPLC to TIP match that of the controller/routine that you wish to download to it. Recall that the SRS is compiled into the executable and ensures that this .EXE can only be downloaded to a GuardPLC with a matching SRS. After you establish communications with the controller, you can Changing the IP Address of change the IP address of the controller to match your Ethernet the Controller network. There are two ways to change the IP address of the controller: 1. From the Control Panel, select Extra → Device Settings. Enter the new IP address and click OK. 2. Or follow “Step 4: Communication Settings” on page 4-9 and “Step 5: Change Settings via MAC Address” on page 4-10. To re-establish communications with the “new” IP TIP address and subnet of your GuardPLC, you may need to change the IP and subnet address of your programming terminal. Use the Network section of the Windows Control Panel to change the programming terminal’s IP address and subnet mask. Publication 1753-UM001A-EN-P - April 2004 Chapter 5 Creating Your First GuardPLC Project This chapter is a tutorial that guides you through the following basic Using This Chapter steps required to create a project: 1. Start a new project. 2. Configure the project and hardware. 3. Create signals and connect them to the I/O points. 4. Create a Function Block program using the signals. 5. Save, compile, test, and download the program to the GuardPLC. 6. Monitor the project online. Start RSLogix Guard PLUS. Create a new project using the New icon or Start a New Project by selecting Project → New. Enter “FirstProject” in the Object Name field as shown below and click OK. 1 Publication 1753-UM001A-EN-P - April 2004 5-2 Creating Your First GuardPLC Project The Hardware Management window opens. This window is used to configure the project, controller, I/O, and signals. Return to the Project Management window and expand the project tree until it matches the example below. When the project is expanded, you can see that it contains a Configuration and under the Configuration there is a Resource, which is the actual GuardPLC Controller. Under the Resource is the program TypeInstance that will run on the GuardPLC Controller. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-3 1. In the Hardware Management window, expand the project tree Configure the Project and so that the Configuration, Resource, and TypeInstance are Hardware visible, as shown below: 2. Right click on [0] Resource and select Properties. Edit the properties as shown below. The Resource Type should match the type of GuardPLC to which you want to connect. The SRS is a code that is compiled with the function block routine. The routine can be downloaded only to a GuardPLC with a matching SRS code stored in its non-volatile memory. For more information on configuring the controller, see page 8-5. The default SRS of a new controller is 60000. TIP You must use this SRS to initially establish communications with the controller. Once you have established communications, you can change the SRS. 3. Click Apply to move these values into the project. Publication 1753-UM001A-EN-P - April 2004 5-4 Creating Your First GuardPLC Project 4. Select the four (4) unchecked boxes and click OK. You can rename the controller using the TIP Program Management window. Expand the project tree and the Configuration. Right-click on Resource and select Rename. 5. Expand the Resource so that the Hardware Management project tree appears as shown below. 6. Right click on COM under GuardPLC 1800, and select Properties. The following window appears. 7. Enter the IP address of your GuardPLC. Neither the Subnet Mask nor the Default Gateway should require changes. Click OK. The GuardPLC controller’s default IP address is TIP 192.168.0.99. T Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-5 Because the example in this chapter uses the GuardPLC 1800 Create Signals and Connect controller, there are predefined I/O listed under the controller in the Them to I/O Points project tree. The 1200/1600/1800 are fixed controllers with pre-configured I/O. If you use a GuardPLC 2000, the I/O must be configured, since it is a modular controller. 1. Select Signals from the Hardware Management menu bar, and select Editor. 2. Create 3 new signals, START, STOP, and MOTOR: a. Left-click on New Signal in the Signal Editor. Type START in the Name field and press the Enter key. b. Left-click on New Signal again. Type STOP in the Name field and press the Enter key. c. Left Click on New Signal again. Type MOTOR in the Name field and press the Enter key. Publication 1753-UM001A-EN-P - April 2004 5-6 Creating Your First GuardPLC Project 3. Connect these three signals to physical I/O terminals. Right-click on the controller’s I/O (DI 20 for 1600 or MI 24/8 FS1000 for 1800) and select Connect Signals. Set up your screen so that you can easily drag TIP signals from the Signal Editor window to the Signal Connections window. Both the Name fields in the Signal Editor and the Signal fields in the Signal Connections window must be visible, as shown above. 4. Verify that the Inputs tab is selected on the Signal Connections window. Two signals exist for each input: Value and Error Code. The GuardPLC 1800 adds another signal called Value Analog. Error Code is a status signal that can be used for point-level diagnostics. The Value contains the actual field state of the input: ON (1) or OFF (0). 5. Connect the START and STOP signals to DI[17].Value and DI[18].Value by dragging START and STOP from the Name field in the Signal Editor to the Signal field in the Signal Connections window. a. Make sure the cursor is not active in any field in either the Signal Editor or the Signal Connections window. b. Left-click and hold on the Name field. Drag the signal to the Signal field in the Signal Connections window. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-7 c. Release when over the proper field. Signals can only be dragged and dropped onto TIP Signal fields of the same data type. Dropping a BOOL signal onto a BYTE field is not permitted. When both signals have been connected, the screens should appear as follows: 6. If your controller is a GuardPLC 1800, an additional step is required. The digital inputs on a GuardPLC 1800 are actually analog circuits with a resolution of one (1) bit. Any voltage greater than 13V dc will be a 1. Any voltage less than 7V dc will be a 0. Since GuardPLC analog circuits require the user to specify which channels are being used, this is also required for the 24 digital inputs on the GuardPLC 1800. a. Add a new signal, called USED, to the Signal Editor. Give this signal an initial value of 1. You will never change this value in your program, so USED will always be 1. b. Select the Outputs tab of MI 24/8 FS1000. c. Connect USED to the DI channels being used: DI[17].Used, and DI[18].Used, as shown on the following page. Publication 1753-UM001A-EN-P - April 2004 5-8 Creating Your First GuardPLC Project 7. Close the DI Signal Connections window. 8. Right-click on DO8 in the project tree and select Connect Signals. 9. The Signal Connections window defaults to the Inputs tab. Select the Outputs tab to view the output fields. 10. Connect the MOTOR signal to the first output, as shown below. The signals have now been connected to physical I/O points. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-9 The following example creates code to start and stop a motor using Create a Function Block the two input signals we created earlier. Program For more information on Function Block TIP programming, consult the online Help and Chapter 17, “Creating User-Defined Function Blocks”. 1. Close the Signal Connections window. Leave the Signal Editor active, and restore the Project Management window. 2. If necessary, expand the project tree in Project Management until [I] TypeInstance is visible and double left-click on [I] TypeInstance. A Function Block Editor program page opens. 1. Drag all three tags from the Signal Editor (in Hardware Management) to any location on the FB Editor program page. To make the Signal Editor and the FB Editor fit TIP comfortably on your screen, restore both the Project Management and Hardware Management windows. Then, select Tile Windows Vertically from the Windows task bar located on the bottom of your screen. Whenever a page is edited for the first time, a window appears asking for a page name. You do not need to name the page. Click OK to close this dialog box. Publication 1753-UM001A-EN-P - April 2004 5-10 Creating Your First GuardPLC Project 2. Minimize the Hardware Management window. You can delete the white areas under the TIP signals, which are used for descriptions, by clicking on the white area and hitting the Delete key. 3. In the Project Management project tree, expand StandardLibs, IEC61131-3, and Bistr as shown below. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-11 4. Drag an AND and an OR block onto the routine (Left-click, hold, drag and release). 5. Connect the blocks with lines by left-clicking and holding the very small dots on the edges of the boxes. Drag and release over the destination dot. TIP Use the Zoom In tool on the toolbar to zoom in to see the dots on the edge of the boxes. 6. Create a duplicate MOTOR signal by right-clicking on MOTOR and selecting Duplicate. Drag and drop the signal on the page. 7. Invert the STOP signal by right-clicking on the dot and selecting Invert. Publication 1753-UM001A-EN-P - April 2004 5-12 Creating Your First GuardPLC Project Save the Program Save, Compile, Test, and Download the Program Left-click on the Save button to save your program edits. A window appears, which you can use to document your changes. Select OK. The FB editor menu bar displays the number of TIP edits since the last save. Following a save, it displays “(unchanged)”. Compile the Code 1. Close the Type Instance Program. (See the arrow below.) 2. Right-click on Resource and select Code Generation. 3. The results of the code generation are shown on the Error State Viewer. If the Error State Viewer is not visible, click on the red triangle to make it visible. If the compile was successful, “Error Free code generated” appears in the Error-State Viewer. If you are using a GuardPLC 1800, you will see a TIP warning in the Error State Viewer. Go to the Hardware Management window to view the warning, which reads “‘USED’ has an initial value, but no source.” Disregard this warning, because the “USED” signal has an initial value of 1, but no source drives its value. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-13 Run an Off-Line Simulation To test the code before downloading it to the GuardPLC, run an off-line simulation: 1. Right-click on Resource and select OFF-Line-Simulation. The OLS tab appears. 2. Double left-click on [I] TypeInstance above. Publication 1753-UM001A-EN-P - April 2004 5-14 Creating Your First GuardPLC Project 3. Select points to toggle/view during the simulation. To select a point, left-click on a point, drag, release, and left-click again to activate. 4. Start the simulation by left clicking on the blue flag button. 5. Double left-click on the yellow field to toggle TRUE/FALSE. Blue lines represent OFF. Red lines represent ON. 6. When finished testing, stop the simulation by selecting the Stop icon. 7. Close the Off-line simulation using the Close OLS icon. If you do not save your changes, you will TIP have to re-select the points to simulate. 8. Click on the PROJ tab to return to the project tree. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-15 Download the Program 1. Connect the GuardPLC to your PC’s Ethernet port using a Cat. 5 Ethernet cable. 2. In the Hardware Management window, close the Signal Editor. 3. Right-click on [60000] Resource. 4. Select Online → Control Panel. 5. The default Username is Administrator with no password. Click OK. The Control Panel opens. You can use the [Ctrl]+[A] shortcut to enter the TIP default Username and Password. If you are unable to go online, see Chapter 4 for information on determining the IP address and SRS of the GuardPLC and for information on the appropriate setting for your PC’s IP address. 6. If the GuardPLC is in RUN mode, change to STOP mode. Left-click on the Stop icon on the Control Panel. Answer Yes to the warning prompt. Publication 1753-UM001A-EN-P - April 2004 5-16 Creating Your First GuardPLC Project 7. Left-click on the Download icon. Answer Yes to the warning prompt. 8. Make sure the download was successful by checking the Status Field for a “Resource Configuration successfully loaded” message. 9. Put the GuardPLC into RUN mode by clicking on the Coldstart button and answering Yes to the warning prompt. Publication 1753-UM001A-EN-P - April 2004 Creating Your First GuardPLC Project 5-17 To monitor the routine online, you must be online with the controller, How to Monitor the Routine and the controller must be in RUN mode. Online 1. In the Project Management window, right-click on Resource and select ON-Line Test. The Project Manager appears as shown below. 2. Double left-click on [I] TypeInstance. If the lines appear RED and BLUE, then the monitor is active. Test the routine and monitor the function code. Publication 1753-UM001A-EN-P - April 2004 5-18 Creating Your First GuardPLC Project 3. Close the On-Line Test when finished testing. 4. Select the PROJ tab to return to the project tree. If the lines are RED/BLACK striped, then the Control Panel is NOT online with the GuardPLC or the GuardPLC is not in RUN mode. See Chapter 4 for information on going online with the GuardPLC controller. Publication 1753-UM001A-EN-P - April 2004 Chapter 6 Check, Download, Start, and Test a Routine Using This Chapter For information about: See page checking consistency (whether you need to download your routine) 6-1 downloading a routine 6-2 starting a routine 6-4 testing a routine 6-5 how a routine executes 6-6 To download and run a routine, you must first: 1. Complete your system configuration and your routine logic. 2. Save your logic by selecting Object → Save on the Project Management menu bar. 3. Generate code. Make sure all your system configuration is complete before you generate code. 4. Connect the programming terminal (running RSLogix Guard PLUS software) to the controller. See Chapter 4 for information on programming over an Ethernet link. 5. Download the routine to the controller. See page 6-2. 6. Start the routine. See page 6-4. To determine whether or not you need to download your routine, you Checking Consistency can use the Check Consistency feature to verify whether the routine running in the controller is the same routine you are editing in RSLogix Guard PLUS. Select Resource → Check Consistency to compare the two programs. If all the codes match, your offline routine has been previously downloaded to the controller. 1 Publication 1753-UM001A-EN-P - April 2004 6-2 Check, Download, Start, and Test a Routine 1. Select Online → Control Panel. The software automatically asks Downloading a Routine you to log in. 2. After you successfully log in, the Control Panel opens. Coldstart Download Stop 3. The routine must be stopped before downloading is permitted. Select Resource → Stop. 4. Select Resource → Download to load the routine into the controller. If your controller is in FAILURE_STOP, it must be IMPORTANT rebooted before you can download a routine. See page 8-4. Publication 1753-UM001A-EN-P - April 2004 Check, Download, Start, and Test a Routine 6-3 Troubleshooting the Download Process The SRS of the controller must match the SRS saved in the routine in order to download the routine. When you specify an SRS for a controller in a project, that SRS gets saved in the routine when you generate code. Checking the SRS of the Controller 1. Select Online → Communication Settings. 2. In the MAC address field, enter the MAC address of the controller. The MAC address is on the sticker on the side of a GuardPLC 1200 controller, on the label positioned over both lower RJ-45 connections on GuardPLC 1600/1800 controllers and I/O, or on the front bezel of the AB-CPU module of a GuardPLC 2000 controller. 3. Click Get. The controller responds back with the IP address and the SRS it is currently using. Now you know the correct SRS to use. Change the SRS and generate code again. Then the download should work. Updating the SRS in the Controller In some cases, most likely after a reboot due to a FAILURE_STOP, the SRS of the controller might be the same as the SRS in the routine, but the routine still will not download. If this happens, change the SRS to the same number and click OK, as shown on the following page. This updates the SRS in the controller and corrects the issue. You should now be able to download the routine. For more information on recovering from TIP FAILURE_STOP, see page 8-4. Publication 1753-UM001A-EN-P - April 2004 6-4 Check, Download, Start, and Test a Routine 1. Select Extra → Change System ID (SRS). 2. Enter the SRS and click OK. 3. Try the download again. After you successfully download a routine, you can start the routine. Starting a Routine From the Control Panel, select Resource → Coldstart or use the Coldstart button on the menu bar. or Options: Description: Warmstart Allows the user routine to be started by the programming terminal and to continue with the previously saved Retain signals. You must have Administrator or Read/Write access to initiate a warmstart. Coldstart If a routine is in STOP or FREEZE mode, it can be started using this cold start option. The cold start option re-initializes the routine and available process values are lost. Stop Use this option to stop a routine that is in RUN or FREEZE mode. Publication 1753-UM001A-EN-P - April 2004 Check, Download, Start, and Test a Routine 6-5 Test a routine to check for and eliminate errors. You must have Testing a Routine Administrator or Read/Write access to test a routine. Test options are discussed in the table below. From the Test Mode menu on the Control Panel, select the test option you want. Test Option: Description: Enter Test Mode (Hot Start) To enter test mode hot, a routine must be loaded and started in the controller. After a security query, the routine is paused (FREEZE) while retaining the current process data after terminating the cycle. No input signals are processed. The output signals retain their current state. Enter Test Mode (Warm Start) Halts the execution of the routine with the signals declared as Retain retaining their values and with all other signals being reset. Enter Test Mode (Cold Start) A routine must be loaded in the controller to allow you to “enter test mode” cold. After a security query, the routine is initialized, started, and immediately enters FREEZE mode. No input signals are processed, and all the output signals stay in their basic state. If the routine was in RUN mode when enter test mode cold was selected, the cycle in progress is terminated and the process data is re-initialized. Single cycle Single cycle can only be executed when the controller is in the test mode. Use single cycle to manually trigger the execution of a single cycle of the routine. The routine is executed exactly once. The input signals are read in, processed, and the resulting output signals are transferred. Use the force editor to perform a step-by-step check of the data. See Chapter 9 for information on monitoring signals. Continue with Run This option terminates the test mode. The routine mode changes from FREEZE to RUN without re-initialization. The current process data are retained. (This corresponds to a routine hot start.) Publication 1753-UM001A-EN-P - April 2004 6-6 Check, Download, Start, and Test a Routine A controller has only one routine. A routine can be in any one of How a Routine Executes these states: Routine State: Description: RUN_RUN The controller is in the RUN mode. • The routine is executed cyclically by the controller. • Input data are processed in the routine. • Output data of the routine are operated. RUN_FREEZE The controller is in the RUN mode. • The routine is not executed. • No input data are processed by the routine. • No output data of the routine are operated. This mode is not permissible for safety-related operation! STOP The controller is in the STOP mode. • The routine is not (no longer) executed. • All outputs have been reset. FAILURE_STOP The controller is in the STOP mode. • The routine was stopped due to an error. • All outputs have been reset. Controlling a Routine You can control a routine using the actions described below: Control Action: Description: Start the routine from STOP Starting the routine is the same as transferring the controller from the STOP mode into the RUN mode. The routine is then transferred into the RUN_RUN mode. If Freezing is activated while starting, the routine will be in the RUN_FREEZE mode. However, freeze operation is only possible if the software switch “Freeze Enable” has been enabled. In addition to starting in freeze mode, cold start is also possible. Starting a routine is only possible when both the controller restart switch and the routine restart switch are enabled. Start the routine from RUN The routine is transferred into the RUN_RUN mode if it has not already been operating in this mode. Starting is also possible in cold start, hot start, and no-freeze modes. This function is not allowed for safety operations of the controller! Single cycle the routine The routine must be in the RUN_FREEZE mode. Exactly one RUN cycle of the routine is executed, and the routine is then put back into the RUN_FREEZE mode. The command for the single cycle is the start command with the attributes hot start and freeze. This does not have any effect on the mode of the controller. Single cycle is only performed by the controller for the routine if freeze mode is enabled. This function is not allowed for safety operations of the controller! Restart the routine If the routine is in the FAILURE_STOP mode, it can be restarted via the programming software using a start command. After the restart, the entire routine is checked again. Stop the routine Stopping the routine is the same as transferring the controller from RUN mode into STOP mode. The routine is then transferred from RUN into the STOP mode. Freeze the routine The routine is transferred from the RUN_RUN mode into the RUN_FREEZE mode. This does not affect the mode of the controller. Freeze mode must be enabled for the routine. This function is not allowed for safety operations of the controller! Publication 1753-UM001A-EN-P - April 2004 Chapter 7 Using the Control Panel The Control Panel is your window into the online functionality of the Using This Chapter controller. Use the tabs to modify or monitor controller status. For information about: See page resource state tab 7-2 safety parameters tab 7-3 statistics tab 7-4 P2P (Peer-to-Peer) state tab 7-4 distributed I/O tab 7-5 HH (High-Level High-Speed) state tab 7-6 environment data tab 7-6 OS tab 7-7 using the Multi-Control Panel 7-8 Control Panel resource menu 7-11 Control Panel extra menu 7-12 1 Publication 1753-UM001A-EN-P - April 2004 7-2 Using the Control Panel Resource State Tab This field: Displays: CPU State the current state of the controller. Possible states are INIT, RUN, STOP/VALID_CONFIGURATION, STOP/INVALID_CONFIGURATION, and FAILURE_STOP. See “Controller Modes” on page 8-2. COM State state of the communication portion of the controller. Possible states are RUN, STOP, and OS_LOADING. Program Name the routine name. The name assigned by the user to the routine. The default name is “Routine.” Program State the current state of the routine. Possible states are RUN, STOP, FREEZE, and FAILURE_STOP. See “Routine Modes”on page 8-8. Faulty I/O Modules the number of faulty I/O modules, when the controller is in RUN. Force State the force status. 0 – forcing is disabled 1 – ready for forcing (the controller is in stop but is set for forcing) 2 – forcing is active Remaining Force Time [s] the remaining force time in seconds. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-3 Safety Parameters Tab This field: Displays: CPU configuration CRC cyclic redundancy check (CRC) selection for the configuration in the CPU (in hexadecimal notation). This identifies the configuration loaded in the controller. System ID the system ID. Safety Time [ms] the safety time in milliseconds. Watchdog Time [ms] the watchdog time in milliseconds. Main Enable whether controller switches can be changed while the controller is executing. Autostart whether the controller automatically starts up after rebooting the controller or applying power to the controller. Start/Restart allowed whether you can start a controller manually. Loading allowed whether you can load new configuration information to the controller. Test Mode allowed whether you can freeze the routine. Forcing allowed whether you can force tags. Stop on Force Timeout whether to stop executing the routine when the force time expires. Publication 1753-UM001A-EN-P - April 2004 7-4 Using the Control Panel Statistics Tab This field: Displays: Cycle Time [ms] average the average cycle time (in milliseconds) of the last 50 cycles. Cycle Time [ms] last the cycle time (in milliseconds) of the last cycle. Cycle Time [ms] min. the fastest cycle time (in milliseconds). Cycle Time [ms] max. the slowest cycle time (in milliseconds). If this value exceeds the Watchdog Time, the controller goes to FAILURE_STOP. Com. Time Slice [ms] the time required to process all Peer-to-Peer communication tasks within a CPU cycle. Number of Time Slices the number of time slices required to process all communication tasks. This value should always be 1 to avoid having multiple CPU cycles to complete all communication tasks. Date/Time the date and time in the controller. P2P (Peer-to-Peer) State Tab This field: Displays: Resource the name of the controller. System ID the network ID of the controller. State the status of the communication. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-5 This field: Displays: RspT (last, avg, the Measured ResponseTime for a message from PES → PES → PES , based on the network hardware, CPU cycle time, 1 2 1 min, max) and Peer-to-Peer profile. This parameter will be optimized later. MsgNr the Counter (32-bit resolution) for all messages sent to a controller. AckMsgNr the number of the received message that the controller has to acknowledge. DataSeq the Counter (16-bit resolution) for sent messages, which contain process data. Opens the number of successful connects to a controller. A figure higher than 1 indicates that a controller dropped out and has been reconnected. Resends the Counter (32-bit resolution) for messages that have been resent due to an elapsed ResendTMO. BadMsgs the Counter (32-bit resolution) for received messages that are corrupted, or are not expected at that instant. A corrupt message, for example, is a message with a wrong sender or with a faulty CRC. An unexpected message, for example, is an “Open” command, when the controllers are already connected. EarlyMsgs the Counter (32-bit resolution) for received messages that are not in the correct sequence. If a message drops out and is lost at the addressee, there is a gap in the received messages, and the next message comes early. Receive Tmo Receive Timeout as entered by the user. ResendTMO Resend Timeout as set by the profile. AckTmo Acknowledge Timeout as set by the profile. CurKeVer CRC for the Peer-to-Peer configuration. Identical to the Peer-to-Peer system signal. NewKeVer Reserved for future use. Distributed I/O Tab This field: Displays: Resource the name of the module. System.Rack the System.Rack ID of the module. State the status of the I/O module: • RUN • ERROR_STOP • STOP/VALID_CONFIGURATION • not connected • STOP/INVALID_CONFIGURATION Publication 1753-UM001A-EN-P - April 2004 7-6 Using the Control Panel HH (High-Level High-Speed) State Tab This field: Displays: Bus Cycle Time the time in milliseconds for a Token cycle. The value is 0, if Token Passing is off (any Cleanroom profile). Resource the name of the controller. LinkID the controller network ID. State the status of communication. RspT • If Link Mode is “TCS direct” (Token Passing OFF), RspT is the ResponseTime of the HH profile for a message from PES → PES → PES , based on the network hardware and topology. This parameter 1 2 1 cannot be changed by the user. • If Link Mode is “TCS TOKCYC” (Token Passing ON), RspT is part of the Bus Cycle Time. Link Mode • “TCS direct” when Token Passing is OFF. • “TCS TOKCYC” when Token Passing is ON. Token Group ID the ID of the Token Group. Environment Data Tab This tab displays status messages in hexadecimal form for Temperature State, Power Supply State, Fan State, and Relay State. See “Programming Controller Data” on page B-1 for an explanation of the error bits. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-7 OS Tab This field: Displays: Serial Number the serial number of the communication module of the controller. CPU OS the version of the operating system and the cyclic redundancy check of the operating system (in hexadecimal). (Version 2.4 or later is required for Peer-to-Peer communication.) CPU Loader the version of the operating system loader and the cyclic redundancy check of the operating system loader (in hexadecimal). CPU BootLoader the version of the boot loader and the cyclic redundancy check of the boot loader (in hexadecimal). COM OS the version of the communication operating system and the cyclic redundancy check of the communication operating system (in hexadecimal). (Version 2.4 or later is required for Peer-to-Peer communication.) COM OS Loader the version of the communication operating system loader and the cyclic redundancy check of the communication operating system loader (in hexadecimal). COM BootLoader the version of the communication boot loader and the cyclic redundancy check of the communication boot loader (in hexadecimal). Publication 1753-UM001A-EN-P - April 2004 7-8 Using the Control Panel The Multi Control Panel allows you to connect the programming Using the Multi-Control terminal to more than one controller in the project in one window and Panel to perform actions such as downloads, controller starts, invoking the force editor, etc. simultaneously. 1. Open the Multi Control Panel by selecting Online → Multi Control Panel. When the Multi Control Panel is opened for the first time, it does not contain any controllers. 2. Add a controller to the Multi Control Panel by dragging and dropping the Resource from the project tree into the Multi Control Panel. 3. After a controller has been dropped in the Multi Control Panel, the Login window opens. Enter the correct Username and Password to connect the controller to the programming terminal. You must have Read/Write or Administrator rights (Access type) to download a routine into the controller. 4. Add as many controllers to the Multi Control Panel as you need. The list of controllers in the Multi Control Panel can be sorted by clicking on the column headlines. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-9 The Multi Control Panel displays the following controller information: This field: Displays: Name Controller name System.Rack Controller ID CPU State Status of the controller CPU, such as RUN, STOP, STOP/VALID CONFIGURATION, STOP/INVALID CONFIGURATION, etc. CPU Configuration Checksum (cyclic redundancy check) of the CPU configuration, CRC displayed in hexadecimal. Avg. Cycle Time Average CPU cycle time in milliseconds. This figure depends on the complexity of the logic and, because of the Schedule Time Slice, on the network load. Rem. Force Time Remaining force time in seconds (time until forcing is deactivated). Value is “0” when forcing is not active or disabled. Faulty I/O Modules Number of faulty IO modules. A fault can result from a hardware malfunction or from incorrect configuration. Action Display of a Multi Control Panel command and command status (e.g. Start, Start:Ok). The field is cleared after five seconds. You can perform a Multi Control Panel command on one or more controllers. To select a single controller, click on the line number left of the controller name. The boundaries of this line become thicker. Hold down the CTRL key and click on another line number to add this controller to your selection. Use the SHIFT key to select controllers from line x to line y. To select all the controllers, use the Select All icon on the tool bar. Publication 1753-UM001A-EN-P - April 2004 7-10 Using the Control Panel The following commands can be carried out using the Multi Control Panel buttons in the button bar: Table 7.1 Multi Control Panel Buttons Button Command Connect Connects the programming software to the selected controller(s) after loss of communication or manual disconnect. After manual disconnect, a new login with password is required. Disconnect Disconnects the programming software from the selected controller(s). Coldstart Performs a coldstart on the selected controller(s). Stop Stops the selected controller(s). Download Loads the routine(s) into the selected controller(s). Prior to download, the code generator must have successfully generated program code and the selected controller(s) must be in STOP mode. NOTE: You cannot download a routine into a controller other than the one for which the logic was created. Control Panel Starts the control panel for the selected controller(s). This command can be carried out for a single controller by selecting Online → Control Panel. Diagnostics Starts the diagnostics display for the selected controller(s). This command can be carried out for a single controller by selecting Online → Diagnostics. Force Editor Starts the force editor for the selected controller(s). This command can be carried out for a single controller by selecting Online → Force Editor. Select All Selects all controllers in the list. Deselect Deselects marked controllers. Remove Controller Removes the selected controller(s) from the list. Removing a controller from the Multi Control Panel also disconnects the communication. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-11 Select Resource → Safety in the Control Panel to modify the safety Control Panel Resource settings of the controller. Menu Any settings you change via the Resource menu are IMPORTANT directly updated in the controller and are saved in the project. Menu Item: Description: Check Consistency compares the program running in the controller with the program you are editing in RSLogix Guard PLUS software. If they match, your offline project has previously been downloaded to the GuardPLC. Set Main Enable allows safety parameters to be changed. You can only select Set Main Enable when the controller is in STOP. For more information, see page 8-7. Reset Main Enable keeps safety parameters from being changed. For more information, see page 8-7. Change Safety Parameters changes the safety parameters, if Set Main Enable is activated. You must have Read/Write or Administrator access to be able to change safety parameters. For more information about these parameters, see page 8-7. See “Downloading a Routine” on page 6-2 and TIP “Starting a Routine” on page 6-4 for information on Warmstart, Coldstart, Stop, and Download menu items. Publication 1753-UM001A-EN-P - April 2004 7-12 Using the Control Panel Use the Extra menu of the Control Panel to modify communications Control Panel Extra Menu settings and change controller operation. You must have Administrator access to use most of these menu options as indicated in the table below. Menu Item: Description: Set Date/Time sets the controller clock, if Set Main Enable is activated. Enter the date as mm/dd/yy and the time as hh:mm. Change System ID (SRS) changes the system ID (SRS) of the controller. You must have Administrator access to be able to change the system ID (SRS). For more information, see page 4-22. Device Settings changes the Ethernet network parameters. You must have Administrator access and the controller must be in STOP mode. Update OS allows you to download new COM OS and CPU OS. Reboot Resource reboots the controller. See “Recovering From A FAILURE_STOP” on page 8-4. Load Resource Configuration from loads a copy of the last executable configuration to the controller Flash Clear Resource Configuration deletes the program memory of the controller and resets the configuration of the CPU and COM modules. GuardPLC 1200 and 2000 only: This does not affect the battery-buffered memory for long term diagnostics, short term diagnostics, date and time settings, system ID (SRS), or IP address. To reset a controller to default settings, clear the controller and remove the backup battery for at least 20 seconds. Removing the backup battery: • deletes date and time • deletes long term and short term diagnosis • deletes the configuration saved in the battery-buffered memory • deletes all user accounts • does not delete the program memory • does not reset the configuration of the CPU and COM modules Use Online → Communication Settings and write this value back to the battery-buffered memory. This validates the configuration and you can restart the routine. Publication 1753-UM001A-EN-P - April 2004 Using the Control Panel 7-13 Menu Item: Description: Set Backplane Type restores backplane information. The individual modules (CPU, COM, I/O) are linked to each other over the backplane. The controller requires this information to be able to conduct hardware tests. If the EEPROM that stores the backplane information loses its contents, use this menu option to write the backplane type back into the EEPROM. You must have Administrator access to be able to set the backplane type. Follow these steps to set the backplane type: 1. Load a project that is consistent with the connected controller type. ATTENTION: If you try to write the backplane type of a controller (such as a GuardPLC 1200 controller) with the backplane type of another controller (such as a GuardPLC 2000 controller), the overwritten controller can no longer be used and must be repaired by the manufacturer. 2. Select Set Backplane Type. The backplane type is automatically entered into the dialog window. 3. Change the Backplane Version to 0. 4. Click OK to confirm the change. Publication 1753-UM001A-EN-P - April 2004 7-14 Using the Control Panel Publication 1753-UM001A-EN-P - April 2004 Chapter 8 Controller Configuration and Modes of Operation Using This Chapter For information about: See page controller modes 8-1 controller configuration 8-5 routine modes 8-8 load a configuration and routine (in STOP mode only) 8-9 routine test mode 8-10 The GuardPLC operating system is stored permanently in the memory of the controller. The operating system is designed to make sure that all tasks of the controller are performed in a safety-related way. You have access to the controller via the RSLogix Guard PLUS software so that you can define the functionality of the controller. The controller can operate in various modes. These modes depend on Controller Modes the results of the tests of the hardware, software, and the system configuration. After you apply power to the controller or reboot the controller, the controller first performs a system test of the data and address lines and the flash and RAM memories. Then the controller checks the operating system in the flash memory. During this time, the controller is in the INIT mode. If all these initialization checks are OK, the operating system is started and the controller changes to the STOP mode. If any hardware and/or software errors are detected, the controller goes to the FAILURE_STOP mode. If the check of the operating system detected errors, the emergency loader starts. The emergency loader loads an operating system from the programming terminal. If the controller has a valid configuration and a routine downloaded to the controller, the controller goes to the STOP mode. 1 Publication 1753-UM001A-EN-P - April 2004 8-2 Controller Configuration and Modes of Operation To have the controller go to the RUN mode: • set the Autostart switch of the both controller and the routine • manually select RUN mode from the programming software. If you stop the controller, it transitions from RUN to STOP and interrupts the execution of the routine. The outputs of the routine and the I/O modules are reset to safe values. You can use the Emergency Stop system variable to put the controller in STOP mode by programming this variable in your logic or forcing it when necessary. The following table and flowchart summarize the controller modes: Mode: Description: INIT Safe state of the controller during initialization and the hardware tests after booting. • The controller is performing hardware and software tests. STOP Safe state of the controller without execution of a routine. • A loaded routine is in the STOP mode. • The outputs of the controller have been reset (LOW). • The controller is performing hardware and software tests. RUN The CPU is active. • The routine is being executed. • I/O signals are being processed. • The controller performs non-safety-related communication. • The controller performs software tests, hardware tests, and I/O module tests. FAILURE_STOP Safe state of the controller after a system fault. • A loaded routine is in STOP or FAILURE_STOP mode. • The outputs of the controller are being reset (LOW). • The controller is not performing software or hardware tests. • The controller is being held in the safe state. • The hardware watchdog is not triggered. • To recover from FAILURE_STOP, a reboot of the controller is necessary. A reboot can only be initiated via RSLogix Guard PLUS. See “Recovering From A FAILURE_STOP” on page 8-4. Publication 1753-UM001A-EN-P - April 2004 Controller Configuration and Modes of Operation 8-3 BOOT Yes No INIT Reboot? No INIT OK? FAILURE_STOP Hardware/Software Errors Yes STOP Yes Hardware/Software Errors? Hardware/Software Errors No No START? Yes RUN Yes Hardware/Software Errors? No No Stop Command? Yes Publication 1753-UM001A-EN-P - April 2004 8-4 Controller Configuration and Modes of Operation Recovering From A FAILURE_STOP If the controller is in FAILURE_STOP, you must reboot the controller by selecting Extra → Reboot Resource from the Control Panel as shown below. A Reboot Resource can only be initiated when the TIP controller is in FAILURE_STOP mode. If you attempt a reboot while the controller is in any other mode, an error message is displayed. If a routine has already been loaded in the controller when FAILURE_STOP occurs, the controller goes to STOP/VALID_CONFIGURATION after booting. If Autostart Enable is activated, the routine starts up automatically. If a Routine has not been loaded in the controller when FAILURE_STOP occurs, the controller goes to STOP/INVALID_CONFIGURATION after booting. If the GuardPLC is in TIP STOP/INVALID_CONFIGURATION after booting, you need to update the SRS. Use the update SRS procedure described on page 6-3. A brand-new GuardPLC 1200 or 2000 controller, into which a backup battery has not yet been installed, is always in FAILURE_STOP and must be rebooted before you can download a routine. Publication 1753-UM001A-EN-P - April 2004 Controller Configuration and Modes of Operation 8-5 To enable the controller to perform its tasks, you have to configure Controller Configuration the controller. The parameters you specify are stored in the non-volatile RAM and in the flash file system of the communication section of the controller. To configure a controller: 1. In the Hardware Management Window, expand the Configuration module. 2. Right-click on Resource and select Properties. 3. Use the Type pull-down menu to select your controller. 4. Set the controller parameters based on the information in the table on page 8-6. The safety time you specify must meet the needs of IMPORTANT the controlled process. See the GuardPLC Controller Systems Safety Reference Manual, publication 1755-RM001. Publication 1753-UM001A-EN-P - April 2004 8-6 Controller Configuration and Modes of Operation For this parameter: Specify: System ID (SRS) the system ID of the controller. The system ID is a component of the SRS (System, Rack, Slot), and can be in the range of 2 to 65535. The programming terminal uses the system ID to communicate with the controller. The purpose of the SRS is to match a routine to a specific resource and guarantee that only a routine with a matching SRS can be downloaded to a resource. The system ID of the controller should not be set at 1 because 1 is the default system ID for the programming terminal. IMPORTANT: The SRS (System, Rack, Slot) set in the configuration is compiled in the routine.EXE file and must match the SRS of the GuardPLC controller in order for a routine to be correctly downloaded to the GuardPLC. A different system ID results in an INVALID_CONFIGURATION error during download. IMPORTANT: The default SRS of a new controller is 60000. You must use this to establish communications with the controller the first time. Once you establish communications, you can change the SRS. Safety Time (ms) the safety time (in milliseconds) for the controller. The safety time is the time: • the controller must react to an input signal with an output signal • within which the controller must react to an error The default safety time is 2 times the default watchdog time. You can specify any time from 20 to 50000ms. Watchdog Time (ms) the maximum amount of time (in milliseconds) that the controller can take to execute one cycle. The watchdog time must be: •≥ 10 ms •≤ 0.5 x Safety Time (Worst case, two cycles must occur within the Safety Time. Therefore, Safety Time ÷ 2 is the maximum watchdog time.) • no more than 5000 ms. The default watchdog time is: • 500 ms for GuardPLC 1200 and GuardPLC 2000 • 50 ms for GuardPLC 1600 and GuardPLC 1800 • 10 ms for 1753-IB16, 1753-IB20XOB8, 1753-OB16 If the controller exceeds the watchdog time, the controller goes into FAILURE_STOP. Publication 1753-UM001A-EN-P - April 2004 Controller Configuration and Modes of Operation 8-7 You can set these switches: This switch: Specifies: Default Main Enable whether CPU switches can be changed while the controller is executing. On/Enabled If Main Enable is disabled, you cannot change the settings of the other 7 switches (described below) while the controller is in operation (routine in RUN). Autostart whether the controller automatically starts up after rebooting the controller or applying Off/Disabled power to the controller. If Autostart Enable is enabled, the routine automatically starts up after a reboot or applying power to the controller. Start/Restart allowed whether you can start a routine manually. On/Enabled If Start/Restart allowed is enabled, you can start a routine manually via the Routine menu of the Control Panel. Select either Coldstart or Warmstart. Coldstart is the recommended setting. If Start/Restart allowed is disabled, you cannot start a routine manually. You can only start a routine by rebooting the controller or applying power to the controller. Loading allowed whether you can load new configuration information to the controller. On/Enabled If Loading allowed is disabled, no (new) configuration can be loaded into the controller. This prevents a user from overwriting the current routine. Test Mode allowed whether you can freeze the routine. Off/Disabled If Test Mode allowed is enabled, the routine currently running on the controller can be frozen. This allows the Test Mode with Single Cycle function. You are not allowed to freeze a routine in standard operation (this would be non-safe operation). Online Test allowed whether you can monitor the Function Block code online. Off/Disabled Forcing allowed whether you can force signals. Off/Disabled If Forcing allowed is enabled, you can force the signals in the controller. If Forcing allowed is disabled, you can still display the force editor, but the forcing functions are locked. Stop on Force Timeout whether to stop forcing when the force time expires. On/Enabled If Stop on Force Timeout is enabled, the controller terminates execution of the routine after the user-set force time expires. All outputs go to LOW. If Stop on Force Timeout is disabled, the controller continues executing the routine with the process values when the force time expires. Max. Communication the time in milliseconds reserved for a controller to carry out and complete all 10 ms Time Slice communication tasks in one CPU cycle. This setting is required for Peer-to-Peer networking. Publication 1753-UM001A-EN-P - April 2004 8-8 Controller Configuration and Modes of Operation The controller runs only one routine. The following table and figure Routine Modes summarize the routine modes: Mode: Description: RUN_RUN The controller is in the RUN mode. • The routine is executed cyclically by the controller. • Input data are processed in the routine. • Output data of the routine are operated. RUN_FREEZE The controller is in the RUN mode. • The routine is not executed. • No input data are processed. • No output data of the routine are operated. STOP The controller is in the STOP mode. • The routine is no longer being executed. • All outputs have been reset. FAILURE_STOP The controller is in the STOP mode. • The routine was stopped due an error. • All outputs are reset. • The hardware watchdog is not triggered. • To recover from FAILURE_STOP, a reboot of the controller is necessary. A reboot can only be initiated via RSLogix Guard PLUS. See “Recovering From A FAILURE_STOP” on page 8-4. TEST MODE (single step) The controller is in RUN mode. • The routine is triggered manually. • I/O data are processed. IMPORTANT: Test Mode is not permitted for safe operation! Publication 1753-UM001A-EN-P - April 2004 Controller Configuration and Modes of Operation 8-9 Load Routine Yes No Restart STOP Routine? Yes Error in FAILURE_STOP Routine? No No Routine start? Yes Yes Freeze RUN_FREEZE enabled? No RUN_RUN Error in Yes Routine? No No Routine stop? Yes You can load a controller configuration and routine when: Load a Configuration and Routine (in STOP mode • the controller is in STOP mode, and only) • the controller Loading allowed switch is set. The controller STOP mode is subdivided into these categories: STOP Mode Category: Description: STOP_VALID_CONFIG The configuration is correctly loaded. The controller can be set to RUN via a command from the programming software. This initiates a loaded user routine. STOP_INVALID_CONFIG No configuration loaded or the loaded configuration is faulty. The controller cannot go to RUN. STOP_LOAD_CONFIG loading configuration in process Publication 1753-UM001A-EN-P - April 2004 8-10 Controller Configuration and Modes of Operation The configuration and the routine are loaded together into the controller. Loading a new configuration and a new routine automatically deletes all previously loaded objects, even if the new objects are faulty. Configuration changes only take effect if you IMPORTANT re-generate code before downloading to the controller. If the controller is in STOP mode, the controller configuration and routine can also be deleted using the programming software’s Clear resource configuration command. The controller goes into the STOP_INVALID CONFIGURATION mode. In order to execute a single-step operation (cycle step), the controller Test Mode of the Routine must be in RUN mode. The Test Mode allowed switch must be set to on. To enter Test mode, select the Test Mode menu from the control panel. Then select from Hot Start, Warm Start, or Cold Start. The controller state changes to Freeze, and you can now single cycle the routine using the Single Cycle option on the Test Mode menu. To return to normal operation, select Continue with Run. See “Testing a Routine” on page 6-5 for more information. Publication 1753-UM001A-EN-P - April 2004 Chapter 9 Monitoring and Forcing Signals Using This Chapter For information about: See page monitoring signals 9-1 forcing 9-3 enabling forces 9-4 starting the force editor 9-4 force time 9-6 specifying force values and force marks 9-5 starting forces 9-7 stopping forces 9-8 The Force Editor provides a window that lets you select signals to Monitoring Signals monitor, whether they are forced or not. 1. Right-click on the resource. Select Online → Force Editor. If the Control Panel is already open, you do not have to login. Otherwise, the software asks you to log in. 1 Publication 1753-UM001A-EN-P - April 2004 9-2 Monitoring and Forcing Signals 2. After you successfully log in, the software displays the Force Editor. 3. In the Force Editor, select Configure. The software displays a list of force signals you can select whether to view or not. Publication 1753-UM001A-EN-P - April 2004 Monitoring and Forcing Signals 9-3 4. If you are not already connected, in the Force Editor, select File → Connect. The software displays the values of the signals you selected. The R-Value (Resource Value) column displays the current values of the signals. You have the ability to force any of the signals that have been configured in the Force Editor. Forcing describes the intervention of the user in the logic of the user Forcing program loaded into the controller. When data is forced, the controller uses the forced values rather than its process values. This changes the value of one or more signals and affects the safety of the controller. Only signals used in the controller can be forced. The user program and the inputs and outputs are only affected when the controller is in RUN mode. When using forcing on a controller with safety tasks, ATTENTION always obey the restrictions listed in the GuardPLC Controller Systems Safety Reference Manual, publication 1755-RM001. Publication 1753-UM001A-EN-P - April 2004 9-4 Monitoring and Forcing Signals To enable forcing, both the Forcing allowed and Main Enable Enabling Forces switches must be set. The Forcing allowed switch can be set via the programming software, but only if the controller is in RUN or STOP mode. A forced value remains saved in the controller until: • the user program is stopped, • the force value is replaced by another value, or • the controller is switched off. If a new configuration is loaded, all of the force TIP switches and associated force values are reset. Any user can start the Force Editor, regardless of access privilege. Starting the Force Editor However, you can only force signals if Forcing allowed is enabled for the controller. Forcing is always disabled for users with Read access. Before you start the Force Editor, make sure the program running in the controller is the same program that you are editing in RSLogix Guard PLUS software. To verify whether these programs are the same, start the Control Panel and select Resource → Check Consistency. If the offline/online programs are not identical then the Force Editor will come up offline. Publication 1753-UM001A-EN-P - April 2004 Monitoring and Forcing Signals 9-5 To set a signal with a force value, you: Specifying Force Values and Force Marks 1. Enter the force value for the signal in the Force column. For Boolean signals, “True” or “False” and TIP “1” or “0” are acceptable values. 2. Double-click in the F column to mark that you want the controller to use the force value rather than the process value. 3. Send the force value(s) to the controller. The Force Editor displays the force value(s) in the R-Force column. A mark in the RF (resource force) column indicates that the controller will use the corresponding force value instead of the process value when forcing is enabled. Multiple force values can be written into the controller at the same time. The force values remain saved in the controller until the routine is reloaded. If the routine is stopped, the resource force marks are also reset. Publication 1753-UM001A-EN-P - April 2004 9-6 Monitoring and Forcing Signals Field: Description: Signal the name of the signal you want to force. Force the value you want to force the signal to have. The value you enter must match the type displayed in the Type field. F (force mark) a check in this field identifies that the force value you entered is sent to and saved in the controller and will become active when forcing is active. Double-click in this column to mark that you want the controller to use this force value rather than the controller’s process value. Type displays the type of the signal, as defined in the signal Editor. R-Value (resource value) displays the controller value, resulting from the current process and program logic. R-Force (resource force value) displays the value of the signal while forcing is active. RF (resource force mark) a check in this field identifies that the controller is using the force value rather than the process value as soon as forcing is active. The force time is monitored by the controller. To enter the force time Force Time in seconds, the controller must be in RUN or STOP mode with Forcing allowed set. For unlimited forcing activity, enter -1. The force time begins when the force process starts. The time is reset to 0 if a new configuration is loaded or if the operating voltage is disconnected. After the specified time, forcing activity ends. If the controller switch Stop on Force Timeout is enabled, the routine returns to STOP mode when forcing ends. If Stop on Force Timeout is disabled, the routine continues with the current process values once forcing ends. Publication 1753-UM001A-EN-P - April 2004 Monitoring and Forcing Signals 9-7 1. To start forces, select the Start… tab or select File → Start Starting Forces (see the arrow below). 2. The Force Time dialog box appears. Enter the Force Time. 3. The Force Editor opens. Once forcing starts, the Forcing activated box is checked and R-Force values take precedence over R-Values. Publication 1753-UM001A-EN-P - April 2004 9-8 Monitoring and Forcing Signals To stop forcing, select the Stop… tab or select File → Stop. Stopping Forces Once forcing is stopped, the Forcing activated check box is cleared. However, the Resource Force Mark (RF) field is still checked, indicating that force values remain in the resource, but are inactive. Publication 1753-UM001A-EN-P - April 2004 Chapter 10 Access Management Using This Chapter For information about: See page how the controller uses access levels 10-1 creating user access 10-2 An Administrator can set up access privileges for a maximum of ten How the Controller Uses users per controller. The controller stores the access privileges in its Access Levels non-volatile memory. The access privileges are not saved with the program, and are not downloaded to the controller with the program. If the controller is changed, access privileges must be re-entered manually. Every controller has the same default user account, which applies when the controller is: • new, out of the box • after disconnecting the operating voltage with the backup battery removed (GuardPLC 1200/2000 only) • utilizing the Reset button (GuardPLC 1600/1800 only) See “Reset Pushbutton”on page 2-13. The default account is: Username:Administrator Password: Access Type: Administrator 1 Publication 1753-UM001A-EN-P - April 2004 10-2 Access Management The following access levels are available: This access level: Allows: Administrator • highest privileges • manage usernames and passwords • read data from controller • write routines and data into controller • force tags • stop, start, freeze, and force a routine • download an operating system • reboot the controller • change IP address and system ID • can also login under read/write and read levels Read/Write • read data from controller • write routines and data into controller • force tags • start, stop, freeze, and force a routine • can also login under read level Read • lowest privileges • only read data from controller To create a user access level: Creating User Access 1. Select Online → Access Management. If the Control Panel is open, you do not have to login. Otherwise, the software asks you to log in. Publication 1753-UM001A-EN-P - April 2004 Access Management 10-3 2. After you successfully log in with Administrator access, the software displays the Access Management window. Field: Description: Username name of the user. Password password of the user. The password is case sensitive. Password Verification verify the password specified above. Access Type the access level of the user. Specify Administrator, Read/Write, Read, or No Access. The username and password are case sensitive and can contain as many as 31 characters. You can use letters, numbers and underscore ( _ ) characters. At least one of the users must have Administrator privileges. If you make changes to the user list, use the Set Accounts button to save the changes in the controller. The Administrator can delete access privileges of all users with the default account access and reset the Administrator account to the default setting of “Administrator” and no password (blank). Changes to access privileges can only be executed IMPORTANT when the controller is in the state STOP. If battery and external power to the controller are simultaneously off, the controller loses all account information and reverts to the default account. Publication 1753-UM001A-EN-P - April 2004 10-4 Access Management Publication 1753-UM001A-EN-P - April 2004 Chapter 11 Diagnostics Using This Chapter For information about: See page viewing diagnostics 11-1 GuardPLC 1200 LED description 11-4 GuardPLC 1600 and 1800 controllers and I/O LED descriptions 11-5 GuardPLC 2000 LED descriptions 11-7 1755-IB24XOB16 digital combination input and output module (AB-DIO) 11-9 LED descriptions 1775-IF8 analog input module (AB-AI) LED descriptions 11-10 1775-OF8 analog output module (AB-AO) LED descriptions 11-11 1775-HSC combination high-speed counter and output module (AB-CO) 11-11 LED descriptions The controller stores short term and long term diagnostics data. The Viewing Controller number of entries the controller can save depends on the controller, Diagnostics as shown below: Type of Data: GuardPLC 1200 GuardPLC 1600 and 1800 GuardPLC 2000 CPU: COM: CPU: COM: CPU: COM: number of short 60 700 60 700 300 700 term entries number of long 250 200 250 200 1000 200 term entries If the memory for short term entries is full and the controller needs to log another entry, the controller deletes the oldest entry. If the memory for the long term entries is full and the controller needs to add a new entry, the controller deletes the oldest entry only if that entry is more than 7 days old. Otherwise, the new entry is rejected and a message is displayed in the diagnostics window. 1 Publication 1753-UM001A-EN-P - April 2004 11-2 Diagnostics 1. To display the diagnostics window, left-click on the Resource and select Online → Diagnostics. If the Control Panel is already open, you do not have to login. Otherwise, the software asks you to log in. 2. After you successfully log in, the software displays the controller diagnostics. This field: Displays: Level whether the entry is INFO, WARNING, or ERROR. Date the date and time the entry was recorded. Text a description of the cause leading to the entry. Origin whether the cause of entry originated from the CPU or COM. Type whether the entry is short term (ST) or long term (LT). Parameter information direct from the CPU or COM. This data is only for error analysis by Rockwell Automation representatives. You can export diagnostic data to a text file for TIP storage by selecting Export from the Diagnostic menu. Publication 1753-UM001A-EN-P - April 2004 Diagnostics 11-3 Selecting Online or Offline Diagnostics When you start the diagnostics window, Diag. Online is automatically activated. This signals that you want all diagnostics data transferred from the controller to the diagnostics buffer in RSLogix Guard PLUS software. As long as Diag. Online is active, new diagnostic data is transferred to this buffer as it becomes available and if the filter you selected applies. Diag. Offline disconnects communication with the controller. This ends the transmission of diagnostic data from the controller to the diagnostics buffer in RSLogix Guard PLUS software. Filtering Diagnostic Data Select from these filters to determine what diagnostic data to display: Filter: Description: Start At Oldest Entry Displays all the data from the RSLogix Guard PLUS buffer starting with the oldest entry. The number of lines shown in the table depends on the Entries Per Diag. Enable Sorting defaults to disabled so that the data appears in chronological order from oldest to newest. Start At Newest Entry Displays all the data from the RSLogix Guard PLUS buffer starting with the newest entry. The number of lines shown in the table depends on the Entries Per Diag. Enable Sorting defaults to disabled so that the data appears in chronological order from oldest to newest. Start At Date Displays entries in chronological order starting at this date and time. The number of lines shown in the table depends on the Entries Per Diag. Enter the date as mm/dd/yy and the time as hh:mm. Stop At Date Displays entries in chronological order ending at this date and time. The number of lines shown in the table depends on the Entries Per Diag. Enter the date as mm/dd/yy and the time as hh:mm. Entries Per Diag. Determines the maximum number of entries to load into the buffer for the CPU and COM diagnostics. For example, if you enable short term and long term diagnostics for CPU and COM and you set Entries Per Diag. = 10, the diagnostic window contains a maximum of 40 entries (10 entries per diagnostic type). RSLogix Guard PLUS can buffer as many as 5000 entries per type of diagnostic. Sort If Sort is disabled, the diagnostic window displays entries in the order they were saved in the controller. If Sort is enabled, the diagnostic window automatically displays entries according to date. CPU Short Term Diagnostic Enables or disables whether to display the diagnostic data for each type. CPU Long Term Diagnostic COM Short Term Diagnostic COM Long Term Diagnostic Publication 1753-UM001A-EN-P - April 2004 11-4 Diagnostics The GuardPLC1200 controller has these LED indicators: GuardPLC 1200 LEDs PLC 1200 Indicator State Condition INput On Digital input channels are high (10 to 30V dc). Off Digital input channels are off. OUTput On Digital output channels are high. Off Digital output channels are off. RUN On This is the normal status of the controller. A routine, which has been loaded into the controller, is executed. The controller processes input and output signals, carries out communication, and performs hardware and software tests. Blink The controller is in STOP mode and is not executing a routine. All system outputs are reset. STOP mode can be triggered by setting the system variable “AB-CPU/Emergency Stop” to TRUE in the routine, or by direct command from the programming terminal. Off The controller is in FAILURE_STOP (see ERROR). ERROR On • A hardware error has been detected by the controller. In this case the controller goes to FAILURE_STOP and the execution of the routine is halted. Hardware errors are errors in the controller, in one or more of the digital input and output modules, or in the counters. • A software error in the operating system has been detected by the controller. • The watchdog has reported an error because of exceeded cycle time. All system outputs will be reset and the controller ceases all hardware and software tests. The controller can only be restarted by a command from the programming terminal. Blink If all the LEDs are on and ERROR blinks, the boot loader detected a corrupted operating system and is waiting for an operating system download. Off No errors are detected. PROGress On The upload of a new controller configuration is in progress. Blink The upload of a new operating system into the Flash ROM is in progress. Off No upload of controller configuration or operating system is in progress. FORCE On The controller is executing a routine (RUN) and FORCE mode is activated by the user. Blink The controller is in STOP, but forcing has been saved and will be activated when the controller is started. Off Forcing is off. Publication 1753-UM001A-EN-P - April 2004 Diagnostics 11-5 Indicator State Condition FAULT On The routine logic has caused an error. The controller configuration is faulty. The upload of a new operating system was not successful and the operating system is corrupted. Blink An error has occurred during a Flash ROM write cycle. One or more I/O errors have occurred. Off None of the above errors have been detected. COMMunication On The programming terminal, with Administrator or Read/Write access, is communicating with the controller via an Ethernet link. Off No communication or read-only communication on an Ethernet link. System LEDs GuardPLC 1600 and GuardPLC 1800 Controllers 24V DC and GuardPLC Distributed RUN ERROR I/O PROG FORCE FAULT OSL BL Indicator State Condition 24V dc On 24V dc operating voltage present. Off No operating voltage. RUN On This is the normal status of the controller. A routine, which has been loaded into the controller, is executed. The controller processes input and output signals, carries out communication and performs hardware and software tests. Flashing The controller is in STOP mode and is not executing a routine. All system outputs are reset. STOP mode can be triggered by setting the Emergency stop system variable to TRUE in the routine, or by direct command from the programming software. Off The controller is in FAILURE_STOP (see ERROR). ERROR On A hardware error has been detected by the controller. The controller goes to FAILURE_STOP and the execution of the routine is halted. Hardware errors are errors in the controller, errors in one or more of the digital input and output modules, or errors in the counters. A software error in the operating system has been detected by the controller. The watchdog has reported an error due to exceeded cycle time. All system outputs will be reset and the controller ceases all hardware and software tests. The controller can only be restarted by a command from the programming software. Off No errors are detected. Publication 1753-UM001A-EN-P - April 2004 11-6 Diagnostics Indicator State Condition PROGress On The upload of a new controller configuration is in progress. Flashing The upload of a new operating system into the Flash ROM is in progress. Off No upload of controller configuration or operating system in progress. FORCE On The controller is executing a routine (RUN) and FORCE mode is activated by the user. Flashing The controller is in STOP, but Forcing has been initiated and will be activated when the controller is started. Off Forcing is OFF. FAULT On The routine (logic) has caused an error. The controller configuration is faulty. The upload of a new operating system was not successful and the operating system is corrupted. Flashing An error has occurred during a Flash ROM write cycle. One or more I/O errors have occurred. Off None of the above errors has occurred. OSL Flashing Emergency Operating System Loader is active. BL Flashing Boot Loader unable to load operating system or unable to start COMM operating system loader. Communication LEDs Safety-Related GuardPLC Ethernet Communication via GuardPLC Ethernet is indicated via two small LEDs integrated into each RJ-45 connector socket. Indicator State Condition Green On Full duplex operation Flashing Collision Off Half duplex operation, no collision Yellow On Connection established Flashing Interface activity Non-Safety-Related Communication Active communication via the serial ports, COMM1 and COMM3, is indicated by an LED located above the port. Publication 1753-UM001A-EN-P - April 2004 Diagnostics 11-7 The GuardPLC2000 controller has LED indicators for: GuardPLC 2000 LEDs • module, both the program and the communication • controller and the system hardware • routine • Ethernet communication to the programming terminal Controller Indicators LED Status Explanation RUN ON This is the normal status of the controller (RUN or STOP mode). 1755- L1 The controller carries out communication and performs software tests. RUN ERR BLINK Downloading an Operating System OFF The controller is in FAILURE_STOP (see LED ERR below), or there is RUN STOP no power supply. PROG FAULT ERR ON The controller is in the FAILURE_STOP state and the execution of the routine is halted. All system outputs will be reset and the controller FORCE ceases all hardware and software tests. The operating system loader has found a flash error (FAULT is blinking). Tx COL BLINK The boot loader has found an error in the operating system in the flash (if all other LEDs are ON); the download of a new operating system is awaited. OFF No errors are detected. 10/100BaseT Publication 1753-UM001A-EN-P - April 2004 11-8 Diagnostics Routine Indicators LED Status Explanation 1755- RUN ON The routine is in RUN or FREEZE. L1 OFF The routine is in FAILURE_STOP. RUN ERR STOP ON The routine is in STOP or FAILURE_STOP. PROG ON The download of a new controller configuration is in progress. RUN STOP BLINK The download of a new operating system into the flash ROM is in PROG FAULT progress. FORCE OFF No download of controller configuration or operating system is in progress. FAULT ON The routine (user program) has caused an error. Tx COL The controller configuration is faulty. The download of a new operating system was not successful and the operating system is corrupted. BLINK An error has occurred during a flash ROM write cycle of the operating system. 10/100BaseT At least one I/O module error is present. OFF No errors have been detected. FORCE ON The controller is executing a routine (RUN) and one or more inputs and/or outputs may be forced by the user. BLINK The controller is in STOP, but one or more inputs and/or outputs have been prepared for forcing and will be activated as soon as the controller is started. OFF No inputs and/or outputs are forced or are prepared to be forced. Ethernet Communication Indicators Tx COL LED Status Explanation Tx On Data is transmitting via Ethernet by the communication processor. COL On A collision on Ethernet is detected. 10/100 Base T Publication 1753-UM001A-EN-P - April 2004 Diagnostics 11-9 Serial Communication Indicators LED Status Explanation FB1 On Field bus no. 1 is active FB1 FB2 On Field bus no. 2 is active FB2 (serial interface module) Only the bottom serial port on the GuardPLC 2000 IMPORTANT controller is active, as indicated by the FB2 LED. The 1755-IB24XOB16 digital combination input and output module 1755-IB24XOB16 LEDs (AB-DIO) has LED indicators for: ERR RUN LS+ 1 I1 2 • power supply I2 3 I3 4 5 I4 • module status 1755- I5 6 IB24XOB16 I6 7 I7 • I/O status 8 I8 9 ERR RUN Power Supply and Module Status LED Status Explanation RUN ON (green) The module has the correct operating voltage (24V dc). OFF The module has no power. ERR ON (red) If the system is in STOP mode, one or more of the inputs or outputs is faulty, or the module is faulty. Use the RSLogix Guard PLUS software to verify the location of the fault. If the module is faulty, replace the module immediately, or the safety-related operation of the GuardPLC 2000 controller is not maintained. OFF The module is operational. Publication 1753-UM001A-EN-P - April 2004 11-10 Diagnostics I/O Status Status Explanation ON (yellow) • Input is high • Output is energized OFF • Input is low • Output is de-energized While the system is in RUN mode, ERR is indicated continuously for both a module and a channel error. Depending on the type of error, the module switches off only a faulty output channel, but the operation of the other outputs continues, or all the output channels are switched off. The inputs are always in operation. A faulty input channel transmits Low-signal to the logic. If the entire module is switched off, all input and output channels are switched off. The 1755-IF8 analog input module (AB-AI) has LED indicators for: 1755-IF8 Analog Input Module LEDs • power supply • module status LED Status Explanation 1755- RUN ON (green) The module has the correct operating voltage (24V dc). IF8 OFF The module has no power. ERR RUN ERR ON (red) If the system is in STOP mode, one or more of the inputs or outputs is faulty, or the module is faulty. Use the RSLogix Guard PLUS software to verify the location of the fault. If the module is faulty, replace the module immediately, or the safety-related operation of the GuardPLC 2000 controller is not maintained. OFF The module is operational. While the system is in RUN mode, ERR is indicated continuously for both a module and a input channel error. Depending on the type of error, the module may switch off only one input channel (i.e., a faulty channel transmits the value 0 to the logic, but the module continues operation with the remaining channels). If the entire module is switched off, all input channels transmit the value 0 to the logic. Publication 1753-UM001A-EN-P - April 2004 Diagnostics 11-11 The 1755-OF8 analog output module (AB-AO) has LED indicators for: 1755-OF8 Analog Output Module LEDs • power supply • module status LED Status Explanation 1755- RUN ON (green) The module has the correct operating voltage (24V dc). OF8 OFF The module has no power. RUN ERR ERR ON (red) If the system is in STOP mode, one or more of the inputs or outputs is faulty or the module is faulty. Use the RSLogix Guard PLUS software to verify the location of the fault. If the module is faulty, replace the module immediately or the safety-related operation of the GuardPLC 2000 controller is not maintained. OFF The module is operational. While the system is in RUN mode, ERR is indicated continuously for both a module and an output channel error. Depending on the type of error, the module may switch only one pair of output channels (1+2, …, 7+8) to the de-energized state (i.e. the value 0V or 0 mA), but the module continues operation with the remaining channels. If the entire module is switched off, all output channels are switched to the de-energized state. The 1755-HSC combination high-speed counter and output module 1755-HSC Combination (AB-CO) has LED indicators for: High-Speed Counter and • power supply Output Module LEDs • module status • I/O status Power Supply and Module Status LED Status Explanation RUN ON (green) The module has the correct operating voltage (24V dc). L- 19 1 20 1755- 2 OFF The module has no power. 21 HSC 3 22 4 ERR ON (red) If the system is in STOP mode, one or more of the inputs or 23 RUN ERR 24 L- outputs is faulty or the module is faulty. Use the RSLogix Guard PLUS software to verify the location of the fault. If the module is faulty, replace the module immediately or the safety-related operation of the GuardPLC 2000 controller is not maintained. OFF The module is operational. Publication 1753-UM001A-EN-P - April 2004 11-12 Diagnostics I/O Status LED Status Explanation 1, 2, 3, 4 ON (green) The corresponding output is energized. OFF The corresponding output is de-energized. While the system is in RUN mode, ERR is indicated continuously for both a module and a counter channel error. Depending on the type of error, the module may switch off only one counter channel (i.e., the counter transmits the value 0 to the logic, the output has no signal, but the module continues operation with the remaining counter channel). If the entire module is switched off, all counter channels are switched off. Publication 1753-UM001A-EN-P - April 2004 Chapter 12 Peer-to-Peer Communication Overview Using This Chapter For information about: See page Peer-to-Peer communication basics 12-1 network configuration 12-3 networking limitations 12-2 High-Level High-Speed protocol parameters 12-3 Peer-to-Peer protocol parameters 12-6 High-Level High-Speed network profiles 12-10 Peer-to-Peer network profiles 12-17 Peer-to-Peer communication is used for data exchange between two Peer-to-Peer or more controllers and distributed I/O on a GuardPLC safe Ethernet Communication Basics network. GuardPLC Ethernet is certified for use in SIL3 and CAT 4 applications and is designed to carry safety-related data. The controllers are usually connected via Ethernet, but other means of communication, such as telephone lines or two-way radios are also possible, using gateways from Ethernet to the respective technology. The Peer-to-Peer protocol is primarily responsible for: • the communication between controller CPUs, including automatic connection setup • extended diagnostics • all safety-relevant features for correct data transfer Each controller is equipped with one or more 10/100 Base T Ethernet ports. The High-Level High-Speed (HH) protocol is implemented in the operating system of the GuardPLC 1200/1600/1800 and GuardPLC 2000 communication module (COM) and interacts with the Ethernet port. The HH protocol is based on UDP/IP and IEEE 802.3 standards and is responsible for the collision-free data exchange via standard Ethernet in various network topologies. 1 Publication 1753-UM001A-EN-P - April 2004 12-2 Peer-to-Peer Communication Overview As seen in the figure below, both the HH and the Peer-to-Peer protocols are vital for safe Ethernet Communication. HH protocol can be considered the wire or transport media through which messages are passed. Peer-to-Peer (P2P) is the protocol that runs on the wire, making sure that the messages are transmitted over the HH connection within the watchdog time. P2P is the mechanism that qualifies GuardPLC Ethernet as a safety network. Controller 1 Controller 2 CPU P2P P2P COM HH HH Ethernet The Peer-to-Peer protocol is designated as a safe TIP protocol according to DIN V 19250(AK6), IEC61508 (SIL 3) and EN 954-1 (CAT 4) respectively. A peer-to-peer link is defined as communication from one GuardPLC Networking Limitations to another GuardPLC, or from a GuardPLC to a distributed I/O block. A device on an Ethernet network must make a connection to another device on the Ethernet network in order for the two of them to communicate. Connections only need to be established between devices that wish to communicate with each other. A single GuardPLC controller may have up to 64 connections to other devices on the GuardPLC Ethernet network (GuardPLC controllers, GuardPLC Distributed I/O Blocks, OPC servers, or programming terminals). Each connection can transfer up to 900 Bytes of data in each direction (read and write). The data size is determined by the number of signals transferred between the devices. In contrast, a GuardPLC Distributed I/O block can only have one connection, the connection to the controller that ‘owns’ it. The amount of data shared between a DIO block and the controller is fixed and defined by the type of I/O block. The total number of controllers, DIO blocks, OPC servers, and programming terminals on a network is only limited by the number of available IP addresses and the network bandwidth (max 100 Mbits per second) of a segment of the network. However, large amounts of data flowing on the network will affect the network response time, and therefore the safety time of the system. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-3 Communication between GuardPLC controllers can be established via Network Configuration different kinds of Ethernet topologies. Both the HH protocol and the Peer-to-Peer protocol can be adapted to the network in use, to allow smooth and efficient data transfer. You configure the HH protocol and the Peer-to-Peer protocol by setting parameters, either manually or with the help of network profiles. Network profiles are preset combinations of parameters you can select to make configuration simpler. To optimize data transfer and customize the configuration, you must have an extensive knowledge of the network in use and the operation of the parameters. The following sections summarize the most important HH and Peer-to-Peer protocol parameters. The HH protocol parameters are displayed in the HH Network/Token HH Protocol Parameters Group window. They can be preset by selecting one of two profiles: • Fast • Medium The profiles are explained in HH Network Profiles on page 12-10. While manual changes to the parameters are possible TIP by selecting the "None" profile, keep in mind that ill-considered changes can disable communication completely. Publication 1753-UM001A-EN-P - April 2004 12-4 Peer-to-Peer Communication Overview Token Group ID The Token Group ID is the numerical identifier for a Token Group. Each Token Group must have its unique ID. Protocol Mode Choose either Normal or RAW protocol mode. Normal In Normal mode, software token passing is ON, meaning that access to the Ethernet network is controlled via token passing. Only the controller that holds the token is allowed to access the network. This mode is recommended for networks with slow hubs to avoid message collisions. RAW In RAW mode, software token passing is OFF. No token is created. Ethernet access is coordinated by hardware only. The affiliated Link Mode is “TCS direct”. Data transfer is faster than in “Normal Mode” and message collisions are prevented by the switching and full-duplex mode ports. This mode is recommended for networks, where full-duplex (recommended) LAN-switches are used exclusively, or the switches integrated into the GuardPLC 1600 and 1800 can be used. Link Mode Select either TCS Direct or TCS TOKCYC. TCS Direct In TCS Direct mode, safety-related data are sent as soon as they are prepared for transmission. Network media access is coordinated by hardware. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-5 TCS TOKCYC This Link Mode corresponds to Protocol Mode “Normal”. Safety-related data are sent when the controller receives the token. Network media access is coordinated by software. Response Time Response Time is the controller’s maximum permissible Response Time for a network message. PES (Programmable Electronic System ) 1 1 sends a message to PES and expects the answer within the Response 2 Timeout. The actual values of the ResponseTime can be read in the HH Status of the Control Panel. Token Cycle Time This is the maximum permissible time for one token cycle. In other words, the time within which a controller expects the token. The Token Cycle Time depends on the number of controllers in a Token Group and can be read in the HH Status of the Control Panel. Token Alive Timeout The current holder of the token must send a token alive message to (1) the Primary controller within this time period or the Primary assumes the token is bad. If the token alive message is missing, a new token is created by the Primary. (1) The Primary is the controller that generates and supervises the token. Publication 1753-UM001A-EN-P - April 2004 12-6 Peer-to-Peer Communication Overview Primary Timeout Time, within which the Primary expects a check for liveliness from the (1) Secondary controller. If the liveliness check fails to appear, the Primary assumes that the present Secondary is disconnected. In this case, the Primary selects a new Secondary. Secondary Interval Time, after which the Secondary checks the Primary for liveliness. The Secondary Interval is less than the Primary Timeout. Link Mode (Extern) Same as Link Mode above, except for the connection is to a controller in another Token Group. Response Time (Extern) Same as Response Timeout above, except for the connection is to a controller in another Token Group. All Peer-to-Peer protocol parameters are displayed in the Peer-to-Peer Peer-to-Peer Protocol Editor. With the exception of the ResponseTime and the ReceiveTMO, Parameters which have to be configured by the user, all other Peer-to-Peer protocol parameters are automatically preset with the selection of a Peer-to-Peer profile. See "Configure Peer-to-Peer Communication" on page 13-11 for detailed instructions on how to configure the Peer-to-Peer protocol. (1) The Secondary is a controller in the same Token Group as the Primary. The Secondary supervises the Primary. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-7 Message Response Time (ReponseTime) ResponseTime is the user-configurable time it takes to receive an acknowledgement of a sent message from the recipient. The ResponseTime is not a freely configurable parameter, but results from the physical conditions of the communication path and the configuration of the network protocol. Because the ResponseTime influences the speed of message exchange, a test run is recommended to investigate network timing. Use the P2P Status tab, in the Control Panel to display the minimum, maximum, and average ResponseTime. The ResponseTime is the sum of the following variables, described in the table below: ResponseTime = T + T + T + T + T GR1 1 GR2 3 2 Table 12.1 Response Time Variables Variable: Definition: T Message delay between two PES: GR1 CPU → COM → network → COM → CPU 1 1 2 2 T Time on CPU to process all protocol stacks: 1 2 T = CycleTime(CPU ) x n 1 2 2 where n is the number of cycles needed on CPU to process all protocol 2 2 stacks. Set the Communication Time Slice (see below) large enough to allow all protocol stacks to be processed in one cycle. T Delay of the acknowledgement on CPU : 2 2 T = AckTMO + n x [0 … CycleTime(CPU )] 2 2 2 If AckTMO = 0 or ProdRate = 0, then T = 0 2 T Message delay between two PES: GR2 CPU → COM → network → COM → CPU 2 2 1 1 (usually identical with T ) GR1 T Time on CPU to process all protocol stacks: 3 1 T = CycleTime(CPU ) x n 3 1 1 where n is the number of cycles needed on CPU to process all protocol 1 1 stacks. Set Communication Time Slice (see page 13-2) large enough to allow all protocol stacks to be processed in one cycle. Publication 1753-UM001A-EN-P - April 2004 12-8 Peer-to-Peer Communication Overview Receive Timeout (ReceiveTMO) ReceiveTMO is the safety-related, user-configurable monitoring time, within which PES must receive a correct response from PES . 1 2 ReceiveTMO is also valid for the return path from TIP PES to PES . 2 1 If ReceiveTMO elapses, safety-related communication closes down and all imported (via communication) safety-related tags reset to their user-configurable initial values. If the ReceiveTMO ≥ 2 x ResponseTime(minimum), the loss of at least one message can be handled without losing the Peer-to-Peer connection. If the ReceiveTMO is not ≥ 2 x ResponseTime(minimum), the availability of the Peer-to-Peer connection is only guaranteed in a collision- and noise-free network. However, this does not result in a safety problem for the CPU! The maximum permissible value for ReceiveTMO TIP depends upon the application and is set in the Peer-to-Peer Editor along with the expected maximum ResponseTime and the profile. Resend Timeout (ResendTMO) Resend Timeout is the safety-related monitoring time of PES . If the 1 receipt of a data transmission is not confirmed by PES within this 2 time period (ResendTMO), PES repeats the data transmission. 1 Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-9 Acknowledge Timeout (AckTMO) Reception of data must be confirmed by the CPU with an ACK (acknowledge) message to the sender of the data. If the CPU is busy, ACK is delayed. Acknowledge Timeout is the maximum delay an ACK message may have. The AckTMO cannot be entered manually, but is set in conjunction with a profile in the Peer-to-Peer Editor. For fast networks, AckTMO is zero. Queue Length (QueueLen) QueueLen describes the number of messages which may be transmitted without having to wait for an acknowledgement. It corresponds to the network bandwidth and delay. QueueLen cannot be entered manually, but is set along with a profile in the Peer-to-Peer Editor. Production Rate (ProdRate) ProdRate is the minimum time interval between two data messages. The purpose of ProdRate is to limit the amount of data to a magnitude which can be transported to the recipient without overloading a (slow) communication channel. This results in an even load on the communication channel and avoids the reception of outdated data. A production rate of 0 means that a data message TIP can be transmitted with each cycle of the user program. Watchdog Time (WDZ) Watchdog Time is the maximum permissible duration of a RUN cycle on a PES. The RUN cycle depends upon the complexity of the user program and the number of Peer-to-Peer connections. Publication 1753-UM001A-EN-P - April 2004 12-10 Peer-to-Peer Communication Overview Worst-Case Reaction Time (T ) R Worst-Case Reaction Time is a safety-relevant application parameter. It is the time between the occurrence of a physical input signal change at PES and the corresponding physical output signal change at PES : 1 2 Worst-Case Reaction Time (T ) ≤ t + t + t + t R 1 2 3 4 where: Table 12.2 Worst-Case Reaction Time Variables Variable: Definition: t The worst-case time for the user program on PES to process the input 1 1 signal and prepare the data for transmission. 2 x WDZ (PES ) 1 t The additional transmission delay on PES . 2 1 Equals 0 ms, if the ProdRate is 0. Otherwise: equals ReceiveTMO + WDZ (PES ) 1 t ReceiveTMO 3 The maximum age of a message when received at PES . 2 t The maximum time for the received data message to be processed by the 4 user program on PES and the output signal to be set. 2 The Worst Case ReactionTime T is process-dependent and has to be R coordinated with the approving board. In the Peer-to-Peer Editor, the Worst Case ReactionTime can be read in the “Worst Case” column. Two HH network profiles are used to configure the appropriate set of HH Network Profiles parameters for the network in use. These profiles, described below, can be selected in the Properties of the HH Network Token Group. • Profile I: Fast • Profile II: Medium A third profile option, None, allows you to set parameters manually. See The “None” Profile on page 12-16 for more information. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-11 Profile I: Fast This is the recommended profile. It provides the fastest data throughput, and covers approximately 95% of all application cases. Use Fast for: • applications which require fast data update rates within a Token (1) Group . (1) • fast communication between two or more Token Groups , where the other Token Groups must run Fast as well. • applications which require the shortest feasible Worst-Case Reaction Time. Because Token Passing is switched off in the Fast TIP profile, it is possible to generate a Token Group with only one controller. No second controller is needed to exchange the token. The single controller can communicate with other Token Groups containing more controllers. The minimum network requirements are outlined in the table below. Table 12.3 Minimum Ethernet Network Requirements for Profile I Requirement Definition Fast 100 Mbit technology (100 Base TX) Switched Fast Ethernet (full-duplex recommended) LAN switches or integrated switches (GuardPLC 1600/1800) required. Cleanroom No loss of data due to traffic overload, harsh environmental conditions, or network defects. The network can be shared with other applications, TIP if sufficient bandwidth is provided. (1) A Token Group consists of at least two controllers, which share the same token. Each controller must be a member of exactly one Token Group. A Token Group can work stand-alone or can exchange data with other Token Groups. Publication 1753-UM001A-EN-P - April 2004 12-12 Peer-to-Peer Communication Overview Example of HH Network Profile I Topology Token Group 1 GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 controllers Token Group 2 GuardPLC 1200 GuardPLC 1200 GuardPLC 1200 GuardPLC 2000 GuardPLC 1600 controllers with integrated Ethernet Switch GuardPLC 2000 Controllers 100 Mbit GuardPLC 1200 LAN Switch GuardPLC 1800 controller with integrated Ethernet Switch Buffer Amp Token Group 3 Programming Terminal GuardPLC 2000 GuardPLC 1800 controller with GuardPLC 2000 integrated Ethernet Switch GuardPLC 1200 GuardPLC 1200 Buffer Amp Backbone GuardPLC 1600 controller with integrated Ethernet Switch 100 Mbit LAN Switch Publication 1753-UM001A-EN-P - April 2004 Fiber Optic Cable Twisted Pair Cable, max. 100 m Peer-to-Peer Communication Overview 12-13 Profile II: Medium This profile provides medium-speed data throughput and covers approximately 4% of all application cases. It is appropriate for applications where timing is not a critical factor. With the Medium profile, network media access within a Token Group and communication with external Token Groups is controlled by Token Passing. These external Token Groups must also run Medium profiles. In the Medium profile, a Token Group must be IMPORTANT comprised of at least two controllers to carry out Token Passing, otherwise the controller configuration is erroneous. (“STOP/INVALID CONFIGURATION”). Table 12.4 Minimum Ethernet Network Requirements for Medium & Cleanroom Requirement: Definition: Medium: 10 Mbit technology (10 Base T) Hubs are used within the Token Groups and LAN switches connect one Token Group to another. Clean: No loss of data due to traffic overload, harsh environmental conditions, or network defects. The network must not be shared with other IMPORTANT applications. Do not use more than one Programming Terminal (recommended). Programming Terminals increase network traffic, but do not participate in Token Passing! Using LAN Switches and Hubs When using a hub instead of a LAN switch to interconnect two or more controllers of the same Token Group, network access within the Token Group is no longer conducted by the hardware, but must be managed by Token Passing. Publication 1753-UM001A-EN-P - April 2004 12-14 Peer-to-Peer Communication Overview Each Token Group handles its Token Passing individually, depending on user settings, CPU cycle times, network topology, etc. This means that for two (or more) Token Groups, which are exchanging data, Token Passing is not synchronized, resulting in a loss of messages between the Token Groups. To minimize loss of messages, only one controller in IMPORTANT a Token Group is allowed to exchange data with exactly one controller in a second Token Group. Furthermore, the overall number of links between Token Groups is limited to eight. Token Group 1 Token Group 2 GuardPLC 1600 controllers with integrated Ethernet Switch GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 GuardPLC GuardPLC 2000 2000 controllers GuardPLC 1200 GuardPLC 1200 GuardPLC 1200 GuardPLC 1200 GuardPLC 1800 controller with integrated Ethernet Switch Programming Terminal 10 Mbit Hub 10 Mbit Switch The illustration above shows an application, consisting of two Token Groups. The Token Groups equipped with hubs require Token Passing to coordinate network access within the Token Groups. The Token Groups are interconnected via a LAN switch. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-15 In this network topology, only one controller in Token Group 1 is allowed to exchange data with one controller in Token Group 2. If Token Group 2 needs data from different controllers in Token Group 1, the “talking” controller in Token Group 1 must collect the data. In the HH Network Profile II Configuration Topology example on page 12-16, only the following links between Token Groups are allowed: • A1 ↔ A2 • B1 ↔ B2 • C1 ↔ C2 To configure this scenario, the controllers are placed in their respective token groups: Token Group 1 Token Group 2 Token Group 3 Controller 1 Controller 5 Controller 9 Controller 2 Controller 6 Controller 10 Controller 3 Controller 7 Controller 11 Controller 4 Controller 8 Controller 12 In the Peer-to-Peer Editor, you create connections between controllers. For example, all controllers in Token Group 1 can communicate to each other, but Controller 1 can also communicate to Controller 5 in Token Group 2: Token Group 1 Connections Controller 1 Controller 2 Controller 3 Controller 4 Controller 2 Controller 1 Controller 1 Controller 1 Controller 3 Controller 3 Controller 2 Controller 2 Controller 4 Controller 4 Controller 4 Controller 3 Controller 5 — — — Publication 1753-UM001A-EN-P - April 2004 12-16 Peer-to-Peer Communication Overview HH Network Profile II Configuration Topology Token Group 1 Token Group 2 Token Group 3 GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 GuardPLC 2000 GuardPLC GuardPLC 3 7 9 2000 2000 1 5 11 controllers controllers 6 GuardPLC 1200 GuardPLC 1200 2 4 12 10 8 10 Mbit 10 Mbit 10 Mbit Hub Hub Hub Programming Buffer Amp Terminal Twisted Pair Cable, max. 100 m Buffer Amp 10 Mbit Switch Fiber Optic Cable The “None” Profile The None profile is different from the profiles described previously because it has no pre-defined parameters. You must set all the parameters manually. To set the parameters, select either Fast or Medium from the HH Network/Token Group window, and press the Apply button. This presets the parameters according to the profile. To enable manual changes and activate the entry fields, select None and press Apply again. The former parameter settings will be overridden and can then be changed. Because the profiles Fast and Medium cover nearly all conceivable network topologies, None is only recommended for evaluation purposes. An extensive knowledge of the functions of the parameters, their value ranges, and their impact on the availability of the network is required for proper manual parameterization. The None profile should not be used in regular IMPORTANT applications. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-17 Due to the variety of parameters, manual network configuration is Peer-to-Peer Network very complex and requires extensive knowledge of the parameters Profiles and how they influence one another. To simplify the setup, RSLogix Guard PLUS provides six Peer-to-Peer profiles, which can be selected by the user, depending upon application requirements and the capabilities of the network. Profiles are combinations of matched parameters which are automatically set when the user chooses a certain profile. The intention of all profiles is to optimize the data throughput on the network, which minimizes the ReceiveTMO and results in a low Worst Case ReactionTime. (For the definitions of the Peer-to-Peer network parameters, see page 12-6). The six profiles are described in the following sections: • Fast & Cleanroom, • Fast & Noisy, • Medium & Cleanroom, • Medium & Noisy, • Slow & Cleanroom, and • Slow & Noisy Publication 1753-UM001A-EN-P - April 2004 12-18 Peer-to-Peer Communication Overview Peer-to-Peer Profile I: Fast & Cleanroom This profile provides the fastest data throughput for applications which require fast data update rates. It is also best for applications which require the shortest feasible Worst-Case ReactionTime. Fast & Cleanrooom Characteristics Fast 100 Mbit technology (100 Base TX) Fast Ethernet (full-duplex recommended) LAN Minimum Ethernet Switched switches or integrated switches (GuardPLC network 1600/1800) required. (1) requirements No loss of data due to traffic overload, harsh Cleanroom environmental conditions or network defects. Characteristics of the Minimum delays communication path ResponseTime ≤ ReceiveTMO ÷ 2 (otherwise ERROR) ResponseTime manually set in the Peer-to-Peer Editor ReceiveTMO manually set in the Peer-to-Peer Editor Variables WDZ manually set in the controller properties (Watchdog Time) Suitable HH network Fast profile • QueueLen = 2 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResendTMO – if ReceiveTMO ≥ 2 x WDZ, then Peer-to-Peer ResendTMO = ReceiveTMO ÷ 2, or parameter presets ResendTMO = ResponseTime, whichever is greater – if ReceiveTMO < 2 x WDZ, then ResendTMO = ReceiveTMO • AckTMO = 0 • ProdRate = 0 (1) The network can be shared with other applications, if sufficient bandwidth is provided. Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-19 Peer-to-Peer Profile II: Fast & Noisy This profile provides fast data throughput for applications which require fast data update rates. It is good for applications which require the shortest feasible Worst-Case Reaction Time where minor loss of messages can be corrected. Fast & Noisy Characteristics 100 Mbit technology (100 Base TX), if HH network profile Fast & Cleanroom is selected. Fast 10 Mbit technology (10 Base T), if HH network profile Medium & Cleanroom is selected. Fast Ethernet (full duplex recommended) LAN Minimum Ethernet switches, if HH network profile Fast & network Cleanroom is selected. requirements Switched 10 MBit hubs, if HH network profile Medium & Cleanroom is selected. Or use switches integrated into the GuardPLC 1600/1800 controllers. Low probability for loss of messages. Noisy Time for ≥ 1 repetitions. Characteristics of the Minimum delays communication path ResponseTime ≤ ReceiveTMO ÷ 2 (otherwise ERROR) ResponseTime manually set in the Peer-to-Peer Editor Variables ReceiveTMO manually set in the Peer-to-Peer Editor WDZ manually set in the controller properties Suitable HH network Fast profile Medium (≤ 10 controllers in a Token Group) • QueueLen = 2 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResendTMO Peer-to-Peer – if ReceiveTMO ≥ 2 x WDZ, then parameter presets ResendTMO = ResponseTime (≥ 1 Resend possible) – if ReceiveTMO < 2 x WDZ, then ERROR • AckTMO = 0 • ProdRate = 0 Publication 1753-UM001A-EN-P - April 2004 12-20 Peer-to-Peer Communication Overview Peer-to-Peer Profile III: Medium & Cleanroom This profile provides medium data throughput for applications where only a moderate data update rate is required and where the Worst Case Reaction Time is not a critical factor. It is well-suited for virtual private networks (VPN), where data exchange is slow due to safety devices (firewalls, encoding/decoding), but error-free. Normally use the profile Medium & Noisy TIP (see page 12-21). Medium & Cleanroom Characteristics 10 MBit (10 Base T) or 100 Mbit technology (100 Base TX) or network with both 10 MBit Medium or Fast and 100 MBit components. Minimum Ethernet LAN switches required. network requirements No loss of data due to traffic overload, harsh Clean environmental conditions or network defects. Time for ≥ 0 repetitions. Characteristics of the Moderate delays communication path ResponseTime ≤ ReceiveTMO (otherwise ERROR) ResponseTime manually set in the Peer-to-Peer Editor Variables ReceiveTMO manually set in the Peer-to-Peer Editor WDZ manually set in the controller properties Suitable HH network Fast profile Medium (≤ 10 controllers in a Token Group) • QueueLen = 3 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResentTMO – if ReceiveTMO ≥ 2 x WDZ, then Peer-to-Peer ResendTMO = ResponseTime (≥ 0 Resends possible) parameter presets – if ReceiveTMO < 2 x WDZ, then ResendTMO = ReceiveTMO • AckTMO = ReceiveTMO or AckTMO = AckTMOMax, whichever is smaller • ProdRate = ResponseTime ÷ 4 Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-21 Peer-to-Peer Profile IV: Medium & Noisy The Medium and Noisy profile provides medium data throughput for applications where only a moderate data update rate is required. It is good for applications where the Worst Case ReactionTime is not a critical factor. Minor loss of messages can be corrected. Medium & Noisy Characteristics 10 MBit (10 Base T) or 100 Mbit technology (100 Base TX) or network with both 10 MBit and 100 Medium or Fast MBit components. Minimum Ethernet Usage of hubs possible. network requirements Low probability for loss of messages. Noisy Time for ≥ 1 repetitions. Characteristics of the Moderate delays communication path ResponseTime ≤ ReceiveTMO ÷ 2 ResponseTime manually set in the Peer-to-Peer Editor Variables ReceiveTMO manually set in the Peer-to-Peer Editor WDZ manually set in the controller properties Suitable HH network Medium or profile Fast • QueueLen = 3 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResendTMO – if ReceiveTMO ≥ 2 x WDZ, then Peer-to-Peer ResendTMO = ResponseTime (≥ 1 Resend possible) parameter presets – if ReceiveTMO < 2 x WDZ, then ERROR • AckTMO = ReceiveTMO or AckTMO = AckTMOMax, whichever is smaller • ProdRate = ResponseTime ÷ 4 Publication 1753-UM001A-EN-P - April 2004 12-22 Peer-to-Peer Communication Overview Peer-to-Peer Profile V: Slow & Cleanroom This profile provides low data throughput for applications where only a low data update rate is required from remote controllers, via communication paths, whose conditions cannot be predicted by the user. Normally use the profile Slow & Noisy TIP (see page 12-23). Slow & Cleanroom Characteristics Primarily for data exchange via ISDN, leased Slow line or slow line-of-sight radio link. Minimum Ethernet network No loss of data due to traffic overload, harsh requirements Clean environmental conditions or network defects. Time for ≥ 0 repetitions. Characteristics of the Moderate to long delays communication path ResponseTime ≤ ReceiveTMO, otherwise ERROR ResponseTime manually set in the Peer-to-Peer Editor ReceiveTMO manually set in the Peer-to-Peer Editor Variables WDZ manually set in the controller properties N number of link partners a controller can talk to defined in the Peer-to-Peer Editor Suitable HH network Medium or profile Fast • QueueLen = 4 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResendTMO – if ReceiveTMO ≥ 2 x WDZ, then Peer-to-Peer ResendTMO = ResponseTime (≥ 0 Resends possible) parameter presets – if ReceiveTMO < 2 x WDZ, then ResendTMO = ReceiveTMO • AckTMO = ReceiveTMO or AckTMO = AckTMOMax, whichever is smaller • ProdRate = ResponseTime ÷ 4 Publication 1753-UM001A-EN-P - April 2004 Peer-to-Peer Communication Overview 12-23 Peer-to-Peer Profile IV: Slow & Noisy This profile provides low data throughput for applications where only low data update rates are required. It is primarily for data exchange via poor quality telephone lines or distorted radio links. Slow & Noisy Characteristics Data transfer via telephone, satellite link, radio Slow etc. Minimum Ethernet Low loss of data due to distortions on the network requirements Noisy communication path or network defects. Time for ≥ 1 repetitions. Characteristics of the Moderate to long delays communication path ResponseTime ≤ ReceiveTMO ÷ 2, otherwise ERROR ResponseTime manually set in the Peer-to-Peer Editor Variables ReceiveTMO manually set in the Peer-to-Peer Editor Suitable HH network Medium or profile Fast • QueueLen = 4 • Communication Time Slice large enough to process and send all data defined for transmission in one CPU cycle. • ResendTMO – if ReceiveTMO ≥ 2 x WDZ, then Peer-to-Peer ResendTMO = ResponseTime (≥ 1 Resend possible) parameter presets – if ReceiveTMO < 2 x WDZ, then ERROR • AckTMO = ReceiveTMO or AckTMO = AckTMOMax, whichever is smaller • ProdRate = ResponseTime ÷ 4 Publication 1753-UM001A-EN-P - April 2004 12-24 Peer-to-Peer Communication Overview Publication 1753-UM001A-EN-P - April 2004 Chapter 13 Configuring Peer-to-Peer Communication Using This Chapter For information about: See page considerations for using Peer-to-Peer 13-1 setting peer-to-peer controller properties 13-2 create HH network 13-4 design the logic 13-7 configure Peer-to-Peer communication 13-11 compiling and downloading 13-16 network optimizing 13-17 Using Peer-to-Peer communication, you can exchange signals between controllers by dragging signals onto pages that create controller-to-controller connections. For example: Controller 1 could send three signals (out1, out2, and out3) to Controller 2. Controller 2 can then use these signals as inputs within its function block code. Before you start a project that exchanges data between several Considerations for Using controllers, you should become familiar with the requirements of your Peer-to-Peer application. Questions about the network design, which should be answered prior to developing the project, are: • Is timing a critical factor of the application? This is the most important question! • How many controllers will be involved? • Is it necessary to establish an Ethernet network exclusively for the application, or can an existing network be shared? • How far away from each other are the controllers? • Are transportation media, other than Ethernet, needed (such as telephone lines, radios, fiber optics, etc.)? • Is it necessary for each controller to communicate with all other controllers? • Can some functions of the application be grouped and executed separately by an isolated group of controllers (Token Group)? 1 Publication 1753-UM001A-EN-P - April 2004 13-2 Configuring Peer-to-Peer Communication Right-click on Resource and select Properties. Set the timing Setting Peer-to-Peer parameters and switches according to the requirements of your Controller Properties application. The “Communication Time Slice” and “Code Generation Version” settings are needed for Peer-to-Peer network parameterization. Communication Time Slice The Communication Time Slice is the time in milliseconds reserved for a controller to carry out and complete all communication tasks in one CPU cycle. The minimum Communication Time Slice depends on the number of communication connections (n) a controller has. The minimum Communication Time Slice (CTS ) is calculated as min follows: For n ≤ 13: CTS (n ≤ 13) = n x 1 ms + 4 ms min For n > 13: CTS (n > 13) = n x 1.3 ms min Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-3 Do not set the Communication Time Slice below the IMPORTANT calculated value. If the Communication Time Slice is too small, it takes more than one CPU cycle to carry out the pending communication tasks. Therefore, more time is needed to complete the communication tasks, which degrades performance and could result in a communication shutdown due to a communication timeout (ReceiveTMO). The time actually needed for communication adds to the CPU cycle time. A short Communication Time Slice limits the communication time to a low value. This prevents the CPU cycle time from being noticeably influenced by network occurrences. Although a Communication Time Slice well above the minimum value may result in cycle time on the local machine slowing down a bit if network traffic is heavy, it is not necessarily negative. If you are transferring safety I/O over the network, you need a Communicatin Time Slice high enough to guarantee that the communications are completed every cycle. If it takes more than one cycle to read/write safety I/O, your safety time will need to increase to compensate. If you are only transferring status data over the network, then a lower Communication Time Slice is permissible, because it leaves more time in the cycle for your program to run. It’s likely to be acceptable even if it takes more than one cycle to read the status. Check the CPU short-term diagnostics for any “Time Slice expired” entries and increase the Communication Time Slice if necessary, before the application goes into regular operation. In the “Statistics” of the Control Panel, “Number of Time Slices” higher than 1 also indicate a Communication Time Slice that is too short. “Number of Time Slices” indicates the number of cycles it took for communications to complete. The maximum Communication Time Slice depends on the application and is calculated as follows: WDZ ≥ Communication Time Slice (max) + Application Execution Time In other words, the Communication Time Slice plus Application Execution Time must not exceed the Watchdog Time. Publication 1753-UM001A-EN-P - April 2004 13-4 Configuring Peer-to-Peer Communication If the controller on page 13-2 has 10 connections, the EXAMPLE minimum Communication Time Slice is: CTS = 10 x 1 ms + 4 ms = 14 ms. min CTS is increased by 6 milliseconds to provide a min safety margin. CTS = 20 ms min With a Watchdog Time of 500 ms, this leaves 480 ms for the application to be executed. Code Generator Version To compile the logic correctly for your type of controller, set Code Generator Version to “3” for RSLogix Guard PLUS software. Set to version 2 for RSLogix Guard software. To create a Peer-to-Peer network, right-click on the project in the Create a Peer-to-Peer Hardware Management window and select New → HH-Network. Network You can right-click on HH-Network and Rename the entry, if desired. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-5 Create Token Group(s) A single Token Group is automatically created with the HH network. If you need more, create Token Groups by right-clicking on HH-Network and selecting New → Token Group. Expand the HH-Network, right-click on the Token Group(s) and Rename the Token Group(s), if desired. Add Controllers to Token Group(s) A controller must be a member of only one Token Group. To add a controller to a Token Group: 1. Expand the HH-Network, right-click on a Token Group and select Node Editor. The Node Editor is empty when you open it for the first time. 2. Click on a controller in the tree view and drag and drop it in the Node Editor. Publication 1753-UM001A-EN-P - April 2004 13-6 Configuring Peer-to-Peer Communication Configure Token Group(s) 1. Right-click on the Token Group and select Properties. In the “HH-Network/Token Group” window select a profile. For a description of the HH-Network profiles, see page 12-10. In general, “Fast” works with most network topologies. 2. Enter a Token Group ID. The Token Group ID must be greater than 0. If you create more than one Token Group, each Token Group must have a unique ID. Do not make changes to the other settings in this window. See page 12-3 for the description of the HH protocol parameters. You must select identical profiles for Token Groups IMPORTANT that you want to interconnect. If Link Mode (External) does not match, communication between Token Groups is impossible. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-7 Create Peer-to-Peer Signals Design the Logic Signals are transferred among controllers over the Peer-to-Peer network. Consider the following when creating signals: • You can create as many signals as you need in the logic for all controllers. • You can add signals anytime. • Signals with the same name can be used on more than one controller without influencing each other (LOCAL variable), as long as they are not exchanged via network. • Signals which are intended for network exchange, must have the same name on the participating controllers. Whether a signal is written to or read from the network is defined in the Peer-to-Peer Editor as explained in “Configure Peer-to-Peer Communication” on page 13-11. Use Peer-to-Peer System Signals The status of the Peer-to-Peer communication as well as some timing parameters can be evaluated in the user program by means of system signals. Furthermore, the user program can control how a Peer-to-Peer connection is set up. Input System Signals Publication 1753-UM001A-EN-P - April 2004 13-8 Configuring Peer-to-Peer Communication The following system signals can be used as inputs for the application: • Connection State. Using the Connection State system signal of the Peer-to-Peer Editor, the user program can evaluate the status of the communication between two controllers. The following table shows the possible values for the Connection State system signal and the corresponding status. Value Status Explanation 0 CLOSED Communication path is closed. No attempt to connect. 1 TRY_OPEN Communication path is closed. Attempt to connect. 2 CONNECTED Communication path is open. No attempt to connect. • Receive Timeout, in milliseconds, is set by the user. For more information see Receive Timeout (ReceiveTMO) on page 12-8 and “Define Peer-to-Peer Parameters” on page 13-13. • Response Time, in milliseconds, is the actual value of the last answer message and is identical to RspT last in the P2P status of the Control Panel. For more information, see “Reconfigure ResponseTime” on page 13-22. • Version indicates the CRC for the Peer-to-Peer configuration between two controllers. The CRC must be identical in order to establish communication. Output System Signal Using the output system Connection Control signal, the user program can control how the Peer-to-Peer connection is set up. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-9 Table 13.1 Connection Control Values Value Setting Explanation 0x0000 AUTOCONNECT After loss of Peer-to-Peer communication, the controller tries to re-establish communication in the next CPU cycle. This is the standard mode of operation. 0x0100 TOGGLE_MODE 0 These modes allow automatic connect with DISABLE after loss of communication. 0x0101 TOGGLE_MODE 1 If TOGGLE_MODE is 0 and communication is lost (Connection State = CLOSED), a connect is performed only after TOGGLE MODE is set to 1 by the user program. If TOGGLE_MODE is 1 and communication is lost, a connect is performed only after TOGGLE_MODE is set to 0 by the user program. 0x8000 DISABLED Peer-to-Peer communication is disabled. No attempt to connect. If the P2PControl signal, in the illustration on page IMPORTANT 13-8, is set to 32768, Peer-to-Peer communication is disabled. If Connection Control is not set by the application, the default is 0 and Autoconnect is enabled. Design the Logic for all Controllers Design the logic for the controllers, considering the variables intended for network exchange. The following examples show part of the routines for controllers Robot A and Robot B, respectively. To evaluate the state of the “OutRange” signal in Robot B, use the same signal name (OutRange) as an input for the logic of Robot B. OutRange is sent over Ethernet, via Peer-to-Peer, from Robot A to Robot B, which uses it as an input. Publication 1753-UM001A-EN-P - April 2004 13-10 Configuring Peer-to-Peer Communication Design Logic for Robot A Design Logic for Robot B Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-11 As discussed in the following sections, you configure Peer-to-Peer Configure Peer-to-Peer Communication by: Communication • Defining Controller Connections • Assigning the HH-Network • Selecting a Peer-to-Peer Profile • Defining Peer-to-Peer Parameters, and • Defining Process Signals for Exchange Define Controller Connections To define all of the controllers each controller can communicate with: 1. Right-click on the resource you want to define controller connections for and select Peer-to-Peer Editor. The title bar of the Peer-to-Peer Editor shows the name of the selected controller. When the Peer-to-Peer Editor is opened for the first time, it does not contain any entries. 2. In the project tree, click on a resource and drag and drop it in the Peer-to-Peer Editor. Repeat this step to add more controller connections. In the example below, RobotA (title bar) has a connection to RobotB and RobotC. Because the return path is automatically added, you do not need to drag RobotA onto the Peer-to-Peer editors of RobotB or RobotC. Publication 1753-UM001A-EN-P - April 2004 13-12 Configuring Peer-to-Peer Communication The following example shows how the three Peer-to-Peer editors would appear if connections existed between all three controllers. Assign HH-Network Peer-to-Peer communication requires the HH-Network, which must be entered in the Peer-to-Peer Editor. To assign the HH-Network, click on the HH-Network in the tree view and drag and drop it in the Network column of the Peer-to-Peer Editor. The return path is automatically updated with the HH-Network. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-13 Select Peer-to-Peer Profile 1. Click in the Profile column and select one of the profiles. Make sure that the profile is suitable for your network topology and matches the HH profile. See page 12-10 for a detailed description of all the profiles. 2. Click outside the table or press the Return key to activate the selection. The profile of the return path is automatically updated with the new profile. Define Peer-to-Peer Parameters The most important timing parameter of a safety related installation is the Safety Time. Safety Time is the time a process can run with incorrect controller outputs without affecting the safety of the process (see the GuardPLC Controller Systems Safety Reference Manual, publication number 1755-RM001 for more details). The Worst Case Reaction Time (T ) is the time within which two R linked controllers must detect the occurrence of a physical input signal at PES and put out the resulting physical output signal at PES . 1 2 To guarantee the integrity of the application, the requirement below must always be fulfilled: T < Safety Time R When you select a Peer-to-Peer profile, most parameters are automatically preset. Because ReceiveTMO (safety-relevant) is part of the Worst Case ReactionTime T (see Peer-to-Peer Protocol Parameters R on page 12-6), ReceiveTMO must be calculated and set manually by overwriting the default value in the Peer-to-Peer Editor. Publication 1753-UM001A-EN-P - April 2004 13-14 Configuring Peer-to-Peer Communication For profiles where ProdRate = 0 (Fast & Cleanroom, Fast & Noisy), ReceiveTMO is: ReceiveTMO = T – 2 x WDZ(PES ) – 2 x WDZ(PES ) R 1 2 For profiles where ProdRate ≠ 0, ReceiveTMO is: ReceiveTMO = [T – 3 x WDZ(PES ) – 2 x WDZ(PES )] ÷ 2 R 1 2 Calculate the ReceiveTMO with the suitable formula and overwrite the default value in the Peer-to-Peer Editor. In first approximation, the ResponseTime can be calculated as: ResponseTime = ReceiveTMO ÷ 2 Overwrite the default value of the ResponseTime with the calculated value. Setting the ResponseTime this way allows the TIP controller to resend a message, in case of unexpected message loss. For best network performance, the ReceiveTMO and the ResponseTime are optimized after the project has been compiled, loaded and started on the controllers. At that time, the actual ResponseTimes and the actual cycle times can be read in the Control Panel. Define The Signals to Exchange Between Each Controller Connection 1. Right-click on a resource in the project tree, select Peer-to-Peer Editor. The Peer-to-Peer Editor opens. 2. Click on a line number (left-most column) in the Peer-to-Peer Editor table. This selects a controller with which the controller, named in the headline of the Peer-to-Peer Editor, exchanges data. 3. Open the Signal Editor (select Signals → Editor). Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-15 4. Click on the Connect Process Signals button in the Peer-to-Peer Editor. 5. Arrange the Signal Editor and the Peer-to-Peer (P2P) Process Signals window side by side. When you open it for the first time, the P2P Process Signals window is empty. 6. Using the tabs below the button bar of the P2P Process Signals, select the direction of data exchange. In the example below, the direction of data exchange is from RobotA to RobotB. 7. In the Signal Editor, click on a signal name and drag & drop it in the P2P Process Signals. You can also add signals using New Connected Signals button. this creates a new line in the list in which you must enter the case-sensitive signal name exactly as defined in the Signal Editor. Sending a signal from one controller to another TIP (PES → PES ) makes the value of this signal 1 2 available in PES . To process this value in the 2 logic of PES , identical signal names must be 2 used in the logic of both PES and PES . 1 2 8. Change the direction of data exchange with the tab and define the return signals. Publication 1753-UM001A-EN-P - April 2004 13-16 Configuring Peer-to-Peer Communication The illustration below shows the signals which RobotB sends to RobotA. Compile Logic Compile and Download If changes, such as adding or deleting a tag, are made to a connection between two controllers, the code must be recompiled for both controllers. To compile logic, right-click on a resource (controller) in the RSLogix Guard PLUS Project Management window, and select Code Generation. If code generation is not successful, carefully check the Error-state viewer in the Hardware Management Window for error messages and correct the errors. Start Download 1. Using the Multi-Control Panel, click the Select all button to select all controllers. 2. Click Stop to make sure that all controllers are in STOP mode. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-17 3. Click Download to start the simultaneous download for all selected controllers. The “Action” column shows the command which is currently executed or a short status message. In the example below, the downloads have completed successfully. 4. After successful download, the CPU Status is STOP/VALID CONFIGURATION. Select all controllers again if necessary and click Coldstart to start the application. With the initial network settings made in the HH protocol and Network Optimizing Peer-to-Peer protocol, communication is likely to work, but the settings can be optimized for homogenous network load and faster message exchange. If there is no real need to reduce Worst Case IMPORTANT ReactionTime, do not make changes to the WDZ and the ReceiveTMO! Only optimize the ResponseTime. A high WDZ or ReceiveTMO does not degrade performance, but an optimized ResponseTime increases availability. Before starting the optimization steps, let the project run for several hours. Test as many operating conditions as possible to address timing factors that may prevent a project from running after optimization. Publication 1753-UM001A-EN-P - April 2004 13-18 Configuring Peer-to-Peer Communication Check Routine Timing 1. In the Multi Control Panel, select all controllers and click the Control Panel button. 2. In the Control Panels of each controller, select the Statistics tab. 3. Write down the maximum “Cycle Time” for each controller. 4. Write down the maximum “Com. Time Slice” for each controller. Before you continue to optimize settings, make sure IMPORTANT that Number of Time Slices (see above) is not greater than 1. If Number of Time Slices max. is greater than 1, more than one CPU cycle is needed to carry out all communication tasks. In this case, you need to determine if it is permissible for communications to take multiple cycles to complete. This depends on how many cycles can be completed within the safety time. If you need to increase the Com. Time Slice, start the code generator again, and download and start the new routine on the controller. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-19 Reconfigure Watchdog Time To optimize the Watchdog Time to the lowest possible value, you must know the maximum CPU cycle time. Cycle Time max., as displayed in the Statistics of the Control Panel (see page 13-19), is the value that occurred so far, but is not necessarily the maximum value that can occur depending on network and process conditions. If the maximum Cycle Time cannot be estimated, run the project for several hours and under as many conditions as possible. To reconfigure Watchdog Time: 1. In the project tree, right-click on the first resource and select Properties. 2. Calculate a Margin of Safety, MoS: MoS = 0.1 x (Cycle Time max.) MoS should be at least 6 ms. If MoS < 6 ms, then MoS = 6 ms 3. Readjust the Watchdog Time: Watchdog Time = (Cycle Time max.) + (MoS) In the example on the following page, the new Watchdog Time is: 8 ms + 6 ms = 14 ms. Publication 1753-UM001A-EN-P - April 2004 13-20 Configuring Peer-to-Peer Communication 4. For all controllers in your project, re-adjust the Watchdog Times to their individual optimum values. After these modifications, you must re-compile TIP the project with the Code Generator and download the routines in the controllers again. 5. Start the project and let it run for a while. If you encounter controller errors due to a Watchdog Time that is too short, increase the Watchdog Time. Otherwise, continue with the network optimization. Check HH Status In the Control Panel, click on the HH Status tab. The HH Status displays the following information: Parameter Explanation Bus Cycle Time Time in milliseconds for a Token cycle. The value is 0, if Token Passing is off (any Cleanroom profile). Resource Name of the controller LinkId Controller network ID State Status of the communication RspT • If Link Mode is “TCS direct” (Token Passing OFF), RspT is the ResponseTime of the HH profile for a message from PES → PES → 1 2 PES , based on the network hardware and topology. This parameter 1 cannot be changed by the user. • If Link Mode is “TCS TOKCYC” (Token Passing ON), RspT is part of the Bus Cycle Time. Link Mode • “TCS direct” when Token Passing is OFF. • “TCS TOKCYC” when Token Passing is ON. Token Group ID ID of the Token Group Read the RspT min parameter. This is the minimum time needed for the communication modules (COM) of two controllers to talk to each other. Refresh RspT values with Communication → Update HH State, if Token Passing is OFF. Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-21 Check Peer-to-Peer Status In the Control Panel, click on the P2P Status tab. The P2P Status displays the following information: Parameter Explanation Resource name of the controller System.Rack network ID of the controller State Status of the communication RspT (last, avg, Measured ResponseTime for a message from PES → PES → PES , based on the network hardware, CPU cycle time, and 1 2 1 min, max) Peer-to-Peer profile. This parameter will be optimized later. MsgNr Counter (32-bit resolution) for all messages sent to a controller. In the illustration above, Robot A has sent message no. 54980 to Robot B. AckMsgNr The number of the received message that the controller has to acknowledge. In the illustration above, Robot A has acknowledged message no. 54979 from Robot B. DataSeq Counter (16-bit resolution) for sent messages, which contain process data. In the illustration above, Robot A has sent data message no. 54980 to Robot B. Opens Number of successful connects to a controller. A figure higher than 1 indicates that a controller dropped out and has been reconnected. Resends Counter (32-bit resolution) for messages that have been resent due to an elapsed ResendTMO. BadMsgs Counter (32-bit resolution) for received messages that are corrupted, or are not expected at that instant. A corrupt message, for example, is a message with a wrong sender or with a faulty CRC. An unexpected message, for example, is an “Open” command, when the controllers are already connected. EarlyMsgs Counter (32-bit resolution) for received messages which are not in the correct sequence. If a message drops out and is lost at the addressee, there is a gap in the received messages, and the next message comes early. Receive Tmo Receive Timeout as entered by the user (see Define Peer-to-Peer Parameters on page 13-13). ResendTMO Resend Timeout as set by the profile. AckTmo Acknowledge Timeout as set by the profile. CurKeVer CRC for the Peer-to-Peer configuration. Identical to the Peer-to-Peer system signal “Version” (see page 13-8). NewKeVer Reserved for future use. Publication 1753-UM001A-EN-P - April 2004 13-22 Configuring Peer-to-Peer Communication Reconfigure ResponseTime The ResponseTime initially configured in Define Peer-to-Peer Parameters on page 13-13 was derived from theoretical considerations and was chosen conservatively, to start the network running. The ResponseTime actually needed is usually much smaller than the theoretical value and can be optimized to improve network performance. To optimize the ResponseTime: 1. Open the Control Panels for all controllers in the project and select P2P State. Position the horizontal slider so that you can read the ResponseTime. 2. Compare the RspT avg of two linked controllers for the forward and return path. Values for RspT avg may jump a bit. Watch both readings for a couple of seconds and pick the largest value. Your reading need not be accurate to the millisecond. Note down the larger of both values. The example on page 13-22 shows RespT avg for Robot A → Robot B (11 ms) and Robot B → Robot A (10 ms). 3. Compare the RspT max of two linked controllers for the forward and return paths. Note down the larger of both values. The example on page 13-22 shows RspT max for Robot A → Robot B (19 ms) and Robot B → Robot A (20 ms). Publication 1753-UM001A-EN-P - April 2004 Configuring Peer-to-Peer Communication 13-23 4. In the P2P State tab, check the entries for Resends and EarlyMsgs. If the entries for both Resends and EarlyMsgs are 0, no messages have been repeated. In this case, delete the noted RspT avg. If one or more entries for Resends or EarlyMsgs is not 0, messages have been repeated. In this case, delete the noted RspT max. 5. Enter the remaining noted value for RspT, either avg or max, in the ResponseTime of the Peer-to-Peer Editor. Reconfigure Receive Timeout 1. Set the new ReceiveTMO to: ReceiveTMO = 2 x ResponseTime 2. The Worst Case Reaction Time is optimized and displayed in the Peer-to-Peer Editor (see above). 3. Compile the project and download the routines in the controllers again. Start and test your application. Publication 1753-UM001A-EN-P - April 2004 13-24 Configuring Peer-to-Peer Communication Publication 1753-UM001A-EN-P - April 2004 Chapter 14 Communicating with ASCII Devices Using This Chapter For information about: See page connecting the controller to an ASCII device 14-1 configuring the ASCII port 14-4 connecting signals 14-5 ASCII protocol 14-6 For the sole purpose of sending the status of the signals from the Connecting the Controller GuardPLC to an external device, you can connect an intelligent ASCII to an ASCII Device device to the GuardPLC serial port. This ASCII connection is one-way from the GuardPLC (slave) to the master device. You cannot program the GuardPLC or change the values in the GuardPLC using this port. To use the ASCII function, signals that you wish to send out the serial port must be connected to placeholders in the ASCII-protocol Connect Signals window. These signals are then capable of being sent out the serial port if a command string is properly received from the master. The command string includes a starting address and number of signals to be sent. The GuardPLC replies to this command string by sending the values of these signals out the serial port in an ASCII string. Connecting to a GuardPLC 1200 Controller PLC 1200 RS-232 ASCII serial port Use a 1761-CBL-PM02 series C cable to connect to the serial port. The mini-DIN connector attaches to the controller. The other end is a 9-pin D-shell connector. This mini-DIN connector is not commercially available, so you cannot make this cable. 1 Publication 1753-UM001A-EN-P - April 2004 14-2 Communicating with ASCII Devices Connecting to a GuardPLC 1600 or 1800 Controller The ASCII COMM3 port location and connector pin assignment are shown below. 3 (—) (—) 4 L- L+ L+ 24V DC RS-485 ASCII PROFIBUS COMM3 COMM2 COMM1 GuardPLC Ethernet 10/100 BaseT 3 (—) (—) 4 Connection Signal Function 1 --- --- 2 RP 5V, decoupled with diodes 3 RxD/TxD-A Receive/Transmit data A 4 CNTR-A Control Signal A 5 DGND Data reference potential 6 VP 5V, positive pole of supply voltage 7 --- --- 8 RxD/TxD-B Receive/Transmit data B 9 CNTR-B Control Signal B The ASCII port is RS-485. You must use and electrical IMPORTANT interface device to connect the controller to an RS-232 device. Publication 1753-UM001A-EN-P - April 2004 Communicating with ASCII Devices 14-3 Connecting to a GuardPLC 2000 Controller 1755- 1755- 1755- 1755- 1755- 1755- 1755- 1755- PB720 L1 IB24XOB16 IB24XOB16 IF8 OF8 HSC HSC RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR RUN ERR 1 LS+ 111 LS+ 1 I1+ 1 O1+ 1 C- 1 C- 2 I1 222 I1 2 I- 2 O1- 2 A1 2 A1 RUN STOP 3 I2 333 I2 3 I2+ 3 O2+ 3 B1 3 B1 4 I3 444 I3 4 I- 4 O2- 4 Z1 4 Z1 PROG FAULT 5 I4 555 I4 5 I3+ 5 O3+ 5 C1 5 C1 6 I5 666 I5 6 I- 6 O3- 6 C- 6 C- FORCE 7 I6 777 I6 7 I4+ 7 O4+ 7 C- 7 C- 8 I7 888 I7 8 I- 8 O4- 8 C- 8 C- 9 I8 999 I8 9 9 9 C- 9 C- GuardPLC 2000 Tx COL 10 LS+ 10 10 LS+ 10 I5+/1-10 O5+ 10 C- 10 C- 11 I9 11 11 I9 11 I- 11 O5- 11 A2 11 A2 12 I10 12 12 I10 12 I6+/2-12 O6+ 12 B2 12 B2 13 I11 13 13 I11 13 I- 13 O6- 13 Z2 13 Z2 14 I12 14 14 I12 14 I7+/3-14 O7+ 14 C2 14 C2 10/100BaseT 15 I13 15 15 I13 15 I- 15 O7- 15 C- 15 C- 16 I14 16 16 I14 16 I8+/4-16 O8+ 16 C- 16 C- 17 I15 17 17 I15 17 I- 17 O8- 17 C- 17 C- 18 I16 18 18 I16 18 18 18 C- 18 C- 19 LS+ 19 LS+ 20 I17 20 I17 21 I18 21 I18 22 I19 22 I19 3V DC 23 I20 23 I20 24 I21 24 I21 LITH-BATT. 25 I22 25 I22 26 I23 26 I23 27 I24 27 I24 28 L- 28 L- 19 L- 19 L- 29 O1 29 O1 20 1 20 1 24V FAULT 30 O2 30 O2 21 2 21 2 3,3V 5V 31 O3 31 O3 22 3 22 3 RESTART 32 O4 32 O4 23 4 23 4 33 O5 33 O5 24 L- 24 L- 1 34 O6 34 O6 25 L- 25 L- FB1 2 35 O7 35 O7 26 L- 26 L- 3 FAULT 36 O8 36 O8 27 L- 27 L- FB2 37 L- 37 L- L+ RS-232 ASCII serial port 38 O9 38 O9 DC 24V 39 O10 39 O10 40 O11 40 O11 L- 41 O12 41 O12 (only the bottom serial port is active) 42 O13 42 O13 43 O14 43 O14 44 O15 44 O15 45 O16 45 O16 PS CPU DIO DIO AI AO CO CO The serial port requires a 9-pin D-shell connector. Pin: Function: 1 none 2 send data 3 receive data 4 none 5 ground 6 none 7RTS 8CTS 9 none Publication 1753-UM001A-EN-P - April 2004 14-4 Communicating with ASCII Devices You must either create a new project or open an existing project Configuring the ASCII before you can configure ASCII communications. Once the software Serial Port opens a project, it automatically displays the Hardware Management window, from which you configure the ASCII port. 1. Right-click on Protocols and select New → ASCII. 2. Right-click on the ASCII icon and select Properties. For this field: Specify: Slave Address the slave address (1 to 65535) of the controller. The ASCII protocol of the controller supports only a direct point-to-point connection between the master and slave. The controller is always configured as slave. It only transfers process values via the serial interface to the master when it receives the corresponding request from the master. Refresh Rate the refresh rate in milliseconds for non-safe communication between the COM and CPU. The default is 0, the fastest refresh rate. Interface select the field bus interface to be used by the ASCII protocol (comm1, comm2, comm3). Select comm3 for GuardPLC 1600 or 1800 controllers. (1) the data transfer speed in bits/s. Select from a dropdown menu of predefined values between 300 Baud Rate and 115,200 bps. The default baud rate is 9600 bps. Parity the parity for the recognition of transfer errors. Select No, Odd, or Even. The default is No parity. Stop Bit either 1 or 2 stop bits for the serial data transfer. The default is 1 stop bit. (1) Even if the baud rate is changed from 9600, the power up string is always sent out at 9600 baud. Publication 1753-UM001A-EN-P - April 2004 Communicating with ASCII Devices 14-5 Only ASCII output signals are sent from the controller. You connect Connecting Signals signals to the ASCII outputs to determine which signal values you want to send from the controller to the connected ASCII device. 1. Expand Protocols. Right-click on the ASCII icon and select Connect Signals. If you want to: Select this tab: create a new signal New Connected Signal renumber offsets sequentially for all signals New Offsets delete the selected signal Delete Connected Signal 2. Edit the output signals you want to send to the ASCII device. • Use the Outputs tab to define output values to send to the ASCII device. • Associate each output with a signal from the signal editor by dragging the signal from the Signal Editor to the Signal field on the Outputs tab in the ASCII Signal Connections Window. • See Chapter 5 for more information about defining signals. NOTE: The signal name is only used in printouts. Publication 1753-UM001A-EN-P - April 2004 14-6 Communicating with ASCII Devices The offset in the ASCII output section is numbered based on bytes. In the example, TIP the first signal uses bytes 0, 1, 2, and 3. The second signal uses bytes 4 and 5. However, when you request these signals in the command string (see ASCII master - request below), the first signal is always 0, the second signal is always 1, the third signal is always 2, etc. The output section automatically sorts the name field based on alphanumerical order. This does not automatically change the offsets, but if you renumber after sorting, the offsets will change and there is no undo feature. This changes the order in which the signals are sent out the serial port. Since names are only used in printouts, you may want to enter these names in alphanumeric order to begin with. (For example signal 101, signal 102, signal 103, signal 104, etc.) The controller is a slave ASCII device and expects this protocol from ASCII Protocol the master device. ASCII master - request If the ASCII master sends a request, the slave can send a response. The master request has this format (each character is one byte): Start Sign Destination Source Function Code Start Address Number of End Sign Variables 1 char 2 char 2 char 1 char 5 char 3 char 1 char Component: Description: Start Sign identifies the start of a message ^ character Destination unique slave address (GuardPLC controller) 01 to 99 Source unique master address (requester) 01 to 99 Function Code read data R character Start Address data start address for characters to read (offset) 00000 to 65535 Number of Variables number of variables to read and send back to master 000 to 999 End Sign identifies the end of a message & character Publication 1753-UM001A-EN-P - April 2004 Communicating with ASCII Devices 14-7 For example, this string requests the first two variables from the slave: Start Sign Destination Source Function Code Start Address Number of End Sign Variables ^ 15 01 R 00000 002 & ASCII slave - controller response If the controller receives a request from an ASCII master, it responds in this format (each character is one byte): Start Sign Destination Source Function Start Number of Number of Data End Sign Code Address Variables Characters 1 char 2 char 2 char 1 char 5 char 3 char 4 char maximum 1 char 10000 char Component: Description: Start Sign identifies the start of a message ^ character Destination unique master address (requester) 01 to 99 Source unique slave address (GuardPLC controller) 01 to 99 Function Code r character identifies data sent by slave E identifies error with master request Start Address data start address for characters to read (offset) 00000 to 65535 Number of Variables number of variables to read and send back to master 000 to 999 Number of Characters number of characters in the data string (This includes the “/” delimiter but not the “&” termination character.) 0000 to 9999 Data data characters End Sign needed to recognize the end of a message & character Publication 1753-UM001A-EN-P - April 2004 14-8 Communicating with ASCII Devices For example, this string replies to the master request for the first two variables from the slave: Start Sign Destination Source Function Start Number of Number of Data End Sign Code Address Variables Characters ^ 01 15 r 00000 002 0005 4/123 & Every data field in the message is separated with a slash ( / ). The slash also counts as a character when counting the total number of characters in the data string. The reply string will have a variable number of TIP characters if non-BOOL are used. For example, 99 is 2 characters, 100 is 3 characters. There is no leading zero. If the master request was not received properly at the GuardPLC, the slave response is the following: Start Sign Destination Source Function Start Number of Number of End Sign Code Address Variables Characters ^ 01 15 E 00000 000 0000 & This error response is typically sent when more signals are requested than exist in the ASCII protocol output tab. For example, 10 signals were dragged to the ASCII output section, but 20 signals were requested in the command string. Publication 1753-UM001A-EN-P - April 2004 Communicating with ASCII Devices 14-9 Data type formats Follow these formats for sending different data types: Data Type: Format: Example: BOOL Description: boolean 0 Size: 1 character 1 Range: 1 = true; 0 = false SINT Description: short integer -101 Size: 1 to 4 characters 5 Range: -128 to 127 127 -128 INT Description: integer -25724 Size: 1 to 6 characters 232 Range: -32768 to 32767 -6 248 DINT Description: double integer -1357679042 Size: 1 to 11 characters 257 Range: -2147483648 to 2147483647 6200471 USINT Description: unsigned short integer 123 Size: 1 to 3 characters 35 Range: 0 to 255 6 255 UINT Description: unsigned integer 65535 Size: 1 to 5 characters 7 Range: 0 to 65535 333 597 UDINT Description: unsigned double integer 4294967295 Size: 1 to 10 characters 256 Range: 0-4294967295 334510 Publication 1753-UM001A-EN-P - April 2004 14-10 Communicating with ASCII Devices Publication 1753-UM001A-EN-P - April 2004 Chapter 15 Communicating with Modbus and Profibus Devices Using This Chapter For information about: See page connecting the controller to a Modbus device 15-2 configuring the Modbus port 15-2 connecting signals 15-3 Modbus protocol 15-5 connecting the controller to a Profibus DP device 15-5 configuring the Profibus DP port 15-6 connecting signals 15-7 configuring the Profibus Master 15-8 Modbus is only available on GuardPLC 1600 or 1800 controllers. You Modbus RTU Slave can connect a Modbus master to the controller’s COMM1 port. This Modbus connection is two-way non-safety-related communication between the controller (slave) and the master device. You cannot program the controller using this port. The controller is a Modbus RTU slave device and only responds to reads and writes from the master. To use the Modbus function, signals that you wish to send out/receive into the COMM1 port must be connected to placeholders in the Modbus-protocol Connect Signals window. 1 Publication 1753-UM001A-EN-P - April 2004 15-2 Communicating with Modbus and Profibus Devices Connecting the Controller to a Modbus Device Connection Signal Function 3 (—) (—) 4 1 --- --- L- L+ L+ 24V DC 2 RP 5V, decoupled with diodes RS-485 ASCII MODBUS COMM3 COMM2 COMM1 3 RxD/TxD-A Receive/Transmit data A 4 CNTR-A Control Signal A RS-485 5 DGND Data reference potential 6 VP 5V, positive pole of supply voltage GuardPLC Ethernet 10/100 BaseT 7 --- --- (—) (—) 3 4 8 RxD/TxD-B Receive/Transmit data B 9 CNTR-B Control Signal B The Modbus port is RS-485. You must use an IMPORTANT electrical interface device to connect the controller to an RS-232 device. Configuring the Modbus Serial Port You must either create a new project or open an existing project before you can configure Modbus communications. Once the software opens a project, it automatically displays the Hardware Management window, from which you configure the Modbus port. 1. Right-click on Protocols and select New → Modbus Slave. Publication 1753-UM001A-EN-P - April 2004 Communicating with Modbus and Profibus Devices 15-3 2. Expand Protocols. Right-click on the Modbus Slave icon and select Properties. For this field: Specify: Slave Address the slave address (1 to 247) of the controller. The Modbus protocol of the controller supports only a direct point-to-point connection between the master and slave. The controller is always configured as slave. It only transfers process values via the serial interface to the master when it receives the corresponding request from the master. Interface select the field bus interface to be used by the Modbus Slave protocol (comm1, comm2, comm3). Select comm1 for GuardPLC 1600 or 1800 controllers. Refresh Rate Refresh rate in ms for non-safe communications. The default is 0, the fastest refresh rate. Baud Rate the data transfer speed in bits/s. Select from a dropdown menu of predefined values between 300 and 115,200 bps. The default baud rate is 9600 bps. Parity the parity for the recognition of transfer errors. Select No, Odd, or Even. The default is No parity. Stop Bit either 1 or 2 stop bits for the serial data transfer. The default is 1 stop bit. Connecting Signals The Modbus RTU Slave protocol allows you to read data from the GuardPLC and write data to the GuardPLC, but none of this data can be used for safety functions. “Inputs” are signals sent from the Modbus master to the controller (slave). “Outputs” are signals sent from the controller (slave) to the master. Publication 1753-UM001A-EN-P - April 2004 15-4 Communicating with Modbus and Profibus Devices To connect signals: 1. Expand Protocols. Right-click on the Modbus Slave icon and select Connect Signals. If you want to: Select this tab: create a new signal New Connected Signal renumber offsets sequentially for all signals New Offsets delete the selected signal Delete Connected Signal 2. Edit the signals you want to receive or send. • Use the Inputs tab to determine which values to read into the controller. • Use the Outputs tab to define output values to send to the Modbus master. Signals in the output tab must match the order of signal types requested by the Modbus master. • Associate each input or output with a signal from the signal editor. You can drag and drop signals from the signal editor to the signal connections dialog. The Modbus function calls must match the order in which the signal offsets appear. For example, if you want to read 3 Boolean signals followed by 4 Registers, the first 3 signals must be “BOOL” and the next 4 must be “INT” signals. Publication 1753-UM001A-EN-P - April 2004 Communicating with Modbus and Profibus Devices 15-5 The offset in the Modbus output section is numbered based on bytes. When you TIP request these signals, the first signal is always 0, the second signal is always 1, the third signal is always 2, etc. The output section automatically sorts the name field based on alphanumerical order. This does not automatically change the offsets, but if you renumber after sorting, the offsets will change and there is no undo feature. This changes the order in which the signals are sent out the serial port. Since names are only used in printouts, you may want to enter these names in alphanumeric order to begin with. (For example signal 101, signal 102, signal 103, signal 104, etc.) Profibus DP Slave protocol is only available via the GuardPLC 1600 Profibus DP Slave and 1800 controller’s COMM1 port. This connection is two-way non-safety-related communication from the controller (slave) to the master device. You cannot program the controller using this port. To use the Profibus DP function, signals that you wish to send out the COMM1 port must be connected to placeholders in the Profibus DP-protocol Connect Signals window. Connecting the Controller to a Profibus DP Device (—) (—) 3 4 Connection Signal Function L- L+ L+ 24V DC 1 --- --- RS-485 ASCII PROFIBUS COMM3 COMM2 COMM1 2 RP 5V, decoupled with diodes 3 RxD/TxD-A Receive/Transmit data A RS-485 4 CNTR-A Control Signal A 5 DGND Data reference potential 6 VP 5V, positive pole of supply voltage GuardPLC Ethernet 10/100 BaseT 7 --- --- 3 (—) (—) 4 8 RxD/TxD-B Receive/Transmit data B 9 CNTR-B Control Signal B The Profibus port is RS-485. You must use an IMPORTANT electrical interface device to connect the controller to an RS-232 device. Publication 1753-UM001A-EN-P - April 2004 15-6 Communicating with Modbus and Profibus Devices Configuring the Profibus DP Serial Port You must either create a new project or open an existing project before you can configure Profibus DP communications. Once the software opens a project, it automatically displays the Hardware Management window, from which you configure the Profibus port. 1. Right-click on Protocols and select New → Profibus dp Slave. 2. Expand Protocols. Right-click on the Profibus dp Slave icon and select Properties. For this field: Specify: Station Address the address which uniquely identifies the Profibus dp slave on the network. The station address must be less than or equal to 126. Refresh Rate Refresh rate in ms for non-safe communications. The default is 0, the fastest refresh rate. Interface select the field bus interface to be used by the Profibus dp Slave protocol (comm1, comm2, comm3). Select comm1 for GuardPLC 1600 or 1800 controllers. Baud Rate the data transfer speed in bits/s. Select from a dropdown menu of predefined values between 300 and 115,200 bps. The default baud rate is 9600 bps. Publication 1753-UM001A-EN-P - April 2004 Communicating with Modbus and Profibus Devices 15-7 Connecting Signals The Profibus DP Slave protocol allows you to read data from the GuardPLC and write data to the GuardPLC, but none of this data can be used for safety functions. “Inputs” are signals sent from the Profibus master to the controller (slave). “Outputs” are signals sent from the controller (slave) to the master. 1. Expand Protocols. Right-click on the Profibus-dp Slave icon and select Connect Signals. If you want to: Select this tab: create a new signal New Connected Signal renumber offsets sequentially for all signals New Offsets delete the selected signal Delete Connected Signal 2. Edit the signals you want to receive or send: • Use the Inputs tab to determine which values to read into the controller. The Inputs tab contains pre-defined system variables which can be interrogated via the assignment of signals. • Use the Outputs tab to define output values to send to the Profibus master. • Associate each input or output with a signal from the signal editor. You can drag and drop signals from the signal editor to the signal connections dialog. Publication 1753-UM001A-EN-P - April 2004 15-8 Communicating with Modbus and Profibus Devices • Click on New Offsets to automatically calculate the offsets for the new signals. Due to the offsets of the system variables, the offset IMPORTANT of the first input signal must begin with 12. The offset for the first output signal begins with 0. The Profibus ID for the first input signal is 0. Configuring the Profibus Master For both the Profibus output and input signals, the Profibus ID of the first signal to communicate, the number of signals, and the number of bytes must be configured in the Profibus Master. Configuration is accomplished via parameter data read from a GSD file. The parameter data consist of 32 bytes in hexadecimal format which may be displayed in different ways depending upon the Profibus DP master software. For more information on using Profibus protocol, consult the online Help. Publication 1753-UM001A-EN-P - April 2004 Chapter 16 Pulse Testing Line control is a short-circuit and line break monitoring system (e.g., E-Stop inputs) which utilizes pulse testing. Line control can be configured for the following GuardPLC controllers and distributed I/O: • GuardPLC 1600 • GuardPLC 2000/1755-IB24XOB16 • 1753-IB16 • 1753-IB20XOB8 Line control cannot be configured on the GuardPLC 1200, GuardPLC 1800, and the 1753-OB16 output-only module. The GuardPLC 1800 is excluded because it features digital inputs that are actually analog inputs with 1-bit resolution. Pulse testing can still be performed on the GuardPLC TIP 1200 and 1800, but software certified function blocks are required. These blocks perform exactly the same function in software as line control does via software configuration. See the Certified Function Block Safety Reference Manual, publication number 1753-RM001, for more information on the Single Pulse Test Output (SPTO) and Redundant Pulst Test Output (RPTO) certified function blocks. GuardPLC 1600 and 1753-IB20XOB8 Wiring for Line Control Up to 8 digital outputs (DO1 to DO8) can be configured as pulsed outputs. The example below shows 2 pulse outputs connected to the digital inputs (DI) of the same system. As a result, the connections to the digital inputs (DI) are monitored. 1 Publication 1753-UM001A-EN-P - April 2004 16-2 Pulse Testing DO 1 2 Emergency OFF 1 Emergency OFF 2 DI5 6 DI 7 8 DO1 configurable 5 to 2000µs DO2 configurable 5 to 2000µs t The digital outputs DO1 and DO2 are pulsed (briefly set to low) so that the connections to the digital inputs are monitored. The duration of the test can be configured in the range of 5 to 2000 µs with a default value of 400 µs. 1753-IB16 For Line Control, the 1753-IB16 has four digital pulse test sources (PO) connected to the following terminals: Terminal Number Designation Function 25 L- Reference pole 26 1 Pulsed source 1 27 2 Pulsed source 2 28 3 Pulsed source 3 29 4 Pulsed source 4 30 L- Reference pole Publication 1753-UM001A-EN-P - April 2004 Pulse Testing 16-3 The example below shows 2 pulse test sources connected to the digital inputs (DI) of the same system. As a result, the connections to the digital inputs (DI) are monitored. . PO 1 2 Emergency OFF 1 Emergency OFF 2 DI 1 2 DI 3 4 When the following occurs, inputs are set to 0, a fault code is Response to Faults generated, and the FAULT LED is on. • short-circuit between two parallel connections • reversal of two connections • earth fault on one of the lines (only with earthed reference pole) • line break or opening of the contacts (e.g., when one of the E-stop off switches is pressed in the example above), the FAULT LED is on and the fault code is generated. If multiple errors exist at the same time, the error TIP code is the sum of the individual error codes. Publication 1753-UM001A-EN-P - April 2004 16-4 Pulse Testing Required Signals Configuration for Line Control Set up the following signals using the Outputs tab of the digital inputs Signal Connections window in RSLogix Guard PLUS: Name Description Type Initial Notes Value Number of Pulse Channels Number of pulse outputs being used USINT 1 to 8 1 to 4 for 1753-IB16 1 to 8 for GuardPLC 1600/2000 1 to 8 for 1753-IB20XOB8 Pulse Slot Slot occupied by the module with the UDINT 1 or 2 2 for GuardPLC 1600 pulsed outputs 2 for 1753-IB20XOB8 1 for 1753-IB16 1 to 6 for GuardPLC 2000 (wherever 1755-IB24XOB16 is located) Pulse Delay Pulse delay is both the low pulse UINT 400 Values in µs from 5 to 2000. width and pulse test duration. (default) Error Code Error code for each switch BYTE See page B-11 for error code descriptions. N/A Value Value for each switch BOOL DI[xx].PulseChannel Indicates which pulse output is USINT 1 to 8 1 to 4 for 1753-IB16 sourcing the input channel 1 to 8 for GuardPLC 1600/2000 1 to 8 for 1753-IB20XOB8 DO[xx].Value Initialization value for the pulse BOOL TRUE Each pulse output must be activated. outputs Pulse Outputs The pulse outputs must begin at DO[01] and must be sequential. For example, if two pulse outputs are required, they must be DO[01] and DO[02]. Inputs To prevent crosstalk, two directly adjacent inputs IMPORTANT must not be sourced from the same pulse output. Publication 1753-UM001A-EN-P - April 2004 Chapter 17 Creating User-Defined Function Blocks Using This Chapter For information about: See page creating user-defined function blocks 17-2 declaring variables 17-5 moving declared variables to the user-defined function block page 17-10 generating function block code 17-11 1 Publication 1753-UM001A-EN-P - April 2004 17-2 Creating User-Defined Function Blocks With RSLogix Guard PLUS software, you can create user-defined Creating User-Defined function blocks that consist of standard function block logic, as shown Function Blocks in the illustrations below. Existing Function Block User-Defined Function Blocks Publication 1753-UM001A-EN-P - April 2004 Creating User-Defined Function Blocks 17-3 To create a function block: 1. In the Program Management Window, right-click on Configuration and select New → Library. 2. Right-click on the new Library and select New → Function Block Type to create the new function block. You can rename the new function block by right-clicking on it and selecting Rename. Publication 1753-UM001A-EN-P - April 2004 17-4 Creating User-Defined Function Blocks 3. Double-click the new function block to start the editor. Interface Declaration Editor Drawing Field Overview Window Variable Declaration Editor The FBD editor for user-defined function blocks differs slightly from the FBD editor for routines. The components of the editor are: Use this component: To: Overview Window displays the function block diagram in reduced scale. Drawing field create the logic of the FB-type. Variable declaration editor create and define internal variables of a block and initialize them for further use. (only in FB type editor) Interface declaration editor define the graphical appearance of a block. (only in FB type editor) The appearance of the block will match the appearance of the user-defined function block in the FBD Editor. You cannot place an instance of a user-defined IMPORTANT function block within itself. Publication 1753-UM001A-EN-P - April 2004 Creating User-Defined Function Blocks 17-5 Variable declaration defines the connecting points of the function Declaring variables block. There are tabs for these types of variables. Use this tab: To define: VAR an internal variable without type limitations. You can also define the attribute: CONST a constant value that cannot be changed by logic VAR_INPUT an input variable, which is also displayed on the block. VAR_OUTPUT an output variable, which is also displayed on the block. VAR_EXTERNAL a global variable that can also be used and edited within function blocks or functions. Value changes are also visible to the outside. ACTION an action block. Action blocks describe what action should be performed and which behavior should trigger it. Valid data types for variables are: BOOL, BYTE, DATE, DATE_AND_TIME, DINT, DWORD, INT, LREAL, REAL, SINT, STRING, TIME, TIME_OF_DAY, UDINT, UINT, USINT, WORD. The default type is BOOL. The controller handles REAL values as float values and LREAL values as double values. Publication 1753-UM001A-EN-P - April 2004 17-6 Creating User-Defined Function Blocks To declare a variable, select the tab for the type of variable from the user-defined FBD editor. Right-click in any blank area and select New Variable. You can either define the variable here or use the Derivation Type buttons (recommended). The Derivation Type buttons activate dialogs to help declare a variable of the selected type. Use these buttons to ensure accurate syntax. This button: Defines a variable type: Direct derived directly from another variable type Publication 1753-UM001A-EN-P - April 2004 Creating User-Defined Function Blocks 17-7 This button: Defines a variable type: Array array of one or more dimensions For example: ARRAY:array[1..10] of INT • one-dimensional array of INT values • ARRAY[7] accesses the 7th element ARRAY:array[1..10,1..10] of REAL • two-dimensional array of REAL values • ARRAY[3,5] accesses the 3rd element of the 5th row Subrange has values that should be within a certain range For example: DINT(0,200) is an DINT value where • the minimum allowable value is 0 and • the maximum allowable value is 200 Enumeration not yet implemented Publication 1753-UM001A-EN-P - April 2004 17-8 Creating User-Defined Function Blocks Defining Technical Units and Scaling You can define technical units and scaling for each variable: In this field: Define: Techn. unit an available unit from the pulldown menu min. value reference points to convert a technical unit into an internal value max. value For example: • technical unit from 0 to 24V internally represented as • internal representation from 0 to 1000 Enter floating point numbers for the scaling. The available technical units are: Abbreviation: Unit: Definition: A Ampere electrical current Bq Bequerel activity of a radioactive source, disintegration rate C Colomb electrical charge cd Candela light intensity F Farad capacitance Gy Gray absorbed dose H Henry inductance Hz Hertz frequency J Joule energy K Kelvin temperature (in Kelvin) kg Kilogram mass lm Lumen illumination lx Lux illumination density m Meter length mol Mol amount of substance N Newton force Ohm Ohm electrical resistance Pa Pascal pressure Rad Radiant plane angle s Siemens electrical conductance S Second time sr sRadiant solid angle T Tesla magnetic flux density V Volt electrical potential W Watt power Wb Weber magnetic flux Publication 1753-UM001A-EN-P - April 2004 Creating User-Defined Function Blocks 17-9 Defining I/O Positions For input and output variables, you need to define the variables’ positions on the function block. The position portion of the variable declaration display is only available for input and output variables. You can define: In this field: Define: Connection the side of the block (left, top, right, or bottom) to which the input or output should be connected Position the position of the input or output within the block Inverted whether to invert I/O of data type BOOL You can only invert BOOL data. Inversions are indicated by a circle around the I/O. Alternate I/O identifier an I/O-name This name appears in the block, rather than the generated name. How the Variables Display Once you declare your variable, the editor displays the variables. The editor uses these symbols to identify the variables: Symbol: Definition: used as source The variable is read from. used as sink The variable is written to. used as source and sink The variable is read from and written to. Variables used in different types of connections are also identified by this symbol. not used as source or sink; but the variable is set in the function block diagram. not used The variable is declared but not set in the function block diagram. Publication 1753-UM001A-EN-P - April 2004 17-10 Creating User-Defined Function Blocks In order to use these declared variables, you must: Moving Declared Variables to the User-Defined 1. Drag them from the Variable Definition Editor to the user-defined function block page. Function Block Page 2. Drag down the required function blocks and make all the necessary connections. To use the completed user-defined function blocks, you must drag them to the function block page and connect signals to them. Publication 1753-UM001A-EN-P - April 2004 Creating User-Defined Function Blocks 17-11 When you complete your function block logic, you must compile that Generating Function Block logic into code the controller can execute. In the Program Code Management Window, expand the project. Right-click the Resource and select Code Generation. You should save before every Code Generate. A save IMPORTANT is required for any change to the function block page. Any time a change is made, the number of changes displayed on the function block menu bar increments. When the save is complete, the menu bar displays “unchanged”. The software compiles your function block logic and generates the files that you download to the controller. When the code generator compiles logic, it also IMPORTANT takes into consideration the settings you specified in the Hardware Management Window. If you change these settings and want the changes to take effect, you must compile and download the project again. Publication 1753-UM001A-EN-P - April 2004 17-12 Creating User-Defined Function Blocks Checking for Errors and Warnings After performing a code generate, check the status bar at the bottom of the Project Management window. The status bar indicates whether or not a .L2P file was successfully generated. If a .L2P file was not created, check the Hardware Management Window to view the errors and/or warnings compiled during the process of code generation. The window below shows an example of code generation warnings. Publication 1753-UM001A-EN-P - April 2004 Chapter 18 Using High-Speed Counters This chapter covers using counters in the following systems: • GuardPLC 1200, • GuardPLC 1800, or • GuardPLC 2000 using a 1755-HSC module. Using This Chapter For information about: See page counter modes 18-1 configuring counter modules 18-3 using counters in a GuardPLC system 18-1 The counters can be used in the following operating modes: Counter/Decoder Modes • counter mode • decoder mode The two counters can be used in different modes at the same time. Counter Mode Counter Mode is used for counting pulses at speeds up to 1MHz on the GuardPLC 2000 and 100kHz on the GuardPLC 1200 and 1800. Tips for Using Counters in a GuardPLC System 1. The 5V signal must be between 4.5V and 5.5V, while the 24V signal must be between 13V and 26.4V. 2. The steepness of the falling edge must be at least 1V per microsecond. 3. The low and high signal times must be at least 5 µs for the GuardPLC 1200 (duty cycle 50% at 100 kHz) and 0.5 µs for the GuardPLC 2000 (duty cycle 50% at 1 MHz). 4. Shield the cable against noise. 1 Publication 1753-UM001A-EN-P - April 2004 18-2 Using High-Speed Counters Counter Mode Inputs Pins Functions A1, A2 counting input for pulses (high-signals) with falling edge of the pulses B1, B2 counting direction input, incrementing the counter with low-signal, decrementing the counter with high-signal Z1, Z2 resets inputs Resets can be made with a short high-signal. A continuous high-signal blocks the counter. Resets can also be made by the controller program. C1, C2 has no function (GuardPLC 2000 - 1755-HSC only) C- GuardPLC 2000 common reference pole, all pins have electrical continuity L- GuardPLC 1800 common reference pole, all pins have electrical continuity I- GuardPLC 1200 common reference pole, all pins have electrical continuity Decoder Mode Decoder Mode is used for safety supervising the inputs by Gray code, but in the application, the bit structure is handled as a normal binary code value. To use this value, it must be converted in the application. The counter inputs can be connected to an incremental encoder with 4-bit binary code to recognize rotation and the direction of rotation. Decoder Mode Inputs Pins Functions A1, A2 bit 1 (LSB) B1, B2 bit 2 Z1, Z2 bit 3 C1, C2 bit 4 (GuardPLC 2000 only) Publication 1753-UM001A-EN-P - April 2004 Using High-Speed Counters 18-3 Counter Mode/Manual Direction Understanding Counter Module Configuration The simplest mode of operation is pulse counting with Manual Direction. It can be used, for example, in connection with a light barrier where counting events are to be recorded. The direction of counting is determined by the routine. The count begins at 0 and is incremented or decremented by 1 at each negative transition of the counting pulse. The resolution of the counter is 24 bits. This results in a value range from 0 to 16,777,215. The counting pulse must be bounce free and must not exceed the maximum frequency of 1 MHz for a GuardPLC 2000 controller or 100 kHz for a GuardPLC 1200 or 1800 controller. The counter input can be set to a voltage of 5V or 24V via the software. To ensure that the counter functions correctly, the following parameters have to be configured: Parameter: Setting: Cnt[0x].5/24V Mode true for 24V or false for 5V You must configure this parameter with a constant. Cnt[0x].Auto Advance Sense (optional according to routine) false to count only up or only down based upon the direction bit Cnt[0x].Direction (optional according to routine) true to decrement (counts from 16,777,215 downward) or false to increment Cnt[0x].Gray Code (optional according to routine) false Cnt[0x].Reset (optional according to routine) true If this parameter is set to false, the counter value is reset to 0. Publication 1753-UM001A-EN-P - April 2004 18-4 Using High-Speed Counters Counter Mode/Direction and Reset In pulse counting with Direction and Reset, the state of input B is evaluated in addition to counter input A. When the B input has a low signal while the counter recognizes a negative pulse edge at its A input, the value of the counter is incremented by 1. When there is a high signal at the B input, the counter is decremented by 1. The counter is released or reset via the Z input. The counter is released when there is a constant LOW signal at the Z input. A constant HIGH signal halts the counter and a short-time HIGH signal resets the counter value to 0. To enable the counter to function correctly, the following parameters have to be configured in the routine: Parameter: Setting: Cnt[0x].5/24V Mode true for 24V or false for 5V The adjusted level also applies to inputs B and Z. You must configure this parameter with a constant. Cnt[0x].Auto Advance Sense true to count up and down simultaneously Cnt[0x].Direction true to decrement (counts from 16,777,215 downward) or false to increment (standard setting) Cnt[0x].Gray Code false Cnt[0x].Reset true If this parameter is set to false, the counter value is reset to 0. Publication 1753-UM001A-EN-P - April 2004 Using High-Speed Counters 18-5 Decoder Mode/Gray Codes The gray code is a binary code where the code only differs by one bit with two neighboring numbers. Gray codes are useful in mechanical encoders, since a slight change in location only affects one bit. The controller uses a Gray code (4 bits for a GuardPLC 2000 controller or 3 bits for GuardPLC 1200 and 1800 controllers) which has the following structure: Step: Gray Code Gray Code Cnt[0x].Value: (GuardPLC 2000): (GuardPLC 1200, 1600, and 1800): 0 0000 000 0 1 0001 001 1 2 0011 011 3 3 0010 010 2 4 0110 110 6 5 0111 111 7 6 0101 101 5 7 0100 100 4 8 1100 12 9 1101 13 10 1111 15 11 1110 14 12 1010 10 13 1011 11 14 1001 9 15 1000 8 Each counter input is fed to three internal counters. When a count is accomplished, the values of the three internal counters are compared, and if the three values differ by more than one bit, the measuring result is rejected and Cnt[0x].State indicates an error. If the measuring result is valid, the system variable Cnt[0x].Value contains the associated value (see the above table). Publication 1753-UM001A-EN-P - April 2004 18-6 Using High-Speed Counters To enable the Gray code decoder to work correctly, the following parameters have to be configured in the routine: Parameter: Setting: Cnt[0x].5/24V Mode true for 24V or false for 5V The adjusted level also applies to inputs B and Z. You must configure this parameter with a constant. Cnt[0x].Auto Advance Sense this setting has no function on the gray code (set to false) Cnt[0x].Direction this setting has no function on the gray code (set to false) Cnt[0x].Gray Code true Cnt[0x].Reset this setting has no function on the gray code (set to true) Publication 1753-UM001A-EN-P - April 2004 Chapter 19 Configuring the GuardPLC OPC Server Using This Chapter For information about: See page selecting an IP address 19-2 adding the controller and OPC server to a project 19-2 configuring the GuardPLC system for OPC communications 19-3 generating code for the OPC server 19-8 going online with the GuardPLC controller 19-8 using the OPC server 19-8 OLE for Process Control (OPC) is a standard interface for exchanging data between different applications. The GuardPLC OPC server provides an Ethernet interface between the GuardPLC system and other systems with OPC interfaces. This chapter describes the steps required to configure the GuardPLC OPC server to read and write data to an OPC client, in this case, a GuardPLC 1600. RSLogix Guard PLUS is used to create a token group and make an HH network connection between the OPC server and the controller. Signals are connected to the input and output sections of this connection. Signals connected to the output section are sent out of the controller to the OPC server. Signals connected to the input sections are sent from the OPC server to the controller. To create an XML file for use by the OPC Server, follow the steps below, which are described in detail in the following sections. 1. Select the IP Address for the OPC Server. 2. Add the controller and the OPC Server to an RSLogix Guard PLUS project. 3. Configure the GuardPLC System for OPC Communication. 4. Generate XML Code for the OPC Server. 1 Publication 1753-UM001A-EN-P - April 2004 19-2 Configuring the GuardPLC OPC Server Select an IP address for the OPC Server and the GuardPLC controller. Select an IP Address In this example, we used the default IP address of the GuardPLC controller, 192.168.0.99. The IP address of the OPC Server is 192.168.0.216. 1. In RSLogix Guard PLUS, select Project → New. Adding the GuardPLC Controller and the OPC 2. Enter the name of the project and confirm OK. In this example, our project is called “OPCtest”. The Hardware Management Server to the Project window opens. 3. In the Hardware Management window, expand Configuration so that the Resource is visible. In this example, we renamed the resource to G16OPC01. It is not necessary to rename the resource. 4. Right-click on G16OPC01 and select Properties. 5. Change the SRS to 60000 and the Type to the controller you are using. This example uses a GuardPLC 1600. 6. Select Apply and check the remaining check boxes. Click OK. Publication 1753-UM001A-EN-P - April 2004 Configuring the GuardPLC OPC Server 19-3 7. In the project tree, right-click on Configuration and select New → OPC-Server. The OPC server appears in the project tree. Configure the Communication Network Configuring the GuardPLC System for OPC 1. In the Hardware Management window, right-click on the Communication OPCtest Project and select New → HH-Network. 2. Expand the HH-Network. 3. Right-click on Token Group and select Node Editor. 4. Drag the OPC-Server and G16OPC01 onto the Node Editor. 5. Close the Node Editor. 6. Right-click on OPC-Server and select Edit. Publication 1753-UM001A-EN-P - April 2004 19-4 Configuring the GuardPLC OPC Server 7. Drag G16OPC01 onto the OPC-Server Resources Editor. The Specify HH-Network Configuration for OPC dialog opens. Click OK. Connecting Signals 1. Select the Signals pulldown menu from the menu bar and choose Editor. 2. Add two new signals: • DI1 - input sent to the OPC Server • DO1 - output sent from the OPC Server 3. Left-click on 1 in the OPC-Server Resources Editor. Select Connect OPC-Signals. 4. Drag DO1 from the Signal Editor to the Inputs section of the OPC Signal Connections window. Publication 1753-UM001A-EN-P - April 2004 Configuring the GuardPLC OPC Server 19-5 5. Click on the Outputs tab. Drag DI1 from the Signal Editor to the Outputs section of the OPC Signal Connections window. Input and Output are identified from the TIP controller’s perspective. Therefore, output means signals sent out from the GuardPLC 1600 and input means signals sent in to the GuardPLC 1600. 6. Close the OPC Signal Connections window and the OPC-Server Resources Editor. 7. Completely expand the G16OPC01 tree. Right-click on [1] DI 20 and select Connect Signals. 8. Drag DI1 from the Signal Editor to DI[01].Value Signal field. 9. Close the DI1 Signal Connections window. 10. Right-click on [2] DO 8 and select Connect Signals. 11. Select the Outputs tab. Publication 1753-UM001A-EN-P - April 2004 19-6 Configuring the GuardPLC OPC Server 12. Drag DO1 from the Signal Editor to the DO[01].Value signal field. 13. Close the DO Signal Connections window and the Signal Editor. Setting the System Properties Controller 1. Right-click on COM under the GuardPLC 1600 tree and select Properties. 2. Set the IP Address to 192.168.0.99 and click OK. 3. Right-click on Programming Terminal and select Properties. 4. Set the System ID (SRS) to 5. Click OK. There are 3 devices in our system: TIP 1. the PC running the Signal Editor, 2. the OPC Server, and 3. the GuardPLC controller. All must have unique SRS numbers. 4. Right-click on OPC-Server and select Properties. Publication 1753-UM001A-EN-P - April 2004 Configuring the GuardPLC OPC Server 19-7 5. Set the System ID (SRS) to 1 and click OK. 6. Expand the OPC-Server and double-click on IP Address. Set the IP Address to 192.168.0.216 and click OK. Token Group 1. Right-click on Token Group and select Properties. 2. Change the profile to “Medium”. 3. Verify that the Token Group ID is 4. Click Apply and then OK. Publication 1753-UM001A-EN-P - April 2004 19-8 Configuring the GuardPLC OPC Server 1. To generate the XML file for the OPC server, right-click on the Generating Code for the OPC Server and select Code Generator. The process should take OPC Server only 1 or 2 seconds. Make sure there are no warnings or errors. 2. The resulting XML file is located in the project path of the RSLogix Guard PLUS project. Make note of this path so that you can point to it from the GuardPLC OPC Server. 3. Return to the Project Management window and save the project. 4. Right-click on Configuration and select Code Generation. Check the Error State Viewer to make sure there are no errors or warnings. Correct any errors indicated. 1. Return to the Hardware Management window and download the Going Online with the project to your controller. Controller 2. Put the controller into RUN. 3. Minimize RSLogix Guard PLUS. 1. Start the GuardPLC OPC Server by selecting Start → Programs Using the OPC Server → RSLogix Guard PLUS → GuardPLC OPC Server. 2. Select File → Open. Publication 1753-UM001A-EN-P - April 2004 Configuring the GuardPLC OPC Server 19-9 3. Point to your opc.xml file and click Open. 4. The controller and the OPC Server should appear in the Root window. Root Name System Connection state IP Addresses ID/SRS G16OPC01 60000.1 Not connected 192.168.0.99, 127.0.0.1 OPC Server_1 1 Not connected 192.168.0.216, 127.0.0.1 5. Click on the Connect to HIPRO button. 6. Answer Yes to the query. 7. A connection opens between the G16OPC01 and the OPC Server. Root Name System Connection state IP Addresses ID/SRS G16OPC01 60000.1 Connected on channel one 192.168.0.99, 127.0.0.1 OPC Server_1 1 Connected on channel one 192.168.0.216, 127.0.0.1 8. In the structure view, expand Root. 9. Expand G16OPC01. 10. Use the Export and Import icons to view input (DI1) and output (DO1) data, respectively. Publication 1753-UM001A-EN-P - April 2004 19-10 Configuring the GuardPLC OPC Server Publication 1753-UM001A-EN-P - April 2004 Appendix A Specifications GuardPLC 1200 Specifications 1754-L28BBB Controller User Memory 500 KB application code memory 500 KB application data memory Digital Inputs No. of Inputs 20 (not electrically isolated from each other, isolated from the backplane) Nominal Input Voltage 24V dc On-State Voltage 10V dc to 30V dc On-State Current 2 mA @ 10V dc, 13 mA @ 30V dc Off-State Voltage 5V dc (max.) Off-State Current 1.5 mA max. (1 mA @ 5V) Digital Outputs No. of Outputs 8 (not electrically isolated from each other, isolated from the backplane) Output Voltage Range 18.4V to 26.8V Output Current 0.5A per Channel (Channel 1 to 6) 2A per Channel (Channel 7, 8) Surge Current per Channel 1A for 10 ms @ 1Hz (Channel 1 to 6) 4A for 10 ms @ 1Hz (Channel 7, 8) Minimum Current Load 2.5 mA per Channel On-State Voltage Drop 2.0V dc @ 500 mA (max.) Off-State Leakage Current 1 mA per Channel (max.) Temporary Overload Output switches off until overload is eliminated Counters No. of Counters 2 Inputs per Counter 3 (Input A, Input B, Z/Gate/Reset) Counter Resolution 24 bit Maximum Input Frequency 100kHz in Counter Modes (Input A) Trigger Negative Edge Edge Steepness 1 V/µs Duty Cycle 50% @ 100 kHz Input Voltages 4.5V to 5.5V for 5V Input 13V to 26.4V for 24V Input Input Current Typ. 15 mA, ≤ 3 mA 1 Publication 1753-UM001A-EN-P - April 2004 A-2 Specifications Specifications 1754-L28BBB Power Supply Supply Voltage (L+) 24V dc Supply voltage range 20.4V dc to 28.8V dc (10 ms buffer), ripple ≤ 15% Maximum Power Rating 8A (1A to run the controller, 7A for inputs and outputs) Environmental Conditions Storage Temperature: -40° C to +85° C without backup battery Operating Temperature: 0° C to +60° C Mechanical Dimensions Width x Height x Depth: 160 mm x 112 mm x 90 mm (6.3 in. x 4.41 in. x 3.54 in.) Weight 680 g (1.5 lb.) Agency Certifications C-UL Listed Industrial Control Equipment CU R S (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 GuardPLC 1600 Specifications 1753-L28BBBM and 1753-L28BBBP Controller User Memory max. 250 KB user program memory max. 250 KB application data memory Minimum Watchdog 10 ms Minimum Safety Time 20 ms Current Consumption max. 8A (with max. load) 0.5A idle current (just running the controller) Operating Voltage 24V dc, -15% to +20%, w ≤ 15% (from a power supply with ss protective separation conforming to IEC 61131-2 requirements) Interfaces: GuardPLC 4 x RJ-45, 10/100BaseT (with 100 Mbit/s) with integrated switch Ethernet Protection IP20 Digital Inputs No. of Inputs 20 (not electrically isolated) On-state Voltage: 15V to 30V dc Current Consumption: ≥ 2 mA @ 15V 7.5 mA @ 30V Off-state Voltage: max. 5V dc Current Consumption: max 1.5 mA (1 mA @ 5V) Switching Point typically 7.5V Supply 5 x 20V / 100 mA @ 24V short-circuit proof Publication 1753-UM001A-EN-P - April 2004 Specifications A-3 Specifications 1753-L28BBBM and 1753-L28BBBP Digital Outputs No. of Outputs 8 (not electrically isolated) Output Voltage Range 18.4V to 26.8V Output Current Channels 1 to 3 and 5 to 7: 0.5 A @ 60°C (140°F) Channels 4 and 8: 1A @ 60°C (140°F); 2A @ 50°C (122°C) Surge Current per 1A for 10ms @ 1 Hz (Channels 1 to 3 and 5 to 7) Channel 4A for 10ms @ 1 Hz (Channels 4 and 8) Minimum Current 2 mA per Channel Load On-State Voltage Drop max. 2.0V dc @ 2A Off-State Leakage max. 1 mA @ 2V Current Environmental Conditions Storage Temperature : -40°C to +85°C (-40°F to +185°F) Operating 0°C to +60°C (+32°F to 140°F) Temperature: Mechanical Dimensions Width 257 mm (10.1 in.) including housing screws Height 114 mm (4.49 in.) including latch Depth 66 mm (2.60 in.) including grounding bolt Weight 1.2 kg (2.64 lb.) Agency C-UL Listed Industrial Control Equipment CU R S Certifications Marked for all applicable directives (when product is marked) Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 A-4 Specifications GuardPLC 1800 Specifications 1753-L32BBBM-8A and 1753-L32BBBP-8A Controller User Memory max. 250 KB user program memory max. 250 KB application data memory Minimum Watchdog 10 ms Time Minimum Safety Time 20 ms Current Consumption max. 9A (with max. load) 0.75A idle current (just running the controller) Operating Voltage 24V dc, -15% to +20%, w ≤ 15% (from a power supply with ss protective separation conforming to IEC 61131-2 requirements) Protection IP 20 Digital Inputs No. of Inputs 24 (not electrically isolated) On State Voltage: 15V to 30V dc Current Consumption: approximately 3.5 mA @ 24V dc Current Consumption: approximately 4.5 mA @ 30V dc Off State Voltage: max. 5V dc Current Consumption: max. 1.5 mA (1 mA @ 5V dc) Input Resistance < 7kΩ Overvoltage Protection -10V, +35V Max. line length 300 m (9.8 ft.) Supply 20V / 100 mA, short-circuit proof Digital Outputs No. of Outputs 8 (not electrically isolated) Output Voltage Range ≥ L+ minus 2V Output Current Channels 1 to 3 and 5 to 7: 0.5 A @ 60°C (140°F) Channels 4 and 8: 1 A @ 60°C (140°F); 2 A @ 50°C (122°C) Surge Current per 1A for 10 ms @ 1 Hz (Channels 1 to 3 and 5 to 7) Channel 4A for 10 ms @ 1 Hz (Channels 4 and 8) Minimum Current Load 2 mA per Channel Internal Voltage Drop max. 2.0V dc @ 2A Off-State Leakage max. 1 mA @ 2V Current Total Output Current max. 7A Publication 1753-UM001A-EN-P - April 2004 Specifications A-5 Specifications 1753-L32BBBM-8A and 1753-L32BBBP-8A Counters Number of Counters 2 (not electrically isolated) Inputs 3 per counter (A, B, Z) Input Voltages 5V and 24V dc High signal (5V dc): 4V to 6V High signal (24V dc): 13V to 33V Low signal (5V dc): 0V to 0.5V Low signal (24V dc): -3V to 5V Input Currents 1.4 mA @ 5V dc 6.5 mA @ 24V dc Input Impedance 3.7 kΩ Counter Resolution 24-bit Max. Input Frequency 100 kHz Triggered on negative edge Edge Steepness 1 V/µs Pulse Duty Factor 1:1 Analog Inputs Number of Inputs 8 (unipolar, not electrically isolated) External Shunt 500 Ω for 0 to 20 mA (for current measurement) Input values related to Nominal Value: 0 to +10V dc or 0 to +20 mA with 500 Ω shunt L- Service Value: -0.1 to +11.5V dc or -0.4 to +23 mA with 500 Ω shunt Input Impedance 1 MΩ Internal Resistance of ≤ 500 Ω the Signal Source Overvoltage Protection +15V, -4V Resolution (A/D 12-bit Converter) Accuracy 0.1% @ 25°C (77°F) 0.5% @ 60°C (140°F) Transmitter Supplies 25.37 to 28.24V / ≤ 46 mA, short-circuit proof Safety Accuracy ± 2% Environmental Conditions Storage Temperature: -40° C to +85° C (-40°F to +185°F) Operating Temperature: 0° C to +60° C (+32°F to 140°F) Publication 1753-UM001A-EN-P - April 2004 A-6 Specifications Specifications 1753-L32BBBM-8A and 1753-L32BBBP-8A Mechanical Dimensions Width 257 mm (10.1 in.) including housing screws Height 114 mm (4.49 in.) including latch Depth 66 mm (2.60 in.) including grounding screw 80 mm (3.15 in.) including shield plate Weight 1.2 kg (2.64 lb.) Agency C-UL Listed Industrial Control Equipment CU R S Certifications Marked for all applicable directives (when product is marked) Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 1753-IB16 Input Module Distributed I/O Specifications 1753-IB16 General Interfaces: GuardPLC 2 x RJ-45, 10/100BaseT (with 100 Mbit/s) with integrated Ethernet switch Operating Voltage 24V dc, -15% to +20%, w 15% from a power supply with ss protective separation, conforming to IEC 61131-2 requirements Response Time ≥ 10 ms Current Consumption max. 0.8A (with max. load) (0.4A idle current) Digital Inputs No. of Inputs 16 (not electrically isolated) 1 Signal Voltage: 15V to 30V dc, Current Consumption: ≥ 2 mA @ 15V 0 Signal Voltage: max. 5V dc, Current Consumption: max 1.5 mA (1 mA @ 5V) Switching Point typically 7.5V Switching Time typically 250 µs Sensor Supply 4 x 19.2V / 40 mA @ 24V short-circuit proof Publication 1753-UM001A-EN-P - April 2004 Specifications A-7 Specifications 1753-IB16 Pulse Test Sources Number of Pulse Test 4 (not electrically isolated) Sources Output Voltage Range approximately 24V Output Current 60 mA Minimum Current Load none Response to Overload 4 x ≥ 19.2V, short circuit current 60 mA @ 24V Environmental Conditions Storage Temperature -40° C to +85° C (-40° F to +185° F) Operating Temperature 0° C to +60° C (+32° F to +140° F) Mechanical Dimensions Width 152 mm (5.99 in.) including housing screws Height 114 mm (4.49 in.) including latch Depth 66 mm (2.60 in.) including grounding bolt Weight 0.7 kg (1.54 lb.) Agency C-UL Listed Industrial Control Equipment R CUS Certifications Marked for all applicable directives (when product is marked) Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 1753-IB20XOB8 Combination I/O Module Specifications 1753-IB20XOB8 General Interfaces: GuardPLC 2 x RJ-45, 10/100BaseT (with 100 Mbit/s) with integrated Ethernet switch Operating Voltage 24V dc, -15% to +20%, w 15% from a power supply with ss protective separation, conforming to IEC 61131-2 requirements Response Time ≥ 10 ms Battery Backup none Current Consumption max. 8A (with max. load), idle current 0.4A @24V Publication 1753-UM001A-EN-P - April 2004 A-8 Specifications Specifications 1753-IB20XOB8 Digital Inputs No. of Inputs 20 (not electrically isolated) 1 Signal Voltage: 15V to 30V dc, Current Consumption: ≥ 2 mA @ 15V 0 Signal Voltage: max. 5V dc, Current Consumption: max 1.5 mA (1 mA @ 5V) Switching Point typically 7.5V Sensor Supply 5 x 20V / 100 mA @ 24V short-circuit proof Digital Outputs No. of Outputs 8 (not electrically isolated) Output Voltage Range ≥ L+ minus 2V Output Current channels 1 to 3 and 5 to 7: 0.5 A @ 60°C (140°F) channels 4 and 8: 1 A @60°C (140°F), 2 A @ 50°C (122°F) Surge Current per 1A for 10 ms @ 1 Hz (Channels 1 to 3 and 5 to 7) Channel 4A for 10 ms @ 1 Hz (Channels 4 and 8) Minimum Current Load 2 mA per channel Internal Voltage Drop maximum 2V @ 2A Leakage Current (with maximum 1 mA @ 2V 0 signal) Total Output Current maximum 7A with exceeding shut down of all outputs with cyclic reconnecting Response Overload shut down of the concerned output with cyclic reconnecting Environmental Conditions Storage Temperature : -40°C to +85°C (-40°F to +185°F) without backup battery Operating Temperature: 0°C to +60°C (+32°F to +140°F) Mechanical Dimensions Width 207 mm (8.16 in.) including housing screws Height 114 mm (4.49 in.) including latch Depth 66 mm (2.60 in.) including grounding bolt Weight 1.0 kg (2.2 lb.) Agency C-UL Listed Industrial Control Equipment CU R S Certifications Marked for all applicable directives (when product is marked) Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 Specifications A-9 1753-OB16 Output Module Specifications 1753-OB16 General Interfaces: GuardPLC 2 x RJ-45, 10/100Base T (with 100 Mbit/s) with integrated Ethernet switch Operating Voltage 24V dc, -15% to +20%, w 15% from a power supply with ss protective separation, conforming to IEC 61131-2 requirements Response Time ≥ 10 ms Battery Backup none Current Consumption approximately 0.2A per group (idle current) Digital Outputs No. of Outputs 16 (not electrically isolated) Output Voltage Range ≥ L+ minus 2V Output Current maximum 1A @ 60°C (140°F), maximum 2A @40°C (104°F) Surge Current Per 4A for 10 ms @ 1 Hz Channel Minimum Current Load 2 mA per channel Current per Group maximum 8A (maximum 16A) (admissible total current) Lamp Load maximum 10 W (for output 1A), maximum 25 W (for output 2A) Inductive Load maximum 500 mH Internal Voltage Drop maximum 2V @ 2A Leakage Current maximum 1 mA @ 2V (with 0 signal) Response to Overload shut down of concerned output with cyclic reconnecting Environmental Conditions Storage Temperature -40°C to +85°C (-40°F to +185°F) Operating Temperature 0°C to +60°C (+32°F to +140°F) Mechanical Dimensions Width 207 mm (8.16 in.) including housing screws Height 114 mm (4.49 in.) including latch Depth 66 mm (2.60 in.) including grounding bolt Weight 0.85 kg (1.87 lb.) Publication 1753-UM001A-EN-P - April 2004 A-10 Specifications Specifications 1753-OB16 Agency C-UL Listed Industrial Control Equipment CU R S Certifications Marked for all applicable directives (when product is marked) Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 GuardPLC 2000 Controller 1755-L1 Specifications User Memory 500 KB application code memory 500 KB application data memory Operating voltages 3.3V dc 5V dc Current consumptions 3.3V / 1.5A 5V / 0.1A 24V dc / 1.0A Front connectors 1 Ethernet connector for RSLogix Guard PLUS 2 ASCII connectors (RS-232) Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +85°C (-40°F to 185°F) Weight 280 g (0.62 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 Specifications A-11 1755-IB24XOB16 Digital I/O Module GuardPLC 2000 Distributed I/O Modules 1755-IB24XOB16 Specifications Digital Inputs Quantity of inputs 24 Nominal input voltage (1 24V dc (10 to 30V) signal) Off-state input voltage (0 max. 5V dc signal) ON state current 2 mA at 10V, 13 mA at 30V (3 groups of 8, each group limited to 100 mA) OFF state current 1.5 mA at 5V Digital Outputs Quantity of outputs 16 Output voltage range operating voltage minus 2V (depending on load) Output current (30 °C) 2A per channel, overload protected, max. 8A per module General Specifications Current consumption 0.3A / 3.3V dc 0.5A / 24V dc (Idle current to run module) Operating voltage 24V dc, -15 to +20%, ripple ≤ 15% Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +85 °C (-40°F to +185°F) Weight 260 g (0.57 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 A-12 Specifications 1755-IF8 Analog Input Module 1755-IF8 Specifications Number of inputs 8 single-ended or 4 differential Input values rated values 0 to ±10V dc or 0 to +20 mA (with shunt) 0 to ±10.25V dc or 0 to +20.5 mA (with shunt) user values External shunt (for current 500 Ω input) Overvoltage protection 30V (±15V dc) Resolution 12 bit Input impedance 1 MΩ (DC) Input signal / source ≤ 500 Ω impedance Accuracy 0.1% at 25°C (77°F) 0.5% at 60°C (140°F) Operating voltage 24V dc -15 to +20% ripple ≤ 15% Maximum common mode ±13V dc voltage to I- Current consumption 150 mA / 3.3V dc 400 mA / 24V dc Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +85°C (-40° to +185°F) Weight 240 g (0.53 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 Specifications A-13 1755-OF8 Analog Output Module 1755-OF8 Specifications Quantity of outputs 8 Max. output values 0 to ±10V or 0 to +20 mA Overvoltage protection 24V Source value UINT Load impedance load ≤ 600 Ω (current) limit resistance > 5 kΩ (voltage) Accuracy 0.3% at +25°C (+77°F) 0.5% at +60°C (+140°F) Safety relevant accuracy 1% Operating voltage 24V dc -15 to +20% ripple ≤ 15% Current consumption 150 mA / 3.3V dc 400 mA / 24V dc Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +85°C (-40°F to +185°F) Weight 280 g (0.53 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 A-14 Specifications 1755-HSC High Speed Counter Module 1755-HSC Specifications Number of counters 2 Input voltage 5V or 24V Input current ≤ 3 mA Input signal frequency 0 to 1 MHz Trigger with falling edge Edge Steepness 1V/µs Input cables ≤ 500 m at 100 kHz, shielded, twisted Input resistance 3.7 kΩ Resolution 24 bit (value range 0 to 16,777,215) Accuracy of time basis 0.2% Quantity of outputs 4 digital Output load ≤ 0.5A, voltage drop: ≤ 3V Output load in summary ≤ 2A ≥ 18V Operating Voltage 24V dc, -15 to +20%, ripple ≤ 15% Current consumption 0.1A / 24V dc without load 0.8A (3.3V dc), 0.1A (5V dc) Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +85°C (-40°F to +185°F) Weight 260 g (0.57 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 Publication 1753-UM001A-EN-P - April 2004 Specifications A-15 GuardPLC 2000 Power 1755-PB720 Specifications Supply Supply voltage 24V dc Supply voltage range 20.4V dc to 28.8V dc (10 msec buffer), ripple ≤ 15% (1) External fusing 30A / IEC (This module has no overcurrent protection.) Outputs 3.3V dc/10A, 5V dc/2A Operating temperature 0°C to +60°C (+32°F to +140°F) Storage temperature -40°C to +60°C (-40°F to +140°F) with battery -40°C to +85°C (-40°F to +185°F) without battery Weight 820 g (1.80 lb.) Agency Certifications UL Listed Industrial Control Equipment R (when product is marked) Marked for all applicable directives Marked for all applicable acts N223 Functional Safety 1oo2D (AK 1 to 6, SIL 1 to 3, according to DIN V 19250 and IEC 61508 respectively) Category 1 to 4, according to EN954-1 (1) The power supply can supply up to 30A for I/O modules. Use an appropriate fuse for your system’s power requirements. Publication 1753-UM001A-EN-P - April 2004 A-16 Specifications Publication 1753-UM001A-EN-P - April 2004 Appendix B System Variables Using This Appendix For information about: See page programming controller data B-1 I/O variables B-3 The controller supports system variables that you can configure. Programming Controller Data The system variables are defined as: • SAFE: the controller can use this information in safety-related functions • NON-SAFE: additional information that safety functions must not rely on The system variables are: (1) System Variable: Unit/Value: Read/Write: Description: Contact Assembly 1 true Write On true, the contact closes; on false the contact does not close. Contact Assembly 2 false Only available for a GuardPLC 2000 controller. Contact Assembly 3 [BOOL] Contact Assembly 4 NON-SAFE Cooling Fan State 0, 1, 2 Read 0 = normal 1 = fans OK 2 = fan error Only available for a GuardPLC 2000 controller. [BYTE] NON-SAFE Cycle Time milliseconds Read Duration of the last cycle [UDINT] SAFE Date Time Seconds seconds Read Time passed since 1970. An automatic switchover from summer to winter time is Date Time milliseconds not supported. Milliseconds [UDINT] NON-SAFE Emergency Stop 1 true Write True triggers Emergency Off Emergency Stop 2 false [BOOL] Emergency Stop 3 SAFE Emergency Stop 4 Use these signals to force all inputs and outputs to the zero/OFF state from within the user program. 1 Publication 1753-UM001A-EN-P - April 2004 B-2 System Variables (1) System Variable: Unit/Value: Read/Write: Description: Force Time milliseconds Read Remaining running time during forcing; 0 if Force is inactive. [DINT] NON-SAFE Power Supply 0-255 Read GuardPLC 1200 and GuardPLC 2000 GuardPLC 1600 and GuardPLC 1800 0 = normal 0 = normal 1 = error of input power supply 24 VDC 1 = 24 VDC undervoltage 2 = error of battery 4 = 5 V undervoltage 4 = module error of power supply 5 V 8 = 3.3 V undervoltage 8 = module error of power supply 3.3 V 16 = 3.3 V overvoltage 16 = 5 V undervoltage [BYTE] 32 = 5 V overvoltage NON-SAFE 64 = 3.3 V undervoltage 128 = 3.3 V overvoltage 255 = status does not exist [BYTE] NON-SAFE System Tick High milliseconds Read Ring counter with 64 bits which is incremented in millisecond steps. [UDINT] System Tick Low SAFE Temperature State 0, 1, 2, 3, Read 0 = normal 255 1 = high 2 = faulty 3 = very high 255 = status does not exist [BYTE] NON-SAFE (but for additional switch-off) (1) Binary values are ORed. Publication 1753-UM001A-EN-P - April 2004 System Variables B-3 Depending upon the type of controller, the various GuardPLC I/O Variables controllers support variables for digital and analog I/O parameters that you can configure or monitor. Digital I/O Module Variables (AB-DIO) for GuardPLC 1200 and 2000 The GuardPLC 1200 and 2000 controllers support these digital I/O parameters: I/O Data: Read/Write: Description: Board.SRS Read System.Rack.Slot Board.Type Read Module type 0x00E1 digital I/O module for GuardPLC 1200 controller 0xFE01 digital I/O module for GuardPLC 2000 controller 0xFFFF missing module in GuardPLC 2000 chassis (1) Read Error mask for the module Board.State 0x000 I/O processing may be running with errors 0x001 No I/O processing (CPU not in RUN) 0x002 No I/O processing during start-up tests 0x004 Manufacturing interface running 0x010 No I/O processing due to faulty parameterization 0x020 No I/O processing due to exceeded fault rate 0x040 No I/O processing because configured module is not plugged in (1) Read Error mask for all digital outputs DO.State 0x0000 No errors detected 0x0001 Error of the DO section of the module 0x0002 Within the multiple error occurrence time: safety switch 1 faulty 0x0004 Within the multiple error occurrence time: safety switch 2 faulty 0x0008 Within the multiple error occurrence time: test sample tests faulty 0x0010 Within the multiple error occurrence time: readback channels faulty 0x0020 Within the multiple error occurrence time: active switch-off faulty 0x0100 Within the safety time: CS signals faulty 0x0200 All outputs switched off; total current too high 0x0400 Within the safety time: temperature limit 1 exceeded 0x0800 Within the safety: temperature limit 2 exceeded 0x01000 Within the safety time: auxiliary voltage monitoring: undervoltage 0x02000 Within the multiple error occurrence time: status of the safety switches Publication 1753-UM001A-EN-P - April 2004 B-4 System Variables I/O Data: Read/Write: Description: (1)(2) Read Error mask for digital output channels DO[0x].State 0x00 No error detected; outputs driven as expected 0x01 Error in digital output module; outputs not driven 0x02 Output switched off due to overcurrent; outputs not driven 0x04 Error during readback of the digital output; outputs not driven (1) Write Output value of digital output channels DO[0x].Value 0 Output de-energized 1 Output activated DI.State Write Error mask for all digital inputs 0x0000 No error detected 0x0001 Error of the DI section of the module 0x0002 Within the safety time: test sample test faulty (3) Read Error mask of digital input channels DI[xy].State 0x00 No error detected 0x01 Error in the digital input module; input value set to 0 (2) Read Input values of digital input channels DI[xy].Value 0 Input not activated 1 Input activated (1) Values are ORed. (2) 0x = output channel 01 to 16 for GuardPLC 2000 controller and 01 to 08 for GuardPLC 1200, 1600, and 1800 controllers. (3) xy = input channel 01 to 24 for GuardPLC 2000 and GuardPLC 1800 controllers and 01 to 20 for GuardPLC 1200 and 1600 controllers. Publication 1753-UM001A-EN-P - April 2004 System Variables B-5 Analog Input Module Variables (AB-AI) for GuardPLC 2000 The GuardPLC 2000 controller supports these analog input parameters: I/O Data: Read/Write: Description: AI.Mode Write Mode for all channels of the analog input module 0 unipolar (single-ended) 1 differential AI.State Read Error mask for all analog inputs 0x0000 No errors detected 0x0001 Error of the module 0x0008 Within the safety time: data bus walking bit error 0x0010 Within the safety time: coefficient table check error 0x0020 Within the safety time: supply voltages error 0x0040 Error on A/D conversion (DRDY_HIGH) 0x0080 Within the multiple error occurrence time: error in multiplexer crosslink 0x0100 Within the multiple error occurrence time: data bus walking bit error 0x0200 Within the multiple error occurrence time: multiplexer address error 0x0400 Within the multiple error occurrence time: supply voltages error 0x0800 Within the multiple error occurrence time: error in characteristic curve (unipolar mode) 0x1000 Within the multiple error occurrence time: limit values/zero point error (unipolar mode) 0x2000 Within the multiple error occurrence time: error in characteristic curve (differential mode) 0x4000 Within the multiple error occurrence time: limit values/zero point error (differential mode) 0x8000 Error in A/D conversion (DRDY_LOW) (1) Read Error mask for analog input channels AI[0x].State 0x00 No error detected 0x01 Error in analog input channel 0x02 Invalid measurement values 0x04 A/D converters faulty 0x08 Measurement values are not within the safety accuracy 0x10 Measurement value overflow 0x20 Channel not in use 0x40 Addressing error of the two A/D converters Publication 1753-UM001A-EN-P - April 2004 B-6 System Variables I/O Data: Read/Write: Description: AI[0x].Used Write Configuration of analog input channel 0 not used 1used (1) Read Analog value of input channel (WORD) AI[0x].Value -10V to +10V = -1000 to +1000 Board.SRS Read System.Rack.Slot Board.Type Read Module type 0xFD02 analog input module for GuardPLC 2000 controller 0xFFFF missing module in GuardPLC 2000 chassis Board.State Read Error mask for the module 0x000 I/O processing may be running with errors 0x001 No I/O processing (CPU not in RUN) 0x002 No I/O processing during start-up tests 0x004 Manufacturing interface running 0x010 No I/O processing due to faulty parameterization 0x020 No I/O processing due to exceeded fault rate 0x040 No I/O processing because configured module is not plugged in (1) 0x = input channel 01 to 08. Analog Output Module Variables (AB-AO) for GuardPLC 2000 The GuardPLC 2000 controller supports these analog output parameters: I/O Data: Read/Write: Description: AO.State Read Error mask for all analog outputs 0x0000 No errors detected 0x0001 Error of the module 0x0002 Within the safety time: co-efficient table check error 0x0004 No communication with the module due to controller error AO[0x].Mode Write Mode of analog output channel 0 voltage 1 current Publication 1753-UM001A-EN-P - April 2004 System Variables B-7 I/O Data: Read/Write: Description: (1) Read Error mask for analog output channels AO[0x].State 0x0000 0001 CPU detected error on AB-AO module 0x0000 0002 CPU detected faulty monotony counter 0x0000 0004 CPU detected error in safe addressing 0x0000 0008 CPU detected faulty CRC 0x0000 0010 CPU detected error in watchdog time of the AB-AO onboard microprocessor 0x0000 0020 CPU cannot communicate with the AB-AO onboard microprocessor 0x0000 0040 CPU detected that the present operating mode (current/voltage) is different from the initialized operating mode 0x0001 0000 AB-AO onboard microprocessor detected read back error 0x0004 0000 AB-AO onboard microprocessor detected wrong supply voltage 0x0008 0000 Within the multiple error occurrence time: AB-AO onboard microprocessor detected faulty safety switch 0x0080 0000 AB-AO onboard microprocessor detected both safety switches as faulty 0x0200 0000 AB-AO onboard microprocessor INITIALIZE 0x1000 0000 AB-AO onboard microprocessor detected error because of module over temperature 0x2000 0000 AB-AO onboard microprocessor detected module over temperature 0x8000 0000 CPU detected error on redundant AB-AO onboard microprocessor channel AO[0x].Used Write Configuration of analog output channel 0 not used 1used (1) Write Output value of analog output channels AO[0x].Value Voltage mode: -10V to +10V = -1000 to +1000 Current mode: 0mA to +20mA = 0 to +1000 for values between -1000 to 0, the output current is 0mA Board.SRS Read System.Rack.Slot Board.Type Read Module type 0xFB04 analog output module for GuardPLC 2000 controller 0xFFFF missing module in GuardPLC 2000 chassis Publication 1753-UM001A-EN-P - April 2004 B-8 System Variables I/O Data: Read/Write: Description: Board.State Read Error mask for the module 0x000 I/O processing may be running with errors 0x001 No I/O processing (CPU not in RUN) 0x002 No I/O processing during start-up tests 0x004 Manufacturing interface running 0x010 No I/O processing due to faulty parameterization 0x020 No I/O processing due to exceeded fault rate 0x040 No I/O processing because configured module is not plugged in (1) 0x = output channels 01 to 08. High-Speed Counter Variables For GuardPLC 1200 and 2000 The GuardPLC 1200 and GuardPLC 2000 controllers support the following variables for counter I/O parameters: I/O Data: Read/Write: Description: Board.SRS Read System.Rack.Slot Board.Type Read Module type 0x0003 counter module for GuardPLC 1200 controller 0xFC03 counter module for GuardPLC 2000 controller 0xFFFF missing module in GuardPLC 2000 chassis Board.State Read Error mask for the module 0x000 I/O processing may be running with errors 0x001 No I/O processing (CPU not in RUN) 0x002 No I/O processing during start-up tests 0x004 Manufacturing interface running 0x010 No I/O processing due to faulty parameterization 0x020 No I/O processing due to exceeded fault rate 0x040 No I/O processing because configured module is not plugged in Publication 1753-UM001A-EN-P - April 2004 System Variables B-9 I/O Data: Read/Write: Description: Cnt.State Read Error mask of both counters 0x0000 No errors detected 0x0001 Error of the counter section of the module 0x0002 Error while comparing the time base 0x0004 Addressing error while reading the time base 0x0008 Parameterization of the time base corrupted 0x0010 Addressing error while reading the counts 0x0020 Parameterization of counter corrupted 0x0040 Addressing error while reading the Gray codes 0x0080 Within the multiple error occurrence time: test sample test faulty 0x0100 Error of the module (1) Read Counts of counter 1 or 2 (cyclic 24-bit) Cnt[0x].Value 24 bits for pulse counter 4 bits for Gray code for GuardPLC 2000; 3 bits for Gray code for GuardPLC 1200 (1) Read/Write 5V or 24V mode of counter 1 or 2 Cnt[0x].5/24V Mode The write values must have initial values or constants. 05V 1 24V Cnt[0x].Auto Advance Read/Write Automatic recognition of direction of counting for counter 1 or 2 (1) Sense 0 Manual setting of direction of counting 1 Automatic recognition of direction of counting (1) Read/Write Direction of counting for counter 1 or 2 Cnt[0x].Direction (only when Automatic Counter Advance Sense = false) 0Up 1Down Cnt[0x].Dummy1 Read/Write reserved memory space for future use Cnt[0x].Dummy2 Read/Write reserved memory space for future use (1) Read/Write Gray code mode of counter 1 or 2 Cnt[0x].GrayCode 0 Pulse 1Gray (1) Read/Write currently not used Cnt[0x].Halt (1) Read/Write Reset for counter 1 or 2 Cnt[0x].Reset 0 Resetting of counter 1 No resetting of counter Publication 1753-UM001A-EN-P - April 2004 B-10 System Variables I/O Data: Read/Write: Description: (1) Read Error mask of counter 1 or 2 Cnt[0x].State 0x01 Error in counter unit 0x02 Error while comparing the counts 0x04 Error while comparing the time stamps 0x08 Error resetting counter (1) Read Overflow indicator of time stamp of counter 1 or 2 Cnt[0x].Time Overflow true 24 bits overflow since last cycle false No 24 bits overflow since last cycle (1) Read Time stamp for Cnt[0x].Value (cyclic 24-bit) Cnt[0x].Time Stamp 24 bits, time resolution 1µs (1) Read Overflow indicator of counter 1 or 2 Cnt[0x].Value Overflow true 24 bits overflow since last cycle (only when Automatic Counter Advance Sense = false) false No 24 bits overflow since last cycle DO.State Read Error mask for all counter outputs 0x0001 Error of the DO section of the module 0x0002 Within the multiple error occurrence time: safety switch 1 faulty 0x0004 Within the multiple error occurrence time: safety switch 2 faulty 0x0008 Within the multiple error occurrence time: test sample tests faulty 0x0010 Within the multiple error occurrence time: readback channels faulty 0x0020 Within the multiple error occurrence time: active switch-off faulty 0x0100 Within the safety time: CS signals faulty 0x0200 All outputs switched off; total current too high 0x0400 Within the safety time: temperature limit 1 exceeded 0x0800 Within the safety time: temperature limit 2 exceeded 0x01000 Within the safety time: auxiliary voltage monitoring: undervoltage 0x02000 Within the multiple error occurrence time: status of the safety switches (2) Read Error mask for counter outputs 1 to 4 DO[0y].State 0x01 Error in output channel 0x02 Output channel switched off due to overcurrent 0x04 Error during readback of the output channel 0x08 Faulty initialization after counter reset (2) Write Output value of counter outputs 1 to 4 (These 4 outputs cannot be driven by counter DO[0x].Value presets. They are driven by user software only.) 0 Output de-energized 1 Output activated (1) Ox = counter 01 or 02. (2) 0y = outputs 01, 02, 03, or 04 Publication 1753-UM001A-EN-P - April 2004 System Variables B-11 Digital Input Module Variables for GuardPLC 1600 and DIO The GuardPLC 1600 controllers and distributed I/O support the following digital input parameters. I/O Data: Read/Write Description: Module.SRS Read Slot number (System.Rack.Slot) Module.Type Read Module type 0x00A5 Digital input module (DI20) for GuardPLC 1600 0x00A5 Digital input module (DI20) for 1753-IB20XOB8 0x002D Digital input module (DI16) for 1753-IB16 Module.Error.Code Read Error mask for the module 0x0000 I/O processing may be running with errors 0x0001 No I/O processing (CPU not in RUN) 0x0002 No I/O processing during start-up tests 0x0004 Manufacturing interface running 0x0010 No I/O processing due to incorrect configuration 0x0020 No I/O processing due to exceeded fault rate 0x0040 No I/O processing because configured module is not plugged in DI.Error Code Read Error mask for all digital inputs 0x0001 Error in digital input range 0x0002 FTZ test of test pattern failed (1) Read Error mask of all digital input channels DI[xy].Error Code 0x01 Error in digital input module 0x10 Short-circuit of the channel 0x80 Line interrupt between pulse output (DO) and pulse input (DI) (1) Write Input value of digital input channels DI[xy].Value 0 Input not set 1 Input set Publication 1753-UM001A-EN-P - April 2004 B-12 System Variables I/O Data: Read/Write Description: DI.Number of Pulse Write Number of pulse outputs (feed outputs) Channel 0 No output channel provided for line monitoring 1 Output channel 1 provided for line monitoring 2 Output channels 1 and 2 provided for line monitoring 3 Output channels 1, 2, and 3 provided for line monitoring 4 Output channels 1to 4 provided for line monitoring 5 Output channels 1to 5 provided for line monitoring 6 Output channels 1to 6 provided for line monitoring 7 Output channels 1to 7 provided for line monitoring 8 Output channels 1to 8 provided for line monitoring DI.Pulse Slot Write Pulse module slot (LC) DI.Pulse Channel Write Source channel of pulse feed 0 Input channel 1 Pulse from first DO channel 2 Pulse from second DO channel 3 Pulse from third DO channel 4 Pulse from fourth DO channel 5 Pulse from fifth DO channel 6 Pulse from sixth DO channel 7 Pulse from seventh DO channel 8 Pulse from eighth DO channel DI.LC Delay Write Waiting time for pulse output (short-circuit-proof) (1) xy = input channel 01 to 24 for GuardPLC 1800 controllers and 01 to 20 for GuardPLC 1600 controllers. Publication 1753-UM001A-EN-P - April 2004 System Variables B-13 Digital Output Module Variables for GuardPLC 1600, 1800 and DIO The GuardPLC 1600 and 1800 controllers and distributed I/O support the following digital output parameters. I/O Data: Read/Write Description: Module.SRS Read Slot number (System.Rack.Slot) Module.Type Read Module type 0x00B4 digital output module (DO8) for GuardPLC 1600, 1800, and 1753-IB20XOB8 0x005A digital output module (DO16) for 1753-OB16 Module.Error.Code Read Error mask for the module 0x0000 I/O processing may be running with errors 0x0001 No I/O processing (CPU not in RUN) 0x0002 No I/O processing during start-up tests 0x0004 Manufacturing interface running 0x0010 No I/O processing due to incorrect configuration 0x0020 No I/O processing due to exceeded fault rate 0x0040 No I/O processing because configured module is not plugged in DO.Error Code Read Error mask for all digital outputs 0x0001 Error in digital output range 0x0002 MEZ test of test pattern failed 0x0004 MEZ test, auxiliary supply failed 0x0010 FTZ test of test pattern failed 0x0020 FTZ test of test pattern of the output switch failed 0x0040 FTZ test of the test pattern of the output switch (disconnection test of outputs) failed (1) Read Error mask of all digital output channels DO[0x].Error Code 0x01 Error in digital output module 0x02 Output switched off due to overload 0x04 Error when reading back the activation of the digital outputs 0x08 Error when reading back the status of the digital outputs (1) 0x = output channels 01 to 08. Publication 1753-UM001A-EN-P - April 2004 B-14 System Variables Counter Module Variables for GuardPLC 1800 Controllers The GuardPLC 1800 controllers support the following counter parameters. I/O Data: Read/Write Description: Module.SRS Read Slot number (System.Rack.Slot) Module.Type Read Module type 0x0003 high speed counter module for GuardPLC 1800 Module.Error.Code Read Error mask for the module 0x0000 I/O processing may be running with errors 0x0001 No I/O processing (CPU not in RUN) 0x0002 No I/O processing during start-up tests 0x0004 Manufacturing interface running 0x0010 No I/O processing due to incorrect configuration 0x0020 No I/O processing due to exceeded fault rate 0x0040 No I/O processing because configured module is not plugged in Cnt.Error Code Read Error mask of counter module 0x0001 Error in module 0x0002 Error comparing the time base 0x0004 Address error reading the time base 0x0008 Parameters for the time base are faulty 0x0010 Address error reading the counter content 0x0020 Configuration of counter damaged 0x0040 Address error reading the Gray Code 0x0080 FTZ test of the test pattern failed 0x0100 FTZ test, error checking the coefficients (1) Read Error mask of counter channels 1 and 2 Cnt[0x].Error Code 0x01 Error in counter module 0x02 Error comparing contents of counters 0x04 Error comparing the timestamps of the counters 0x08 Error setting the parameters (reset) (1) Read Content of counters: 24-bit for pulse counter, 3-bit for Gray Code Cnt[0x].Value (1) Read Time stamp for Cnt[0x].Value 24-bit, time resolution 1µs Cnt[0x].Timestamp (1) Read Counter overflow indication Cnt[0x].Value Overflow True 24-bit overflow since last measurement (only if Cnt[0x].Auto Advance Sense = False) False No overflow since last cycle Publication 1753-UM001A-EN-P - April 2004 System Variables B-15 I/O Data: Read/Write Description: (1) Read Overflow indication for the time stamp of the counters Cnt[0x].Time Overflow True 24-bit overflow since last measurement False No 24-bit overflow since last measurement (1) Read/Write Counting direction of the counter Cnt[0x].Direction (only if Cnt[0x].Auto Advance Sense = False) True upward (increment) False downward (decrement) Cnt[0x].Auto Advance Read/Write Automatic counter direction recognition (1) Sense True Automatic recognition on False Manual setting of counter direction (1) Read/Write Reset counter Cnt[0x].Reset True No reset False Reset (1) Read/Write Counter input 5V or 24V Cnt[0x].5/24V Mode True 24V False 5V (1) Read/Write Decoder or pulse operation Cnt[0x].Gray Code True Gray Code decoder False Pulse operation (1) Ox = counter 01 or 02. Publication 1753-UM001A-EN-P - April 2004 B-16 System Variables Digital (Analog) Input Variables for the GuardPLC 1800 Controller The digital inputs on the GuardPLC 1800 are actually analog inputs with the following configurable parameters: I/O Data: Read/Write Description: Module.SRS Read Slot number (System.Rack.Slot) Module.Type Read Module type 0x00D2 Digital input module (MI24/8 FS:1000) for GuardPLC 1800 0x0096 Digital input module (MI24/8 FS:2000) for GuardPLC 1800 Module.Error.Code Read Error mask for the module 0x0000 I/O processing may be running with errors 0x0001 No I/O processing (CPU not in RUN) 0x0002 No I/O processing during start-up tests 0x0004 Manufacturing interface running 0x0010 No I/O processing due to incorrect configuration 0x0020 No I/O processing due to exceeded fault rate 0x0040 No I/O processing because configured module is not plugged in AI.Error Code Read Error mask for all digital (analog) inputs 0x0001 Error in input range 0x0008 FTZ test: walking bit of data bus faulty 0x0010 FTZ test: error checking coefficients 0x0020 FTZ test: operating voltages faulty 0x0040 A/D conversion faulty (DRDY_LOW) 0x0080 MEZ test: cross links of MUX faulty 0x0100 MEZ test: walking bit of data bus faulty 0x0200 MEZ test: multiplexer addresses faulty 0x0400 MEZ test: operating voltages faulty 0x0800 MEZ test: measuring system (characteristic) faulty (unipolar) 0x1000 MEZ test: measuring system (final values, zero point) faulty (unipolar) 0x8000 A/D conversion faulty (DRDY_HIGH) Publication 1753-UM001A-EN-P - April 2004 System Variables B-17 I/O Data: Read/Write Description: AI[xx].Error Code Read Error mask for analog input channels (1 to 8) DI[xx].Error Code Read Error mask for digital input channels (9 to 32) 0x01 Error in input module 0x02 Measured values invalid 0x04 A/D converter faulty 0x08 Measured value not within the safety accuracy 0x10 Measured value overflow 0x20 Channel not in operation 0x40 Address error of both A/D converters 0x80 Configuration of hysteresis faulty AI[xx].Value Analog Read Analog value of AI channels (1 to 8) [WORD] from 0 to +1000 The validity is dependent on the error mask. DI[xx].Value Analog Read Analog value of the DI channels (9 to 32) [WORD] from 0 to +3000 The validity is dependent on the error mask. DI[xx].Value Bool Read Digital value of DI channels (9 to 32) [BOOL] according to hysteresis The validity is dependent on the error mask. AI[xx].Hysteresis LOW Write Upper limit of the 0-signal voltage range DI[xx].Value Bool AI[xx].Hysteresis HIGH Write Lower limit of the 1-signal voltage range DI[xx].Value Bool AI[xx].Used Write Configuration for indicating utilization of channels 1 to 8 DI[xx].Used Write Configuration for indicating utilization of channels 9 to 32 Publication 1753-UM001A-EN-P - April 2004 B-18 System Variables Publication 1753-UM001A-EN-P - April 2004 Appendix C Replacing the Backup Battery The following procedures apply only to GuardPLC 1200 controllers and GuardPLC 2000 power supplies. Other GuardPLC controllers and I/O modules are not equipped with backup batteries. Only qualified personnel with knowledge of ESD protective measures Preventing Electrostatic may replace the back-up battery. Discharge Electrostatic discharge can damage integrated circuits ATTENTION or semiconductors. Follow these guidelines when you handle the module: • Touch a grounded object to discharge static potential. • Wear an approved wrist-strap grounding device. • If available, use a static-safe workstation. • When not in use, keep the GuardPLC controller in its static-shield box. Replace the backup battery on your GuardPLC 1200 controller every GuardPLC 1200 two years. The battery case is located on the left-hand side of the cabinet (see drawing below). The battery must be replaced together with the case. Replacements are available from Rockwell Automation under part number 1754-BAT. Follow the steps on page C-2 to replace the battery. 1 Publication 1753-UM001A-EN-P - April 2004 C-2 Replacing the Backup Battery battery case backup battery and case (bottom view) 42911 Make sure that the GuardPLC 1200 is powered on. ATTENTION Replacing the backup battery while the controller is de-energized causes a reset. All data including the clock settings will be lost. 1. Pull the left side of the battery case toward you to remove the battery case. 2. Insert a new battery case making sure that the case is correctly aligned and the pins inside the GuardPLC 1200 are not bent. Press on the left edge of the case until the battery snaps into place. Used batteries must be packaged and transported to a proper disposal site in accordance with local regulations. Replace the backup battery every four years. Replacement batteries GuardPLC 2000 Power are available from Rockwell Automation (1755-BAT). Follow the steps Supply on page C-3 to replace the battery: Make sure that the GuardPLC 2000 is powered on. ATTENTION Replacing the backup battery while the controller is off causes a reset. All data including the clock settings will be lost. Publication 1753-UM001A-EN-P - April 2004 Replacing the Backup Battery C-3 1. Remove the lid by removing the two screws. – + 2. Use a flat-head screwdriver to remove the battery from its compartment. 3. Insert a new battery, following the polarity shown on the compartment. Make sure that the contact pins inside the battery compartment are not damaged. Used batteries must be packaged and transported to a proper disposal site in accordance with local regulations. Publication 1753-UM001A-EN-P - April 2004 C-4 Replacing the Backup Battery Publication 1753-UM001A-EN-P - April 2004 Index Modbus device 15-2 Numerics Modbus signals 15-3 1755-HSC LEDs 11-11 Profibus DP device 15-5 1755-IF8 LEDs 11-10 Profibus DP signals 15-7 1755-OF8 LEDs 11-11 connection control system tag 13-8 connection state system tag 13-8 control panel 7-1 A controllers access level 10-1 changing IP address 4-22 acknowledge timeout 12-9 changing SRS 4-22 analog data B-5, B-6 configuring 8-5 ASCII connecting ASCII device 14-1 connecting 14-1 connecting Modbus device 15-2 data type formats 14-9 connecting Profibus DP device 15-5 master request 14-6 connecting programming terminals 4-1 overview 1-9 control panel 7-1 protocol 14-6 determining IP address 4-21 serial port 14-4 determining SRS 4-21 signals 14-5 GuardPLC 1200 LEDs 11-4 slave response 14-7 GuardPLC 1600 LEDs 11-5 GuardPLC 1800 LEDs 11-5 GuardPLC 2000 LEDs 11-7 B logging in 4-20 Bus Cycle Time 12-5 modes 8-1 serial port 14-4 C switches 8-7 system variables B-1 check consistency 6-1, 7-11 counter configuration 18-3 code 17-11 counter mode code generator version 13-4 inputs 18-2 communication time slice 13-2 counter modes 18-1 communications counters ASCII 14-1 data B-8 changing IP address 4-22 gray code 18-5 changing SRS 4-22 with direction and reset 18-4 control panel 7-1 with manual direction 18-3 determining IP address 4-21 creating determining SRS 4-21 user access 10-2 logging in 4-20 Modbus 15-1 Peer-to-Peer 12-1 D configuration data types 14-9 counters 18-3 decoder mode 18-5 configuring inputs 18-2 controllers 8-5 default password 10-1 programming terminals 4-19 default user name 10-1 serial port 14-4 diagnostics connecting 1755-HSC LEDs 11-11 ASCII device 14-1 1755-IF8 LEDs 11-10 ASCII signals 14-5 1755-OF8 LEDs 11-11 controllers and programming terminals distributed I/O 11-5 4-1 filtering 11-3 GuardPLC 1200 4-1 GuardPLC 1200 LEDs 11-4 GuardPLC 2000 4-2 Publication 1753-UM001A-EN-P - April 2004 2 Index GuardPLC 1600 11-5 overview 1-6 GuardPLC 1800 11-5 GuardPLC Ethernet GuardPLC 2000 LEDs 11-7 overview 1-8 viewing 11-1 digital data B-3 H distributed I/O HH Network Profiles 12-10–12-16 LEDs 11-5 fast 12-11 downloading routines 6-2 medium 12-13 None 12-16 E HH protocol parameters 12-3–12-6 editing HH-Network 13-4–13-6 forces 9-5 entering I force values and force marks 9-5 I/O data B-3 Ethernet IP address 4-22 connecting controller and programming terminal 4-1 see GuardPLC Ethernet L line control F 1753-IB16 16-2 1753-IB20XOB8 16-1 Faults configuration 16-4 response 1-2 GuardPLC 1600 16-1 filtering diagnostic data 11-3 response to faults 16-3 forcing link mode 12-4 force values and force marks 9-5 link mode (extern) 12-6 function blocks logging in 4-20 generating code 17-11 scaling 17-8 technical units 17-8 M managing G user access 10-1 manuals, related P-2 generating code 17-11 Modbus gray code 18-5 configuring 15-2 GuardPLC 1200 connecting 15-2 connecting 4-1 overview 1-9 connecting ASCII device 14-1 protocol 15-5 LEDs 11-4 signals 15-3 overview 1-3 modes GuardPLC 1600 controllers 8-1 overview 1-4 routines 8-8 GuardPLC 1800 monitoring overview 1-4 diagnostics 11-1 GuardPLC 2000 signals 9-1 1755-HSC terminals 3-33 1755-IB24XO16 terminals 3-8 1755-IF8 terminals 3-9 O 1755-OF8 terminals 3-9 OPC Server connecting 4-2 overview 1-10 connecting ASCII device 14-3 overview 1-1 LEDs 11-7 Publication 1753-UM001A-EN-P - April 2004 Index 3 variables 12-7 P response time (extern) 12-6 password default 10-1 routines Peer-to-Peer Network Profiles 12-17– controlling 6-6 12-23 downloading 6-2 fast & cleanroom 12-18 execution states 6-6 fast & noisy 12-19 modes 8-8 medium & cleanroom 12-20 starting 6-4 medium & noisy 12-21 testing 6-5 slow & cleanroom 12-22 slow & noisy 12-23 power supply connections S distributed I/O 3-15 Safe States GuardPLC 1600 3-15 inputs 1-2 GuardPLC 1800 3-15 outputs 1-3 primary controller 12-5 safety concept 1-1 primary timout 12-6 scaling 17-8 production rate 12-9 secondary controller 12-6 Profibus DP Slave secondary interval 12-6 configuring 15-6 serial port 14-4 connecting 15-5 signals overview 1-10 ASCII 14-5 protocol 15-8 counter data B-8 signals 15-7 force values and force marks 9-5 programming terminals I/O data B-3 configuring 4-19 Modbus 15-3 connecting controller 4-1 monitoring 9-1 SRS 4-19 Profibus DP 15-7 protocol system variables B-1 ASCII 14-6 SRS High Level High Speed (HH) 12-1 changing 4-22 Modbus 15-5 starting Peer-to-Peer 12-1 routines 6-4 publications, related P-2 switches 8-7 pulse test sources system variables B-1 1753-IB16 16-2 T Q technical units 17-8 queue length 12-9 terminals 1755-HSC 3-33 R 1755-IB24XO16 3-8 1755-IF8 3-9 receive timeout 1755-OF8 3-9 definition 12-8 testing routines 6-5 reconfiguring 13-23 token alive timeout 12-5 setting 12-8 token cycle time 12-5 related publications P-2 token group resent timeout 12-8 configuring 13-6 reset pushbutton 2-13 creating 13-5 response time definition 12-11 definition 12-5, 12-7 ID 12-4, 13-6 reconfiguring 13-22 Publication 1753-UM001A-EN-P - April 2004 4 Index U W user access 10-1 watchdog time 12-9 user name default 10-1 reconfiguring 13-19 worst-case reaction time definition 12-10 V variables 12-10 variables system B-1 user defined function blocks 17-5 Publication 1753-UM001A-EN-P - April 2004 Rockwell Automation provides technical information on the web to assist you Rockwell Automation in using our products. At http://support.rockwellautomation.com, you can Support find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. For an additional level of technical phone support for installation, configuration and troubleshooting, we offer TechConnect Support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://support.rockwellautomation.com. Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your module up and running: United States 1.440.646.3223 Monday – Friday, 8am – 5pm EST Outside United Please contact your local Rockwell Automation representative for any States technical support issues. New Product Satisfaction Return Rockwell tests all of our products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned: United States Contact your distributor. You must provide a Customer Support case number (see phone number above to obtain one) to your distributor in order to complete the return process. Outside United Please contact your local Rockwell Automation representative for States return procedure. Publication 1753-UM001A-EN-P - April 2004 7 Supersedes Publication 1755-UM001C-EN-P - June 2002 Copyright © 2004 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.