ControlNet PLC-5 Programmable Controllers Catalog Numbers 1785-L20C15, -L40C15, -L46C15, -L80C15 User Manual Because of the variety of uses for the products described in this Important User Information publication, those responsible for the application and use of these products must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. In no event will Allen-Bradley be responsible or liable for indirect or consequential damage resulting from the use or application of these products. Any illustrations, charts, sample programs, and layout examples shown in this publication are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication. Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited. Throughout this publication, notes may be used to make you aware of safety considerations. The following annotations and their accompanying statements help you to identify a potential hazard, avoid a potential hazard, and recognize the consequences of a potential hazard: Identifies information about practices or WARNING circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ! Identifies information about practices or ATTENTION circumstances that can 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. Environment and Enclosure ATTENTION This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters ! without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as "open type" equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the Allen-Bradley publication 1770-4.1 ("Industrial Automation Wiring and Grounding Guidelines"), for additional installation requirements pertaining to this equipment. Ethernet is a registered trademark of Intel Corporation, Xerox Corporation, and Digital Equipment Corporation. ControlNet is a trademark of ControlNet International. Allen-Bradley, PLC, PLC-2, PLC-3 and PLC-5 are registered trademarks of Rockwell Automation, Inc. Data Highway Plus, DH+, RSLinx, RSLogix, RSNetWorx, RSNetworx for ControlNet, FLEX I/O , PLC-5/11, -5/20, -5/20C, -5/26, -5/30, -5/40, -5/46, -5/40L, -5/40C, -5/60, -5/60L, -5/80, -5/80C, -5/86, -5/20E, -5/40E, and -5/80E are trademarks of Rockwell Automation, Inc. Before you contact Rockwell Automation for technical assistance, we Rockwell Automation suggest you please review the troubleshooting information contained Support in this publication first. If the problem persists, call your local Rockwell Automation representative or contact Rockwell Automation in one of the following ways: Phone United 1.440.646.5800 States/Canada Outside United You can access the phone number for your States/Canada country via the Internet: 1. Go to http://www.ab.com 2. Click on Product Support (http://support.automation.rockwell.com) 3. Under Support Centers, click on Contact Information Internet 1. Go to http://www.ab.com ⇒ 2. Click on Product Support (http://support.automation.rockwell.com) Your Questions or Comments on this Manual If you find a problem with this manual, please notify us of it on the enclosed How Are We Doing form. Summary of Changes Summary of Changes The information below summarizes the changes to the ControlNet PLC-5 Programmable Controllers User Manual. To help you find new and updated information, look for the revision bars as shown to the left of this paragraph. New Information The following table highlights new information and where its located in this manual. The following paragraphs describe software requirements product enhancements. For This New Information See Requested Packet Interval details Chapter 2 ControlNet Unscheduled Data-Transfer Operations Scheduled Connection Types Multicast Inputs Distributed Keeper Functionality Understanding ControlNet System Software Chapter 3 Using the ControlNet I/O Transfer Instruction Chapter 4 CIP Generic and Generic Bi-directional CIO Command Types Using Selectable Timed Interrupts Recovering from Major Fault 200 Using the General Status Indicators Chapter 5 Relay Cartridge Capability Appendix A Processor Status File - Memory Card ID Word 68 Appendix B Hot Backup Major Fault Codes ControlNet I/O Map Entry Status Words Appendix D Error Messages Hot Backup Major Fault Codes Appendix E Software and Hardweare Use the following table to understand specific features that are only available with specific versions and releases of software and PLC-5 Requirements processors: You need both of these And this PLC-5 Processor versions of software: If you want this feature: (ControlNet Series F, Revision A or later) RSLogix5 RSNetWorx: Standard functionality 2.2 or later 1.8 or later all Hot Backup (1771 and Flex I/O) 3.21 or later 1.8 or later PLC-5/40 or -5/80 Multicast Outputs 3.21 or later 3.0 or later PLC-5/20, -5/40 or -5/80 SLC I/O (also with Hot Backup) 5.0 or later 3.0 or later PLC-5/40 or -5/80 1785-UM022B-EN-P - February 2002 soc-ii Notes 1785-UM022B-EN-P - February 2002 Table of Contents Installing Your ControlNet Chapter 1 PLC-5 Processor Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Identifying ControlNet PLC-5 Processor Components . . . . . . . . . . . . . 1-3 Before You Install the Programmable Controller . . . . . . . . . . . . . . . . . 1-5 Install or Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Setting the I/O Chassis Backplane Switches. . . . . . . . . . . . . . . . . . . . 1-9 Setting the I/O Chassis Configuration Plug . . . . . . . . . . . . . . . . . . . . 1-10 Installing Keying Bands for the Processor. . . . . . . . . . . . . . . . . . . . . 1-10 Selecting the DH+ Station Address of Channel 1A . . . . . . . . . . . . . . 1-11 Specifying the Serial Interface of Channel 0. . . . . . . . . . . . . . . . . . . 1-12 Selecting the ControlNet Network Address of Channel 2 . . . . . . . . . 1-12 Inserting/Removing the Processor into/from the I/O Chassis. . . . . . . 1-13 Installing a Remote I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Installing a DH+ Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Connecting to a ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Connecting a Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . 1-19 DH+ Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Serial Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 ControlNet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Selecting Appropriate Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Serial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 DH+ Programming Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Remote I/O Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 ControlNet Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Planning to Use Your ControlNet Chapter 2 PLC-5 Processor Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Understanding ControlNet I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Scheduled Data-Transfer Operations on a ControlNet Network. . . . 2-2 Unscheduled Data-Transfer Operations on a ControlNet Network . . 2-4 Using I/O Forcing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Using Immediate Data-Transfer Operations . . . . . . . . . . . . . . . . . . 2-8 Using Process Control Sample Complete . . . . . . . . . . . . . . . . . . . . 2-9 Clearing the PCSC New Data and PCSC Overflow Bits. . . . . . . . 2-11 Considerations When Using PCSC. . . . . . . . . . . . . . . . . . . . . . . 2-11 Understanding Scheduled Connection Types . . . . . . . . . . . . . . . . . . 2-11 Allowable Scheduled Connection Type Combinations . . . . . . . . . . 2-12 Multiple Processors Can Control I/O . . . . . . . . . . . . . . . . . . . . . 2-13 1785-UM022B-EN-P - February 2002 ii Table of Contents – ControlNet PLC-5 Programmable Controllers Understanding Multicast Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Understanding Multicast Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Using Multicast Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Understanding ControlNet I/O Mapping . . . . . . . . . . . . . . . . . . . . . . 2-16 Reserving Space for Non-ControlNet I/O. . . . . . . . . . . . . . . . . . . . 2-16 Processor-Resident Local I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Remote I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Supported ControlNet I/O Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Discrete I/O Data Transfer Mapping . . . . . . . . . . . . . . . . . . . . . 2-19 Non-Discrete I/O Data Transfer Mapping . . . . . . . . . . . . . . . . . 2-19 1771 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 1747 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 1794 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Other ControlNet Processors . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Using I/O Mapping Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Understanding Discrete Mapping . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Optimizing the I/O Image Table . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Optimizing the I/O Image Table without Slot Complementary . . 2-23 Optimizing the I/O Image Table with Slot Complementary. . . . . 2-27 Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Using the ControlNet PLC-5 Processor in a ControlNet I/O System . . 2-31 Distributed Keeper Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Converting from a Non-ControlNet Remote I/O System to a ControlNet I/O System . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Converting from ControlNet Phase 1.0 or 1.25 to ControlNet Phase 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Understanding the ControlNet Chapter 3 Configuring and Programming Your ControlNet System . . . . . . . . . . . 3-1 System Software Using ControlNet Message Instructions . . . . . . . . . . . . . . . . . . . . . . . 3-1 I/O Configuration Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Uploading and Downloading Software Projects. . . . . . . . . . . . . . . . 3-3 Using RSNetWorx to Perform Verification Activities. . . . . . . . . . . . . 3-4 For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 1785-UM022B-EN-P - February 2002 Table of Contents – ControlNet PLC-5 Programmable Controllers iii Programming Your Chapter 4 ControlNet System Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Using ControlNet Message Instructions . . . . . . . . . . . . . . . . . . . . . . . 4-1 Multihop Messaging Via the MSG Instruction . . . . . . . . . . . . . . . . . 4-2 Option to Close Communication Connection when MSG is Done. . . 4-3 Understanding the ControlNet PLC-2 Compatibility File . . . . . . . . . 4-3 Using the ControlNet I/O Transfer Instruction . . . . . . . . . . . . . . . . . . . 4-3 Sending Continuous Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 1771 ControlNet Transfers in PIIs and STIs. . . . . . . . . . . . . . . . . . . 4-5 Using ControlNet Immediate Data Input and Output Instructions. . . . . 4-6 Using Selectable Timed Interrupts with a Program on a ControlNet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Recovering from Major Fault 200 and 201 . . . . . . . . . . . . . . . . . . . . . 4-9 Monitoring and Troubleshooting Chapter 5 Your ControlNet System Using This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Using the General Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Using the ControlNet Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Using the DH+/RIO Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Monitoring ControlNet Configuration and Status. . . . . . . . . . . . . . . . . 5-6 Processor Specifications Appendix A Processor Status File Appendix B S:0 - S:2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 S:3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 S:11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 S:12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 S:13-S:24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11 S:26-S:35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12 S:36-S:78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13 S:79-S127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15 ControlNet Instruction Set Appendix C ControlNet I/O Transfer Instruction . . . . . . . . . . . . . . . . . . . . . . . . C-1 Message Instructions on a ControlNet Network . . . . . . . . . . . . . . . C-1 Immediate Data I/O Instructions . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Instruction Timing and Memory Requirements . . . . . . . . . . . . . . . . . . C-2 1785-UM022B-EN-P - February 2002 iv Table of Contents – ControlNet PLC-5 Programmable Controllers ControlNet I/O Map-Entry Appendix D Status Words and I/O Map-Entry Status Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 Error Messages Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Fault Codes Appendix E Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Additional Major Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 ControlNet Diagnostics Appendix F File Layout 1785-UM022B-EN-P - February 2002 Preface Preface Introduction This manual describes how to install your programmable controller and how to plan for, configure, and use the features of a 1785-L20C15, 1785-L40C15, 1785-L46C15 or 1785-L80C15 ™ programmable controller that are unique to the ControlNet network. When we refer to ControlNet PLC-5 programmable controllers (or “processors”) in this manual, we mean the phase 1.5 programmable controllers: ™ • Catalog number 1785-L20C15 (or PLC-5/20C ) ™ • Catalog number 1785-L40C15 (or PLC-5/40C ) ™ • Catalog number 1785-L46C15 (or PLC-5/46C ) ™ • Catalog number 1785-L80C15 (or PLC-5/80C ) For detailed information about features that the ControlNet PLC-5 processors share with Ethernet and Enhanced processors, see the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12. Audience The information in this manual is intended for engineers and technicians who are installing, programming, and maintaining a control system that includes a ControlNet PLC-5 programmable controller. You should have a background in control-system applications and a basic knowledge of: • programmable real-time control systems ® •the PLC-5 control system • your operation’s required systems and applications Contents If you want to read about: Go to: Installing your ControlNet PLC-5 processor Chapter 1 Setting switches Installing communication links Planning to use your ControlNet PLC-5 processor Chapter 2 Understanding ControlNet I/O Using a ControlNet PLC-5 processor Understanding the programming software used to configure your ControlNet Chapter 3 system Programming your ControlNet system Chapter 4 1785-UM022B-EN-P - February 2002 P-2 Preface If you want to read about: Go to: Monitoring and troubleshooting your ControlNet system Chapter 5 Using the status indicators Processor specifications Appendix A Processor status file Appendix B ControlNet instructions Appendix C ControlNet I/O map table entry status words and error messages Appendix D Fault codes Appendix E ControlNet diagnostics file layout Appendix F Terminology Term Description Actual Packet Interval (API) the actual time it takes for the ControlNet network to update the requested data. The largest binary multiple of the Network Update Time (NUT), smaller or equal to the Requested Packet Interval (RPI). For more information, see page 2-2. ControlNet network communication architecture that allows the exchange of data between Allen-Bradley Company, Inc. products and certified third-party products ControlNet PLC-5 processors references PLC-5/20C, -5/40C, -5/46C and -5/80C programmable controllers phase 1.5 connection opened communication path between two nodes on a ControlNet network DData Input File (DIF) integer file used by ControlNet PLC-5 processors to store discrete and non-discrete input data. The DIF cannot be forced Data Output File (DOF) integer file used by ControlNet PLC-5 processors to store discrete and non-discrete output data. The DOF cannot be forced discrete I/O data transfer type of data transfer in which single units of I/O have discrete relationships with values in the processor’s data table; uses the processor’s input- and output-image tables (I and O files); configured on a per-node basis in the ControlNet I/O map table frame single data transfer on a ControlNet link drop cable cable that connects a ControlNet node to the trunk cable; integral part of 1786 taps I/O map table table that you configure using the programming software to map data from an I/O chassis and other devices on the ControlNet network to particular data table file addresses (scanlist configuration) keeper device that stores and distributes ControlNet configuration data to all nodes on the network. A minimum of one keeper device is required on each ControlNet network. link collection of ControlNet nodes with unique network addresses in the range of 01-99; segments connected by repeaters make up a link; links connected by bridges make up a network map table entry one entry in the I/O map table that you configure using the programming software to map data from one I/O chassis or other device on ControlNet to particular data table file (scanlist entry) addresses network access port (NAP) port that provides a temporary ControlNet-network connection through an RJ-45 connector network address node’s address on the ControlNet network network update interval (NUI) single occurrence of the ControlNet Network Update Time (NUT) 1785-UM022B-EN-P - February 2002 Preface P-3 Term Description network update time (NUT) smallest repetitive time interval in which data can be sent on the ControlNet network node port of a physical device connecting to the ControlNet network that requires a network address in order to function on the network; a link may contain a maximum of 99 nodes non-discrete I/O data transfer type of data transfer in which blocks of data transferred to or from a single I/O module use integer input and output data table files that you specify; scheduled transfers are configured in the ControlNet I/O map table, unscheduled transfers make use of ControlNet I/O Transfer (CIO) instructions owner device that controls the outputs of an adapter processor any one of the ConrolNet PLC-5 programmable controllers redundant media dual-cable system that allows you to receive the best signal over a ControlNet network repeater two-port active physical-layer device that reconstructs and retransmits all traffic that it hears on one ControlNet segment to another segment Requested Packet Interval the maximum time allowed for the ControlNet network to update requested data. The RPI is (RPI) user-selectable on a per connection basis. For more information, see page 2-2. scheduled maximum node the maximum ControlNet node number that can transmit and receive scheduled data (SMAX) scheduled transfers deterministic and repeatable transfers that are continuous and asynchronous to the ladder- logic program scan scheduled connection types rack connection - scheduled connection made from the PLC-5C to I/O adapters to some or all of the discrete I/O on the adapter module connection - scheduled connection made from the PLC-5C to I/O adapters to individual modules segment trunkline section of ControlNet network with terminators at each end; a segment does not include repeaters; segments connected by repeaters make up a link tap component that connects products to the ControlNet trunk cable; a tap is required for each node and for each side of a repeater terminator 75W resistor—mounted in a BNC plug—placed on each end of a ControlNet segment to prevent reflections from occurring at the ends of the cable trunk cable bus or central part of the ControlNet cable system trunk-cable section length of trunk cable between any two ControlNet taps unscheduled maximum node the maximum ControlNet node number that can transmit and receive unscheduled data (UMAX) unscheduled transfers non-deterministic data transfers through ladder-initiated communication or programming devices 1785-UM022B-EN-P - February 2002 P-4 Preface Related PLC-5 Publications The 1785 PLC-5 programmable-controller and ControlNet documentation is organized into manuals according to the tasks that you perform: Publication Publication Number Enhanced PLC-5 Processor System Overview 1785-2.36 Enhanced and Ethernet PLC-5 Programmable Controllers User 1785-6.5.12 Manual ControlNet PLC-5 Programmable Controllers User Manual 1785-UM022B-EN-P ControlNet Cable System Planning and Installation Manual 1785-6.2.1 ControlNet PLC-5 Programmable Controllers Quick Start 1785-10.6 1785-PLC-5 Programmable Controllers Quick Reference 1785-7.1 For more information about 1785 PLC-5 programmable controllers, contact your local Rockwell Automation sales office or distributor. To view or order these publications online, visit: www.theautomationbookstore.com Related ControlNet Publications For detailed information about different aspects of planning and installing your ControlNet network, see the following publications: Publication Publication Number ControlNet Cable System Component List AG-2.2 ControlNet Coax Cable System Planning and Installation Manual 1786-6.2.1 ControlNet Network Access Cable Installation Instructions 1786-2.6 ControlNet System Overview 1786-SO001A-EN-P ControlNet PLC-5 Hot Backup System User Manual 1785-6.5.24 ControlNet Fiber Planning Installation Guide CNET-IN001A-EN-P Industrial Automation Wiring and Grounding Guidelines 1770-4.1 System Design for Control of Electrical Noise GMC-RM001A-EN-P To view or order these publications online, visit: www.theautomationbookstore.com or contact your local Rockwell Automation sales office or distributor. 1785-UM022B-EN-P - February 2002 Chapter 1 Installing Your ControlNet PLC-5 Processor Using This Chapter If you want to read about: Go to page: Preventing Electrostatic Discharge 1-2 Identifying the processor components 1-3 What to do before you begin installation 1-5 Installing and disposing of the processor battery 1-6 Setting the I/O chassis backplane switches 1-11 Setting the I/O chassis configuration plug 1-10 Installing keying bands for the processor 1-10 Selecting the Data Highway Plus™ (DH+™) station address 1-11 of Channel 1A Specifying the serial interface for Channel 0 1-12 Selecting the ControlNet network address of Channel 2 1-12 Inserting/removing the processor into/from the I/O chassis 1-13 Installing a remote I/O link 1-13 Installing a DH+ link 1-15 Connecting to a ControlNet network 1-17 Connecting a programming terminal 1-19 Selecting appropriate cables 1-22 For detailed information about installing chassis and adapters, see the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12. 1785-UM022B-EN-P - February 2002 1-2 Installing Your ControlNet PLC-5 Processor Prevent Electrostatic Discharge This equipment is sensitive to electrostatic discharge ATTENTION which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • touch a grounded object to discharge potential ! static • wear an approved grounding wrist strap • do not touch connectors or pins on component boards • do not touch circuit components inside the equipment • if available, use a static-safe workstation • when not in use, store the equipment in appropriate static-safe packaging 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-3 Identifying ControlNet PLC-5 Figure 1.1 and Figure 1.2 show the front panels of the ControlNet PLC-5 processors. Processor Components Figure 1.1 PLC-5/20C Processor Front Panel Battery Status Indicator (Red) Keyswitch-selects processor mode Processor RUN/FAULT Status Indicator ControlNet I/O Status Indicator (Green/Red) (Green/Red) Force Status Indicator Channel 2 ControlNet Status Indicators (Amber) (Green/Red) Channel 0 Communication ACTIVE/ ControlNet Network Access Port FAULT Status Indicator (NAP)-RJ45 connector (Green/Red) Channel 2 ControlNet Redundant Media Ports BNC; dedicated Memory Module Space Channel 0 Serial Port-25-pin D-shell; supports standard EIA RS-232C and RS-423; is RS-422A compatible 1 Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports processor programming: DF1 point-to-point one stop-bit 2400 bit/s BCC error check no parity no handshaking Channel 1 Status Indicators (Green/Red) Battery Compartment DH+ Programming Terminal Connection to Channel 1A 8-pin mini-DIN, parallel with 3-pin connectors of Channel 1A Channel 1B 3 pin; default is remote I/O scanner; Channel 1A configurable for: 3 pin; dedicated DH+ remote I/O scanner remote I/O adapter DH+ communication unused 1 Channel 0 is optically coupled (provides high electrical noise immunity) and can be used with most RS-422A equipment as long as: termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements 1785-UM022B-EN-P - February 2002 1-4 Installing Your ControlNet PLC-5 Processor Figure 1.2 PLC-5/40C, -5/46C, and -5/80C Processors Front Panel Battery Status Indicator (Red) Keyswitch-selects processor mode Processor RUN/FAULT Status Indicator (Green/Red) ControlNet I/O Status Indicator (Green/Red) Force Status Indicator (Amber) Channel 2 ControlNet Status Indicators (Green/Red) Channel 0 Communication ACTIVE/FAULT Status Indicator ControlNet Network Access Port (Green/Red) (NAP)-RJ45 connector Channel 2 ControlNet Redundant Media Ports* Channel 0 Serial Port-25-pin D-shell; supports standard EIA BNC; dedicated RS-232C and RS-423; is RS-422A compatible 1 Use this port with ASCII or DF1 full-duplex, half-duplex master, and half-duplex slave protocols. The port's default configuration supports Channel 1 Status Indicators (Green/Red) processor programming: DH+ Programming Terminal Connection DF1 point-to-point one stop-bit to Channel 1A 2400 bps BCC error check 8-pin mini-DIN, parallel with 3-pin connectors no parity no handshaking of Channel 1A; use only when Channel 1A is configured for DH+ communications Memory Module Space Channel 1A 3 pin; default is DH+; configurable for: remote I/O scanner remote I/O adapter DH+ communication unused Battery Compartment Channel 1B 3 pin; default is remote I/O scanner; configurable for: remote I/O scanner remote I/O adapter DH+ communication Channel 0 is optically coupled (provides high 1 unused electrical noise immunity) and can be used with most RS-422A equipment as long as: termination resistors are not used the distance and transmission rate are reduced to comply with RS-423 requirements 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-5 Before You Install the Before installing your ControlNet PLC-5 processor: Programmable Controller 1. Check your processor package, and make sure that you have the following: ® ControlNet PLC-5 Programmable Controller, Processor 1785-L20C15, -L40C15, -L46C15, or -L80C15 Contents of Tray 1 Lithium Battery, 1770-XYC 1 DIN connector cover 1 4 Terminating resistors—150Ω 2 3 2 or 4 Terminating resistors—82Ω 2 2 or 4 3-pin connectors 2Keys 1 Battery cover with screw 1 1784-CP7 cable adapter for 1784-CP, -CP5 cables ControlNet PLC-5 Programmable Controllers Quick Documentation Start, publication number 1785-10.6 1 Identified by four colored bands: brown, green, brown, and gold 2 Two with a PLC-5/20C processor, four with PLC-5/40C, -5/46C and -5/80C processors 3 Identified by four colored bands: gray, red, black, and gold If any items are missing or incorrect, contact your local Rockwell Automation sales office or distributor. 2. Install and connect a chassis and power supply. Use the following table to find more information about completing these tasks: Chassis Type Chassis Document Power Supply Power Supply Document 1771-A1B, -A2B, -A3B, - A3B1, -A4B 1771-2.210 1771-P1 1771-2.6 1771-P2 1771-2.7 1771-P3 1771-2.111 1771-P4 1771-2.111 1771-P4R 1771-5.3 1771-P4S 1771-2.13 1771-P5 1771-2.111 1771-P6R 1771-5.3 1771-P6S 1771-5.11 1771-P7 1771-5.56 1785-UM022B-EN-P - February 2002 1-6 Installing Your ControlNet PLC-5 Processor Install or Replace the Battery A 3.0 volt lithium battery (cat. no. 1770-XYC) is included with your processor. If the LED on the front of the processor indicates BATT, it means that the battery must be replaced. You must use an exact replacement battery (cat. no. 1770-XYC). Lithium battery requirements: ATTENTION • do not short, recharge, heat above 85° C, disassemble or expose contents to water • use only the 1770-XYC battery in the processor. DO NOT use any other type or size of battery. ! Important: In non-hazardous environments, it may be possible to replace the battery while the processor is powered so that your programs are maintained in memory. You may lose your programs if you remove the battery when power is removed. When you connect or disconnect the battery, an WARNING electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. ! • For safety information on the handling of lithium batteries, including handling and disposal of leaking batteries, refer to Guidelines for Handling Lithium Batteries, publication AG-5.4 • Store batteries in a cool, dry environment. We recommend 25° C with 40% or 60% relative humidity. You may store batteries up to 30 days between -45° - 85° C, such as during transportation. To avoid possible leakage, do not store batteries above 60° C for more than 30 days. 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-7 To install or replace the battery: 1. Remove the battery from the shipping bag. 2. Remove the battery cover from the processor. 3. If you are replacing an existing battery, detach the wired clip from the mating connector on the processor and remove the battery. 4. Connect the new or replacement battery by attaching the wired clip to the mating connector on the processor. 5. Place the battery and tuck the wires inside the battery area on the processor. 6. Replace the battery cover. 7. Use a pencil or erasable pen to write the battery installation date on the battery cover. When you connect or disconnect the battery, an WARNING electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. ! • For safety information on the handling of lithium batteries, including handling and disposal of leaking batteries, refer to Guidelines for Handling Lithium Batteries, publication AG-5.4 • Store batteries in a cool, dry environment. We recommend 25° C with 40% or 60% relative humidity. You may store batteries up to 30 days 5 between -45° - 85° C, such as during transportation. To avoid possible leakage, do not store batteries above 60° C for more than 30 days. 1785-UM022B-EN-P - February 2002 1-8 Installing Your ControlNet PLC-5 Processor Estimated Battery Lifetimes Worst-Case Battery-Life Estimates 1 Processor Temperature Power Off 100% Power Off 50% Battery Duration PLC-5/20C 60° C 173 days 346 days 70 hours 25° C 1.69 years 3.38 years 14.5 days PLC-5/40C 60° C 92.5 days 185 days 38 hours 25° C 1.25 years 2.5 years 10.8 days PLC-5/46C 60° C 92.5 days 185 days 38 hours 25° C 1.25 years 2.5 years 10.8 days PLC-5/80C 60° C 80 days 160 days 33 hours 25° C 1.18 years 2.36 years 10 days 1 The battery status indicator (BATT) warns you when the battery is low. These durations are based on the battery supplying the only power to the processor—power to the chassis is off—once the status indicator first lights. Dispose of a Battery If you need to dispose of a battery, follow the procedures described in Guidelines for Handling Lithium Batteries, (pub. no. AG-5.4). Follow these precautions to prevent the battery from ATTENTION exploding. An exploding battery exposes toxic, corrosive and flammable chemicals and causes burns. • do not incinerate or expose the battery to high temperatures ! • do not solder the battery or leads • do not open, puncture or crush the battery • do not charge the battery • do not short positive or negative terminals together 1785-UM022B-EN-P - February 2002 8 7 6 5 4 3 2 1 O N O F F Installing Your ControlNet PLC-5 Processor 1-9 Setting the I/O Chassis Set the I/O chassis backplane switches using a ball-point pen to set each switch. Backplane Switches Important: Do not use a pencil because the tip can break off and short the switch. Switch Last State 1 Outputs of this I/O chassis remain in their last state when a hardware ON failure occurs. 1 Outputs of this I/O chassis are turned off when a hardware failure occurs. OFF Always OFF Switches Addressing ON 4 5 2- slot OFF OFF OFF 1- slot OFF ON 1/2- slot ON OFF ON ON Not allowed Switches EEPROM Transfer 67 2 3 OFF OFF EEPROM memory transfer to processor memory at powerup. EEPROM memory transfers to processor memory if processor ON ON memory not valid. 4 ON OFF EEPROM memory does not transfer to processor memory. Switch Processor Memory Protection 8 OFF Processor memory protection disabled. 5 ON Processor memory protection enabled. 1 Regardless of this switch setting, outputs are turned off when any of the following occurs: processor detects a runtime error an I/O chassis backplane fault occurs you select Program or Test mode you set a status file bit to reset a local rack If an EEPROM module is not installed and processor memory is valid, the processor©s 2 PROC indicator blinks and the processor sets bit S:11/9 in the major fault status word. To clear this fault, change the processor from Program mode to Run mode and back to Program mode. 3 If the processor©s keyswitch is set in Remote, the processor enters Remote Run mode after it powers up and has its memory updated by the EEPROM module. 4 A processor fault (solid red PROC LED) occurs if processor memory is not valid. 5 You cannot clear processor memory when this switch is on. 19309 1785-UM022B-EN-P - February 2002 ! 1-10 Installing Your ControlNet PLC-5 Processor Setting the I/O Chassis Set the I/O chassis configuration plug as follows: Configuration Plug Y N 1. Locate the chassis configuration plug (between the two left most slots of the chassis). 2. Set the I/O chassis configuration plug. USING A The default setting is N (not using a POWER-SUPPLY power-supply module in the chassis). MODULE IN THE CHASSIS? Y N Y N Important: You cannot power a single I/O chassis with both a power-supply module and an external power supply. Set Y when you install Set N when you a power-supply module use an external in the chassis. power supply. 17075 Installing Keying Bands You receive plastic keying bands with each I/O chassis. Insert the keying bands as follows: for the Processor 2 Install a keying band in the left-most I/O Chassis 4 slot between the following pins: 6 Backplane 8 Connector 10 12 40 and 42 Use these 14 54 and 56 16 numbers 18 20 as a guide. 22 24 26 28 30 32 34 36 38 40 ATTENTION: A module inserted into a wrong slot Keying 42 could be damaged by improper voltages connected 44 Bands 46 through the wiring arm. Use keying bands to prevent 48 (1771-RK) damage to the module. 50 52 54 56 12062 1785-UM022B-EN-P - February 2002 7 6 5 4 3 2 1 Installing Your ControlNet PLC-5 Processor 1-11 Selecting the DH+ Station To select the DH+ station address of Channel 1A, set the switches of assembly SW1. Address of Channel 1A Side View of PLC-5/20C, -5/40C, -5/46C, -5/80C Switch Assembly SW1 Toggle pushed toward TOP To select: Set switch: To: OFF DH+ Station Number 1 through 6 (See below) Toggle pushed toward BOTTOM Channel 1A DH+ Configuration 7 on (bottom) 57.6 kbps ON off (top) 230.4 kbps Switch Switch DH+ DH+ Station Station Number 1 2 3 4 5 6 Number 1 2 3 4 5 6 0 on on on on on on 40 on on on on on off 1 off on on on on on 41 off on on on on off 2 on off on on on on 42 on off on on on off 3 off off on on on on 43 off off on on on off 4 on on off on on on 44 on on off on on off 5 off on off on on on 45 off on off on on off 6 on off off on on on 46 on off off on on off 7 off off off on on on 47 off off off on on off 10 on on on off on on 50 on on on off on off 11 off on on off on on 51 off on on off on off 12 on off on off on on 52 on off on off on off 13 off off on off on on 53 off off on off on off 14 on on off off on on 54 on on off off on off 15 off on off off on on 55 off on off off on off 16 on off off off on on 56 on off off off on off 17 off off off off on on 57 off off off off on off 20 on on on on off on 60 on on on on off off 21 off on on on off on 61 off on on on off off 22 on off on on off on 62 on off on on off off 23 off off on on off on 63 off off on on off off 24 on on off on off on 64 on on off on off off 25 off on off on off on 65 off on off on off off 26 on off off on off on 66 on off off on off off 27 off off off on off on 67 off off off on off off 30 on on on off off on 70 on on on off off off 31 off on on off off on 71 off on on off off off 32 on off on off off on 72 on off on off off off 33 off off on off off on 73 off off on off off off 34 on on off off off on 74 on on off off off off 35 off on off off off on 75 off on off off off off 36 on off off off off on 76 on off off off off off 37 off off off off off on 77 off off off off off off 1785-UM022B-EN-P - February 2002 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 1-12 Installing Your ControlNet PLC-5 Processor Specifying the Serial Specify RS-232C, RS-422A, or RS-423 communication for Channel 0 by setting the switches of assembly SW2. Interface of Channel 0 Bottom View of PLC-5/40C, -5/46C, -5/80C Processor Bottom View of PLC-5/20C Processor Switch Assembly SW2 Switch Assembly SW2 Front of processor Front of processor Set Switches: To Specify: 1 2 3 4 5 6 7 8 9 10 OFF OFF OFF OFF ON ON ON ON ON ON Toggle pushed RS-232C toward TOP OFF Toggle pushed OFF OFF OFF OFF OFF OFF OFF OFF ON ON toward BOTTOM RS-422A ON OFF OFF OFF OFF OFF ON ON ON ON ON RS-423 Selecting the ControlNet Select your processor’s ControlNet network address by setting the two 10-digit rotary switches on the top of the processor. Network Address of Channel 2 20 30 23 1 10 40 4 Network address 01 00 50 0 5 is shown 90 60 9 6 8 7 80 70 NET ADDRESS You can select from as many as 99 network addresses (from 01 to 99) For optimum throughput, assign addresses to your ControlNet nodes in a sequential for a processor on a ControlNet link. 0 is invalid. order starting with 01. Important: Do not power-up the processor if the processor’s ControlNet network address is set to 0. If you do, you will not be able to communicate with your processor and your ladder program will be lost, even if you have a battery installed. If this happens, select a valid network address for the processor and cycle power. 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-13 Inserting/Removing the Processor To insert/remove the processor into/from the chassis, do the following: into/from the I/O Chassis If you insert or remove the processor while WARNING backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. ! To insert a processor into the chassis: Locking Bar 1. Lift the locking bar and the ejector tab. 2. Slide the processor into the left-most slot of the Ejector I/O chassis. Tab 3. Press down on the ejector tab, and then close the locking bar over the processor. To remove a processor from the chassis: 1. Save processor memory. 2. Remove power to the processor-resident chassis. 3. Disconnect all cables from the processor©s ports. 4. Lift the locking bar and the ejector tab, and then Card Guides slide the processor from the chassis. Installing a Remote Install a remote I/O link using 1770-CD cable and either a daisy-chain or trunk-cable/drop-cable configuration. I/O Link Verify that your system’s design plans specify cable lengths within Trunk-cable/drop-cable considerations: allowable measurements. When using a trunk-cable/drop-cable configuration, use 1770-SC station connectors Important: The maximum cable length for remote I/O depends on and follow these cable-length guidelines: the transmission rate. Configure all devices on a remote • trunk-cable length—depends on the communication rate of the link; see Table I/O link to communicate at the same rate. Table 1.A • drop-cable length—30.4 m Table 1.A Correct Cable Length Based on Communication Rate (100 cable-ft) maximum Important: When using a trunk-cable/ A remote I/O link using this Cannot exceed this cable length: drop-cable configuration, set your communication rate: communication rate to 57.6K bit/s. 57.6K bit/s 3,048 m (approximately 10,000 ft) 115.2K bit/s 1,524 m (approximately 5,000 ft) 230.4K bit/s 762 m (approximately 2,500 ft) For more information about designing trunk-cable/drop-cable configurations, see the For proper operation, terminate both ends of a remote I/O link by Data Highway/Data Highway Plus/Data Highway II/Data Highway 485 Cable Installation Manual, using the external resistors shipped with the programmable controller. publication 1770-6.2.2. Use either a 150Ω or 82Ω terminator. 1785-UM022B-EN-P - February 2002 MORE 1-14 Installing Your ControlNet PLC-5 Processor The maximum number of logical rack Use this physical devices numbers that you resistor that you can connect can scan on the If your remote I/O link: rating: on the link is: link is: Operates at 230.4K bit/s Operates at 57.6K or 115.2K bit/s, and no devices listed below are linked Scanners 1771-SN; 1772-SD, -SD2; 1775-SR, -S4A, -S4B; 82Ω 32 16 6008-SQH1, -SQH2 Adapters 1771-AS; 1771-ASB (Series A Only); 1771-DCM Miscellaneous 1771-AF Connects to any device listed below: Scanners 1771-SN; 1772-SD, -SD2; 1775-SR, -S4A, -S4B; 6008-SQH1, -SQH2 150Ω 16 16 Adapters 1771-AS; 1771-ASB (Series A Only); 1771-DCM Miscellaneous 1771-AF Operates at 57.6K or 115.2K bit/s, and you do not require over 16 physical devices You can install a remote I/O link two ways: - trunk cable/drop cable--from the drop cable to the connector screw terminals on the remote I/O connectors of the processor - daisy chain--to the connector screw terminals on the remote I/O connectors of the processor and then to the remote I/O screw terminals of the next remote I/O device To connect remote I/O cable, use the Phoenix MTSB2.5/3-ST 3-pin header connector provided in the accessory kit. 1. Run the 1770-CD cable from the processor to each remote I/O adapter module or processor in the remote I/O system. 2. Connect the signal conductor with blue insulation to the 3-pin connector terminal labeled 1 on the processor and to each remote I/O adapter module (or PLC-5 adapter) in the remote I/O system. 3. Connect the shield drain wire to the center terminal of the 3-pin connector. 4. Connect the signal conductor with clear insulation to the 3-pin connector terminal labeled 2. 5. Tie-wrap the remote I/O network cable to PLC-5/40C, -5/46C, PLC-5/20C the chassis to relieve strain on the cable. -5/80C Processor Processor 6. Terminate the remote I/O link by connecting an external terminator resistor between the remote I/O terminals labeled 1 and 2. Blue Blue 82W or Shield Shield 150W 1770-CD Clear Clear resistor To another I/O link device 1770-CD Terminate both ends of a remote I/O link 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-15 If you connect or disconnect the 1770-CD cable with WARNING power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! Installing a DH+ Link Use 1770-CD cable to connect the processor to a DH+ link. Follow these guidelines while installing DH+ communication links: • do not exceed these cable lengths: – trunk-cable length—3,048 m (approximately 10,000 cable-ft) – drop-cable length—30.4 m (approximately 100 cable-ft) • do not connect more than 64 stations on a single DH+ link 1785-UM022B-EN-P - February 2002 1-16 Installing Your ControlNet PLC-5 Processor Use the 3-pin connector on the processor to connect a DH+ link. The connector’s port must be configured to support a DH+ communication link. You can install a DH+ link two ways: - trunk cable/drop cable--from the drop cable to the connector screw terminals on the DH+ connectors of the processor. - daisy chain--to the connector screw terminals on the DH+ connectors of the processor. To make connections, use the Phoenix connector MTSB2.5/3-ST 3-pin header connector provided in the accessory kit. 1. Connect the signal conductor with clear insulation to the 3-pin connector terminal 1 at each end of each cable segment. PLC-520C PLC-5/40C, -5/46C processor or -5/80C processor 2. Connect the shield drain wire to the center terminal of the 3-pin connector at both ends of each cable segment. 3. Connect the signal conductor with blue insulation to the 3-pin connector terminal 2 at each end of each cable segment. Clear Clear Shield Shield Blue Blue 82W or 150W resistor 82W or 150W resistor If you connect or disconnect the 1770-CD cable with WARNING power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-17 Connecting to a Connect a ControlNet PLC-5 processor to a ControlNet network via a tap with a 1-m (39.4-in) drop cable. ControlNet Network If you connect or disconnect the ControlNet tap cable WARNING with power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! Four taps are available from Rockwell Automation: Straight T-tap Straight Y-tap Right-angle T-tap Right-angle Y-tap 1786-TPYS 1786-TPR 1786-TPYR 1786-TPS Important: ControlNet taps contain passive electronics and must be purchased from Rockwell Automation for the network to function properly. After terminating your segments, you connect your node to the network. Remove the tap’s dust cap – located on the straight or right-angle connector – and set it aside. BATT If your Connect the tap’s straight or network supports: right-angle connector: Redundant Media Nonredundant Media nonredundant media to the channel A connector on the CH 0 CH 0 1 A A processor – channel B is not used redundant media • from trunk-cable A to channel A B on the processor and •from trunk-cable B to channel B on the processor 1 Rockwell Automation recommends using channel A for nonredundant media. 1785-UM022B-EN-P - February 2002 1-18 Installing Your ControlNet PLC-5 Processor For detailed information about planning and installing your ControlNet system, see the following publications: Publication Publication Number ControlNet Cable System Component List AG-2.2 ControlNet Cable System Planning and Installation Manual 1786-6.2.1 ControlNet Network Access Cable Installation Instructions 1786-2.6 ControlNet Fiber Planning and Installation Guide CNET-IN001A-EN-P System Design for Control of Electrical Noise GMC-RM001A-EN-P Industrial Automation Wiring and Grounding Guidelines 1770-4.1 Terminating Your ControlNet Coaxial Cables CD-ROM CNET-DM001A-EN-C To view or order these publications online, visit: www.theautomationbookstore.com 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-19 Connecting a You can connect a programming terminal to a ControlNet PLC-5 processor via a: Programming Terminal • DH+ connection • serial channel • ControlNet connection When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! If you connect or disconnect the DH+ cable with WARNING power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. DH+ Connection To attach a personal computer to a ControlNet PLC-5 processor using a DH+ connection: CH 0 8-pin mini-DIN connector 8-pin mini-DIN connector Personal computer Personal computer PLC-5/40C, -5/46C, PLC-5/20C Processor -5/80C Processor DH+ Link DH+ Link 1785-UM022B-EN-P - February 2002 1-20 Installing Your ControlNet PLC-5 Processor When using this Use this cable: communication card: 1784-KTX, KTXD • 1784-CP13 1784-PCMK • 1784-PCM6 • 1784-PCM5 with 1784-CP7 adapter 1784-PKTX, -PKTXD • 1784-CP13 Serial Channel To program the processor using Channel 0, configure the channel for RS-232C using DF1 point-to-point protocol. If your personal computer has a 9-pin serial port, use the 1784-CP10 cable. If your personal computer has a 25-pin serial port, use the 1784-CP11 cable. Personal computer Personal computer PLC-5/20C PLC-5/40C, -5/46C Processor or -5/80 C Processor If you connect or disconnect the serial cable with WARNING power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-21 ControlNet Connection ATTENTION: Do not connect the same You can connect programming devices to a ControlNet network ! communication card to both the NAP and a tap on the ControlNet network. through: • the ControlNet network access cable (1786-CP) • the ControlNet 1784-PCC1 cable • a tap on a ControlNet network Examples of ControlNet Connection Types Personal computer with 1784-KTCX15 card Personal computer Personal computer or Laptop computer with (ISA-based) and with PCIC card (PCI-based) other serial device 1784-PCC card (PCMCIA-based) your HMI or and your HMI and your HMI or and your HMI or programming software or programming software programming software programming software PLC-5/40C 1784-PCC1 to PLC-5 (NAP port or any other NAP port)* Serial connection 1770-KFC15 Tap (4 choices) Interface 1786-TPR Remote I/O link Tap (4 choices) Data Highway Plus link 1786-TPR ControlNet Network** PLC-5/40C 1794-ACNR15 Flex I/O Adapter 1747-ACNR15 Adapter 1771-ACNR15 Adapter *A programming terminal connected through this cable is counted as a node and must have a unique address. **Redundant media not required. Important: Use the 1786-CP cable when connecting a programming terminal to the network through a NAP. Using a commercially available RJ-style cable could result in network failure. If you connect or disconnect the ControlNet cable WARNING with power applied to this processor or the device on the other end of the cable, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the ! area is nonhazardous before proceeding. 1785-UM022B-EN-P - February 2002 1-22 Installing Your ControlNet PLC-5 Processor When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! Selecting Appropriate Cables This section lists information about: • serial cables • DH+ programming cables • remote I/O cables • ControlNet cables For more information about cables, see the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12. Serial Cables You can make your own serial cables or purchase them from Rockwell Automation. The side label of the processor shows the following table, which lists Channel 0 (serial port) pin assignments. Pin RS-232C RS-422A RS-423 Pin RS-232C RS-422A RS-423 1 C.GND C.GND C.GND 14 NOT USED - SEND COM TXD.OUT + 2 TXD.OUT TXD.OUT 15 TXD.OUT + 3 RXD.IN RXD.IN 16 NOT USED - REC COM RXD.IN RXD.IN + 4 RTS.OUT RTS.OUT 17 RTS.OUT + 5 CTS.IN CTS.IN 18 CTS.IN + 6 DSR.IN DSR.IN 19 NOT USED - NOT USED DSR.IN RTS.OUT + 7 SIG.GND SIG.GND SIG.GND 20 DTR.OUT DTR.OUT DTR.OUT + 8 DCD.IN DCD.IN 21 DCD.IN 9 22 NOT USED - NOT USED DSR.IN - - 10 NOT USED NOT USED 23 NOT USED NOT USED DCD.IN DTR.OUT 11 24 12 25 13 NOT USED - NOT USED CTS.IN The shading indicates that the pin is reserved. 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-23 This processor’s serial port can support these configurations: Digital Interface Maximum Cable Length RS-232C 15 m (approximately 50 ft) RS-422A (compatible) 61 m (approximately 200 ft) RS-423 61 m (approximately 200 ft) Important: Follow these guidelines: • When Channel 0 is configured for RS-422A compatibility, do not use terminating resistors anywhere on the link. • When Channel 0 is configured for RS-422A (compatible) and RS-423, do not go beyond 61 m (approximately 200 ft). This distance restriction is independent of the transmission rate. DH+ Programming Cables When using this Use this cable: communication card: 1784-KTX, KTXD • 1784-CP13 1784-PCMK • 1784-PCM6 • 1784-PCM5 with 1784-CP7 adapter 1784-PKTX, -PKTXD • 1784-CP13 Remote I/O Cables Use 1770-CD or cable for remote I/O. See page 1-13 for more information. ControlNet Cables Several types of RG-6 quad-shield cable may be appropriate for your ControlNet installation—depending on the environmental factors associated with your application and installation site. 1785-UM022B-EN-P - February 2002 1-24 Installing Your ControlNet PLC-5 Processor The following ControlNet cable system components are available from the Rockwell Automation: 1 Cat. No. Item ControlNet Coax Tool Kit 1786-CTK Coax Tap Kit Right-angle T-tap 1786-TPR Straight T-tap 1786-TPS Right-angle Y-tap 1786-TPYR Straight Y-tap 1786-TPYS Repeaters Repeater adapter 1786-RPA Copper 1786-RPCD Fiber -short 1786-RPFS Fiber - medium 1786-RPFM 2 Fiber ring - long 1786-RPFRL 2 Fiber ring - extra long 1786-RPFRXL Dummy load 1786-TCAP Fiberoptic Repeaters Low-voltage dc 1786-RPA RG-6 Quad Shield Cable Standard-PVC CM-CL2 1786-RG6 ControlNet Network Access Cable—3.05 m (10 ft) 1786-CP PC Card Cable for 1784-PCC 1784-PCC1 BNC Connectors Barrel (plug to plug) 1786-BNCP BNC/RG-6 plug 1786-BNC Bullet (jack to jack) 1786-BNCJ Isolated-bulkhead (jack to 1786-BNCJI jack) Terminators (BNC-75Ω) 1786-XT 1 For a complete list of ControlNet cable system components that are available from Rockwell Automation and other sources, see the ControlNet Cable System Component List, publication AG-2.2. 2 Planned availability - March 2002. Important: Install all wiring for your ControlNet system in accordance with the regulations contained in the National Electric Code (or applicable country codes), state codes, and applicable municipal codes. 1785-UM022B-EN-P - February 2002 Installing Your ControlNet PLC-5 Processor 1-25 For detailed information about ControlNet cabling, see the following publications: Publication Publication Number ControlNet Cable System Component List AG-2.2 ControlNet Cable System Planning and Installation Manual 1786-6.2.1 ControlNet Network Access Cable Installation Instructions 1786-2.6 ControlNet System Overview 1786-2.9 ControlNet Fiber Planning and Installation Guide CNET-IN001A-EN-P System Design for Control of Electrical Noise GMC-RM001A-EN-P Industrial Automation Wiring and Grounding Guidelines 1770-4.1 Terminating Your ControlNet Coaxial Cable CNET-DM001A-EN-C 1785-UM022B-EN-P - February 2002 1-26 Installing Your ControlNet PLC-5 Processor Notes 1785-UM022B-EN-P - February 2002 Chapter 2 Planning to Use Your ControlNet PLC-5 Processor Using This Chapter If you want to read about: Go to page: Understanding ControlNet I/O 2-1 Understanding Scheduled Connection Types 2-11 Understanding ControlNet I/O mapping 2-16 Using I/O Mapping Techniques 2-21 Using the ControlNet PLC-5 processor in a ControlNet I/O system 2-31 Converting from a non-ControlNet remote I/O system to a 2-34 ControlNet I/O system Converting from ControlNet phase 1.0 or 1.25 to ControlNet 2-35 phase 1.5 To distinguish phase 1.5 ControlNet processors from earlier phase processors, new catalog numbers were created for each of the phase 1.5 ControlNet processors: 1785-L20C15, 1785-L40C15, L46C15, and 1785-L80C15. You cannot mix phase 1.5 and earlier phase (such as ATTENTION 1.0 and 1.25) products on the same ControlNet network. ! Understanding The ControlNet system is designed to: ControlNet I/O • provide high-speed, repeatable, deterministic I/O transmission • allow control and message information to co-exist on the same physical media • make sure that I/O data transfers are not affected by - programming-terminal message activity - inter-PLC processor message activity on the network 1785-UM022B-EN-P - February 2002 2-2 Planning to Use Your ControlNet PLC-5 Processor Scheduled Data-Transfer Operations on a ControlNet Network ControlNet scheduled data transfer on a ControlNet PLC-5 processor: • is continuous • is asynchronous to the ladder-logic program scan • occurs at the actual rate displayed in the Actual Packet Interval (API) field on the programming software scanlist configuration screen in RSNetWorx for ControlNet Important: The Requested Packet Interval (RPI) rate requested for a connection establishes the data transfer rate on the ControlNet network. API is determined by RSNetWorx when the schedule is built. The API will always be the same or less than the RPI. The API does not imply the actual I/O throughput. I/O data is sent on the network every API regardless of whether the I/O data has been refreshed with newer I/O data. I/O throughput time may be slower due to delays caused by module update times, processor scan times and adapter to I/O module transfer times. What Happens During Scheduled Output Data Transfer Scheduled data transfer Output data is written from a private occurs between the PLC-5 memory buffer on the adapter to the and the adapter module in Data from the output-image file is put into module. The output data stays in the I/O chassis. Data may a private memory buffer. New output data the private memory buffer for as long stay in the private memory may stay in the data table files up to 1 as it takes the I/O chassis backplane buffer for up to 1 API. program scan or until the next housekeeping. update to occur. 1 2 3 Logic Scan In scheduled I/O data In the same manner, transfer, updates occur the I/O adapter has Private Data Private Scheduled Data between logic scans scheduled I/O data Memory Table Data Update Memory Data Update Transfer (i.e. during transfer with I/O Buffers Files Buffers "housekeeping") modules Housekeeping Program Scan I/O Modules Adapter Module PLC-5 Programmable Controller I/O Chassis 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-3 What Happens During Scheduled Input Data Transfer PLC-5 Programmable Controller I/O Chassis Logic Scan In scheduled I/O data In the same manner, transfer, updates occur the I/O adapter has Private Data Private Scheduled Data between logic scans scheduled I/O data Memory Table Data Update Memory Data Update Transfer (i.e. during transfer with I/O Files Buffers Buffers "housekeeping") modules Housekeeping Program Scan I/O Modules Adapter Module 3 2 1 Input data from the private memory buffer is put Scheduled data transfer Input data is written from the I/O module into the input image file. New input data occurs between the PLC-5 to a private memory buffer on the adapter. may stay in the private memory buffer up to 1 and the adapter module in The new input data may stay in program scan or until the next housekeeping. the I/O chassis. Data may the private memory buffer for as long stay in the private memory as it takes to complete the I/O chassis buffer for up to 1 API. backplane update. The frequency of I/O chassis backplane updates depends on the adapter, the type of scheduled data transfer (rack or module connection) and the number of different modules being updated. Actual I/O throughput times must be determined with real products to determine if the I/O throughput times meet the requirements of the application. 1785-UM022B-EN-P - February 2002 2-4 Planning to Use Your ControlNet PLC-5 Processor The following scheduled data-transfer operations are supported by the ControlNet processors on a ControlNet network: Table 2.A ControlNet Scheduled Data-Transfer Operations Operation Description Discrete I/O Data Performed in a deterministic and repeatable manner Transfer (can be done asynchronous to and independent of the ladder-logic as a rack or module program scan. You configure all ControlNet discrete I/O connection) data transfers on a per-node basis in the I/O map table 1 (scanlist configuration). Handled with the same priority as discrete I/O data Non-discrete I/O Data transfer. You can update analog data without using Transfer (can be done block-transfer instructions in ladder programs. You do as a module this by including non-discrete I/O data-transfer connection) configurations in the I/O map table (scanlist configuration). This data is updated in the buffers and data-table files between logic scans in the same 1 manner as that used in discrete I/O data transfer. Peer-to-peer Allows a ControlNet processor to communicate with Communication any other ControlNet processor on the ControlNet network with the same priority as that of the discrete 1 and non-discrete I/O data transfers discussed above. 1 While scheduled data transfer is asynchronous to program scanning, all data is presented synchronously to and from the user data table during housekeeping. Unscheduled Data-Transfer Operations on a ControlNet Network The ControlNet network allows you to use unscheduled messaging when deterministic delivery is not required. Unscheduled operations include: • unscheduled I/O data transfers, or when unscheduled messaging is event-driven—through ControlNet I/O Transfer (CIO) instructions • peer-to-peer messaging—through Message (MSG) instructions • messaging from programming devices • messaging from Human Machine Interface (HMI) devices 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-5 The ControlNet system places your scheduled transfers in the first part of each Network Update Interval (NUI). Time is automatically reserved for network maintenance. Unscheduled transfers are performed during the time remaining in the interval. One occurrence of the NUT is a NUI You reserve a The system specific amount reserves time of time for all for network scheduled maintenance operations Any time remaining is used . . . for unscheduled operations . . . Unscheduled messaging on a ControlNet network is non-deterministic. Your application and your configuration—number of nodes, application program, NUT, amount of scheduled bandwidth used, etc.—determine how much time there is for unscheduled messaging. Important: The ControlNet network reserves time for at least one maximum-sized unscheduled transfer per NUI. Depending on how much time there is for unscheduled messaging, every node may not have a chance to send unscheduled data every NUI. 1785-UM022B-EN-P - February 2002 2-6 Planning to Use Your ControlNet PLC-5 Processor Table 2.B ControlNet Unscheduled Data-Transfer Operations Operation Description Features Perform ladder-initiated unscheduled non-discrete I/O data transfers on • As many as 32 1771 READ and/or 1771 WRITE Non-discrete I/O 1 a ControlNet network by using ControlNet I/O Transfer (CIO) instructions. Data Transfer CIOs can be active at a time The data type for these transfers (CT) has the following information: • Minor fault bit S:17/14 is set when 32 1771 • Command: CIO Instructions READ and/or 1771 WRITE CIOs are active at a 1771 READ reads data from a 1771 non-discrete time I/O module • As many as a total of 8 1794 Flex I/O and 1747 1 1771 WRITE writes data to a 1771 non-discrete SLC I/O CIOs can be active at a time I/O module • Minor fault bit S:17/15 is set when 8 1794 Flex 1794 READ reads data from a 1794 I/O module I/O CIOs are active at a time 1794 WRITE writes data to a 1794 I/O module • Any transfer initiated from a Processor Input 1794 FAULT ACTION changes the action a module takes Interrupt (PII) or Selectable Timed Interrupt (STI) when it faults program suspends execution of the program scan until the transfer is completed 1794 IDLE ACTION changes the action a module takes when it is idle Important: This can extend your program scan by tens of milliseconds. 1794 CONFIG DATA changes a module’s configuration data • No transfer is initiated when the processor is in Program mode 1794 SAFE STATE DATA changes a module’s safe-state data • Transfers that have been running with the.CO CIP GENERIC sends user-specified CIP service bit set automatically restart on the Generic bi-directional sends user-specified CIP service Program-to-Run transition when the Continue which requires reply data Last step bit is set and the data table has not 1747 READ INPUT reads data from SLC I/O module changed input file • A transfer has a maximum size of 64 words 1747 WRITE OUTPUT writes data to SLC I/O module output file • If the SFC startover bit is set in the processor 1747 READ M0 FILE reads data from SLC I/O module configuration file, continuous CIOs may time out M0 file if you cycle power in RUN mode. If this happens, 1747 WRITE M0 FILE writes data to SLC I/O module M0 the CIO error bit is set. To reset the error bit, the CIO instruction rung condition must go from file FALSE to TRUE. 1747 READ M1 FILE reads data from SLC I/O module M1 file See Chapter 4 and Appendices C and F for more 1747 WRITE M1 FILE writes data to SLC I/O module M1 information. file 1747 SAFE STATE change SLC I/O module safe state DATA data 1747 WRITE FLAGS change action SLC I/O module take when it faults and/or goes to idle 1747 CONFIG DATA change SLC module’s configuration data • Data-table address in source processor • Size of message in words • Network address of destination node • Slot of destination module • Port number—set to 2 for the ControlNet network • Flags: .TO forces a transfer to time out .EW indicates that the transfer is waiting for an open connection .CO transfer is made continuously in Run mode .ER indicates that the transfer was terminated due to an error .DN indicates that the transfer was made without error .ST indicates that the transfer was started .EN indicates that the transfer instruction is enabled 2 • Error code—indicates the error when the.ER bit is set • Done length—indicates the number of words transferred 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-7 Operation Description Features You can use ControlNet message (MSG) instructions and the data-type • As many as 32 ControlNet MSGs can be active Peer-to-peer 1 MG to create unscheduled messages that are initiated by one ControlNet Messaging at a time PLC-5 processor and sent to another ControlNet PLC-5 processor. The • Minor fault bit S:17/13 is set when 32 MG data type for the ControlNet instruction has the following MSG Instructions ControlNet MSGs are active at a time information: • All messages have the same priority • Command—PLC-5 TYPED READ, PLC-5 TYPED WRITE, PLC-3 WORD • No message is initiated when the processor is RANGE READ, PLC-3 WORD RANGE WRITE, PLC-2 UNPROTECTED in Program mode READ, PLC-2 UNPROTECTED WRITE • Messages that have been running with the.CO • Data-table address in source processor bit set automatically restart on the Program- • Size of message in elements to-Run transition when the Continue Last step • Network address of destination processor bit is set and the data table has not changed • Data-table address in destination processor • Each message has a maximum size of 1000 • Port number—set to 2 for the ControlNet network elements • Flags: See chapter 4 and Appendices C and F for more information. .TO forces a message to time out .EW indicates that the message is waiting for an open connection .CO message is sent continuously in Run mode .ER indicates that the message was terminated due to an error .DN indicates that the message was sent without error .ST indicates that the message was started .EN indicates that the message instruction is enabled .NC forces the connection to close when the message is done 2 • Error code—indicates the error when the.ER bit is set 1 Because connections are opened and closed as needed, more can exist in a program as long as no more than this number are active at one time. 2 See Appendix D for a list of ControlNet error codes. Using I/O Forcing Operations ControlNet I/O forcing occurs in the same way as remote I/O forcing in the ControlNet processors. The processor performs the forcing and transmits the forced data to the output- and input-image tables. You can force any discrete I/O data placed in the I/O image; however, forcing of DIF and DOF data is not supported. For detailed information about forcing, see your programming software documentation. 1785-UM022B-EN-P - February 2002 2-8 Planning to Use Your ControlNet PLC-5 Processor Using Immediate Data-Transfer Operations ControlNet Immediate Data I/O transfers—Immediate Data Input (IDI) and Immediate Data Output (IDO)—perform similarly to the Remote-I/O supported immediate I/O transfers—Immediate Input (IIN) and Immediate Output (IOT)—which the ControlNet system also supports. The logic scan is temporarily interrupted while the most recent state of up to 64 words is read from or written to the private memory buffer. Immediate Data Transfer Private Data- Memory Table Data Update Buffers Files ControlNet Data Transfer Program Scan = NUI = Scheduled Data Transfer = Unscheduled Data Transfer 1785-UM022B-EN-P - February 2002 Housekeeping Logic Scan Planning to Use Your ControlNet PLC-5 Processor 2-9 Table 2.C ControlNet Immediate Data-Transfer Operations Instructions Description In the case of an IIN, the most recent copy of the specified input word secured in the last discrete I/O Immediate I/O-ControlNet and Remote I/O data transfer from the corresponding I/O chassis is used. This value is moved from the private memory buffer to the working data table and is used in all subsequent ladder instructions. This data could be as old as the time taken since the last asynchronous I/O update, and it may not actually 001 reflect the latest state of the input word. () IIN In the case of an IOT, the current state of the specified output word is copied to the private memory buffer and is used on the next output update to the I/O chassis. The actual change is not 001 communicated until the next asynchronous I/O transfer. () IOT Only 1 word of I/O data can be updated per instruction. The ControlNet Immediate Data I/O instructions work in much the same way as the immediate I/O ControlNet Immediate Data I/O instructions. During an input instruction, the most recent data is copied from the private memory buffer to a data-table address that you specify. In the case of an output instruction, the data is IDI copied from an area that you specify to the private memory buffer and sent on the next I/O update. IMMEDIATE DATA INPUT As many as 64 words can be transferred per instruction. Data file offset 232 Length 10 Important: In most cases, you should set the Data file offset and the Source of an IDO or the Data Destination N11:232 file offset and the Destination of an IDI to the same address. See Chapter 4 for more information on this and other aspects of using ControlNet IDI and IDO instructions. IDO IMMEDIATE DATA OUTPUT Data file offset 175 Length 24 Source N12:175 Using Process Control Sample Complete Scheduled data transfers occur continuously and asynchronously to the program scan. If a scheduled connection is an input, then incoming data is copied to a private input buffer upon its receipt. If a scheduled connection is an output, then data from a private output buffer is transmitted during each scheduled communication. Your data table files and private buffers are synchronized during housekeeping, which occurs between program scans. During housekeeping, the latest inputs are copied from the private memory buffers to the processor’s input data table files (file 1 and the DIF) and the output data table files (file 0 and the DOF) are copied to the private output buffers. In some instances, however, it is useful to have access to new input data as soon as it has been received without waiting for housekeeping to take place at the end of the program scan. Process control sample complete enables you to do so for the following scheduled connection types: • 1747 analog or module connection • 1771 analog or module connection • 1794 analog or module connection • receive scheduled message 1785-UM022B-EN-P - February 2002 2-10 Planning to Use Your ControlNet PLC-5 Processor You enable process control sample complete on a per connection basis by setting the PCSC enable bit in the connection’s ControlNet I/O status file entry. When process control sample complete is enabled for a connection and the processor is in RUN mode, newly received data for that connection is immediately copied into your data table (even if the processor is in the middle of a program scan) and the PCSC new data bit is set in the connection’s ControlNet I/O status file entry. This data will not be updated again during a program scan until you clear the PCSC new data bit. The data is updated during housekeeping, regardless of the state of the new data bit. If new data is received and the PCSC new data bit is already set, then the PCSC overflow bit is set. In this event, your data table will not be updated. Process control sample complete uses bits 2, 3, and 4 of the first word of the ControlNet I/O status file entry. See Appendix D for more information about the ControlNet I/O status file. The input data must be mapped into the DIF. PCSC is not enabled if the input data is mapped into the discrete input image table. PCSC Overflow Bit PCSC New Data Bit PCSC Enable Bit First Word 15 14 013 12 11 10 009 08 07 06 0 05 04 03 0 02 01 000 Bit Description 2—PCSC Enable When this bit is set, the processor updates your ControlNet data input file when new data is received. Process control sample complete can be dynamically enabled and disabled by your program during a program scan. This can be done by setting and clearing the PCSC enable bit of the connection’s entry in the ControlNet status file. After this bit has been set, the input data should not be read until the PCSC new data bit has been set by the processor. 3—PCSC New Data This bit is set by the processor when the PCSC enable bit is set to one and new data has been copied to the ControlNet data input file. To insure that you do not access this data while the processor is copying new data to the data input file, do not access the data until the PCSC new data bit has been set by the system. When this bit is set to one, it signifies that new data has been received and it is safe to read from your ControlNet data input file. This data is not updated again until you clear this bit or until housekeeping occurs between program scans. Never set this bit to one. 4—PCSC Overflow This bit indicates that your program is not checking the PCSC new data bit often enough to use all processor control sample complete data that has arrived. If the PCSC new data bit has not been cleared by the time a new data sample arrives, the PCSC overflow bit is set and the new data is not copied to the ControlNet data input file. You must clear this bit. If you clear the PCSC New Data bit but not the PCSC overflow bit, the ControlNet data input file is still updated when the next process control sample complete data is received. Never set this bit to one. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-11 Clearing the PCSC New Data and PCSC Overflow Bits If it is crucial to maintain the integrity of the PCSC overflow bit after new data has arrived while clearing the PCSC new data and overflow bits. Then do the following: 1. Disable process control sample complete by setting the PCSC enable bit for the connection to zero. When process control sample complete is disabled, the system will not modify the new data and overflow bits while you clear them. 2. Clear the PCSC new data and the PCSC overflow bits. 3. Re-enable process control sample complete by setting the connection’s PCSC enable bit back to one. Considerations When Using PCSC When using scheduled ControlNet 1.5 communications to analog I/O (such as map entries) and you are using the PID instruction in the PLC-5/15, then you should do the following: • the analog module must be set up to use RTS (Real Time Sample) mode • set your analog RPI (Repetitive Packet Interval) to be at least twice the RTS time • your ladder program needs to set the PCSC enable bit • your ladder program needs to use the PCSC done bit to condition the execution of the PID instruction • the PID loop update must equal the RTS rate • your ladder program must use the PCSC overflow bit to take appropriate action on an overflow condition Understanding Scheduled Scheduled connections are made to I/O devices such as I/O adapters and to peer-to-peer devices such as other controllers. Connection Types There are some common scheduled connection types made from the ControlNet PLC-5 to other Allen-Bradley products that are detailed in the following section. These scheduled connection types have certain behaviors and limitations that you must understand before configuring the connections. The ControlNet PLC-5 can also make scheduled connections to products not manufactured by Allen-Bradley. Refer to the literature that accompanies those products for information on their scheduled connection behavior. Scheduled connection types made from the ControlNet PLC-5 to I/O adapters can be made either to some or all of the discrete I/O on the adapter (called a rack connection), or to individual modules (called a module connection). 1785-UM022B-EN-P - February 2002 2-12 Planning to Use Your ControlNet PLC-5 Processor There are four general types of scheduled connections from the ControlNet PLC-5 to I/O adapters: • exclusive owner - these scheduled connections indicate the PLC-5 has exclusive ownership of the outputs. These scheduled connections can also gather inputs from the device. There cannot be more than one exclusive owner connection made to either the rack connection or module connection at a time. • input only - these scheduled connections only gather inputs from the I/O adapters. These scheduled connections do not require other scheduled connection types to be first established before its scheduled connection can be established. • listen only - these scheduled connections are similar to input only scheduled connections, except that they require a different scheduled connection to be first established before its connection can be established. • redundant owner - these scheduled connections are similar to exclusive owner scheduled connections because they both can control outputs and gather inputs. The difference between them is that with redundant owner scheduled connections, multiple ControlNet PLC-5 controllers can establish identical redundant connections. Only one of the controllers that establish the redundant scheduled connection will own the outputs. Redundant connections can only be used in a PLC-5 ControlNet Hot Backup system. Refer to the PLC-5 ControlNet Hot Backup User Manual, publication 1785-6.5.24 for more information on using redundant connections. Allowable Scheduled Connection Type Combinations for I/O Adapter Connections Only specific combinations of scheduled connection types are allowable. RSNetWorx will have a pull down list showing all allowable schedule connection types. The following details about these combinations assume that different processors are making either rack connections to the same adapter or module connections to the same slot. Important: The 1771-ACN(R15) requires a rack connection to be established before any module connections are accepted. If an exclusive owner connection is made to the adapter: • another exclusive owner connection will be rejected • an input only connection can be made • a listen only connection can be made • a redundant owner connection will be rejected 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-13 If an input only connection is made to the adapter: • an exclusive owner connection can be made • another input only connection can be made • a listen only connection can be made • a redundant owner connection can be made A listen only connection can only be made to the adapter if: • an exclusive owner connection already exists, or • an input only connection already exists, or • a redundant owner connection already exists If a redundant owner connection is made to the adapter: • an exclusive owner connection will be rejected • an input only connection can be made • a listen only connection can be made • another identical redundant owner connection can be made Multiple Processors Can Control I/O on the Same ControlNet Link A processor at any valid node address can control the outputs of a particular module or rack. However, only one processor can control the same outputs at any one time. In the following figure, the processor at node 1 can control the outputs of node 2 while the processor at node 3 controls the outputs of node 4. node 1 node 2 node 3 node 4 1785-UM022B-EN-P - February 2002 2-14 Planning to Use Your ControlNet PLC-5 Processor Understanding Multicast Inputs This feature enables input devices to send the same data to multiple processors simultaneously. Advantages of multicast inputs include: • Network optimization - reduces network usage since data is sent only once simultaneously to all connections. This reduction may allow more complex scheduled connection configurations or improved unscheduled connection performance. • Device synchronization - inputting data to all devices simultaneously improves synchronization between devices In the following example, the ControlNet PLC-5 processor at node 2 is sending outputs to the adapter at node 3. Nodes 1, 2, and 4 are all receiving the same input packet from node 3. Nodes 1 and 4 are considered listen-only and are producing heartbeats to keep their connections to the adapter alive. Heartbeat Connection Heartbeat Connection Point-to-Point Outputs ControlNet PLC-5 ControlNet PLC-5 ControlNet PLC-5 ControlNet Adapter Processor Processor Processor Node 3 Node 1 Node 2 Node 4 Multicast Inputs Understanding Multicast Outputs This feature enables the PLC-5 to simultaneously send the same output data to more that one target device. To use this feature, both the PLC-5 and the target devices must support multicast outputs. Advantages of multicast outputs include: • Network optimization - reduces network usage since data is sent only once simultaneously to all connections. This reduction may allow more complex scheduled connection configurations or improved unscheduled connection performance. • Device synchronization - outputting data to all devices simultaneously improves synchronization between devices 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-15 Using Multicast Outputs To use multicast outputs, you must first configure each Multicast Output connection in RSNetworx 3.0: 1. In the Details Tab of Connection Properties dialog, change the Scanner to Target Network Connection to Multicast. You cannot modify this field for any device that does not support multicast outputs. 2. The Scanner to Target Multicast ID of the Details Tab indicates to which multicast output group the connection belongs. All connections with the same Multicast ID will have their output data combined into a single transmission on the ControlNet network. The processor will combine the output data into a single packet and simultaneously send it to all assigned connections that have the same: • Request Packet Interval • Output Address in the PLC-5 data table • Output Size You must determine if the output data being sent to each device of a multicast group is compatible with the application. Using Multicast Outputs affects the ControlNet I/O Status file Immediate Inhibit bit and ControlNet I/O Status file Reset bit functionality: • ControlNet I/O Status file Immediate Bit - since all connections in a Scanner to Target Multicast ID group share the same output data, the Immediate Inhibit Bit will not take affect until all connections of that group have their immediate inhibit bit set. After the immediate inhibit takes place, you may independently re-enable each connection by clearing this bit. • ControlNet I/O Status file Reset Bit - all connections of a Scanner to Target Multicast ID group must have this bit set or cleared so that the target devices are put into the correct state. The Reset Bit affects all connections for a given multicast ID group. 1785-UM022B-EN-P - February 2002 2-16 Planning to Use Your ControlNet PLC-5 Processor Understanding ControlNet All scheduled data transfers must be mapped on a ControlNet network. You specify where I/O data is to be read from or written I/O Mapping to—i.e., mapped. You do this and establish the relationship between processors, I/O adapters, and data-table file addresses by creating and maintaining an I/O map table. An I/O map-table entry is required for each scheduled data transfer. The map table is stored in the configuration section of memory and is not accessible by your application program. Using your programming software, you can automatically configure and map nodes attached to your ControlNet I/O. See Using I/O Mapping Techniques in Chapter 2 for information about ControlNet automatic configuration and I/O mapping. Reserving Space for Non-ControlNet I/O Non-ControlNet processor-resident local I/O and Remote-I/O devices can only use fixed I/O image locations based on rack number for discrete I/O data transfer, while discrete I/O data transfer between ControlNet nodes can be mapped to any unused location in the I/O image tables. Before mapping your ControlNet I/O, therefore, you should configure any processor-resident local I/O and any Remote I/O racks on non-ControlNet channels. This allows the programming software to reserve input- and output-image space for all non-ControlNet processor-resident local I/O and Remote-I/O chassis. Processor-Resident Local I/O If you first configure processor-resident local I/O on your processor, the programming software reserves processor-resident local chassis input- and output-image space starting at offset 0 in both files. The following table shows the default number of input and output words automatically reserved by the programming software for the different sizes and addressing modes of processor-resident local I/O: Addressing Number of Words Reserved Mode 4 Slots 8 Slots 12 Slots 16 Slots 2 Slot 888 8 1 Slot 8816 16 1/2 Slot 8 16 24 32 Important: ControlNet I/O cannot map into any part of a rack number used by the processor-resident rack. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-17 Remote I/O The following table shows the default number of input and output words reserved by the programming software for the different sizes and addressing modes of non-ControlNet Remote I/O if you first configure non-ControlNet Remote I/O on your processor: Number of Words Reserved Addressing Mode 4 Slots 8 Slots 12 Slots 16 Slots 2 Slot 246 8 1 Slot 4812 16 1/2 Slot 8 16 24 32 The programming software reserves non-ControlNet Remote-I/O output- and input-image space according to these guidelines: • It does not overlap processor-resident local I/O reserved image space • It addresses input- and output-image space offset in octal from – 00-37—for the PLC-5/20C15 processor – 00-177—for the PLC-5/40C15 processor – 00-177—for the PLC-5/46C15 processor – 00-277—for the PLC-5/80C15 processor • The output-image offset value in the I/O map corresponds to the first slot of the referenced chassis—i.e., in a 4-slot chassis set for 1-slot addressing, the corresponding output-image offset of O:10 would map the words O:10, O:11, O:12, and O:13 to slots 0, 1, 2, and 3 respectively • The input-image offset corresponds to the first slot in the referenced rack, and the offset location of the input modules in that rack corresponds to the same offset in the image table—i.e., if a chassis set for 1-slot addressing has an input-image offset of I:10 and an input module in slot 3, the word that corresponds to that input module would be I:10 + 3, or I:13 1785-UM022B-EN-P - February 2002 2-18 Planning to Use Your ControlNet PLC-5 Processor Supported ControlNet I/O Sizes The following table shows the maximum I/O map entries allowed in the ControlNet I/O map table: Table 2.D Maximum I/O Map Entries Number of Number of DIF Number of DIF Number of DOF Number of DOF Processor: Mappings: Files: Words: Files: Words: PLC-5/20C15 64 2 2000 2 2000 PLC-5/40C15 96 3 3000 3 3000 PLC-5/46C15 96 3 3000 3 3000 PLC-5/80C15 128 4 4000 4 4000 Each map-table entry corresponds to one transfer—input only, output only, or both input and output—of data between the ControlNet processor and an I/O rack, an I/O module, or another ControlNet processor. Table 2.E Files That You Configure with the I/O Map for Scheduled I/O Usage File Description ControlNet Status File User-specified integer data table file containing status information about this processor’s scheduled I/O map-table entries. Each I/O map table entry has a status-file offset field pointing to three status words associated with that entry. Refer to Appendix D for more information on I/O map-table entry status words. ControlNet Diagnostics File User-specified integer data table file containing diagnostics about the ControlNet network (not required). See Appendix F. Data Input File (DIF) User-specified integer data-table file with a maximum of: • 2000 words for the PLC-5/20C processor (spanning two contiguous data table files) • 3000 words for the PLC-5/40C processor (spanning three contiguous data table files) • 3000 words for the PLC-5/46C processor (spanning three contiguous data table files) • 4000 words for the PLC-5/80C processor (spanning four contiguous data table files) This file is typically used for non-discrete input data and peer-to-peer input. Discrete input data may be mapped to DIF as well. Data Output File (DOF) User-specified integer data-table file with a maximum of: • 2000 words for the PLC-5/20C processor (spanning two contiguous data table files) • 3000 words for the PLC-5/40C processor (spanning three contiguous data table files) • 3000 words for the PLC-5/46C processor (spanning three contiguous data table files) • 4000 words for the PLC-5/80C processor (spanning four contiguous data table files) This file is typically used for non-discrete output data and peer-to-peer output. Discrete output data may be mapped to DOF as well. Configuration File User-specified integer data-table file used to store non-discrete I/O data transfer configuration data. This configuration data is sent to the target device each time the connection is opened. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-19 Discrete I/O Data-Transfer Mapping Regardless of the type of I/O—e.g., 1747, 1771, 1794—all ControlNet discrete I/O data is stored within the processor according to the corresponding I/O map-table entry. Discrete I/O data can be stored in either the I/O image table or the DIF/DOF. Any status information transferred along with the I/O data is stored in a separate status file that you specify during configuration. Important: If you want to force your discrete I/O, you must map it to the I/O image table. Non-discrete I/O Data-Transfer Mapping ControlNet non-discrete I/O data can be stored in either the I/O image table or the DIF/DOF. The ControlNet processor supports two distinct image files; both are integer data-table files that you specify: • Data Input File (DIF) • Data Output File (DOF) Each map-table entry for a non-discrete I/O data transfer defines an offset into the DIF or DOF where the data is stored. Using separate data-table files for non-discrete I/O data transfer allows the processor to scan non-discrete I/O data asynchronously to the program scan. Like discrete I/O, the data is presented synchronously to the processor and output buffers during housekeeping. The DIF and DOF can be overlapped (as in Figure 2.1) so that inputs from one device can be used as outputs to another device. As a result of the overlap, no ladder logic is required to copy the data. If either the DIF or DOF size is greater than 1000 words, then it will span multiple physical files. The physical files comprising the DIF or DOF must be contiguous. Figure 2.1 Data Input and Data Output Files N10:0 DIF N10:999 N11:0 DOF N11:249 N11:499 1785-UM022B-EN-P - February 2002 2-20 Planning to Use Your ControlNet PLC-5 Processor 1771 Modules ControlNet 1771 discrete I/O data-transfer mapping requires one map-table entry per node. ControlNet 1771 non-discrete I/O data-transfer mapping requires one map-table entry per module. The ControlNet scheduled I/O data-transfer mechanism makes it possible to eliminate block-transfer programming to communicate with the 1771 modules. For a complete list of these modules, refer to RSNetWorx for ControlNet documentation. The types of modules that may be accommodated by the processor’s scheduled non-discrete I/O data-transfer mechanism are typically those modules that require a one-time configuration and then continuously read or write. To communicate with 1771 modules, you can also include explicit CIO instructions in your ladder-logic program. See Chapter 4 and Appendix C for more information. The 1771 discrete rack must be owned by a processor before any non-discrete connections (scheduled or unscheduled) can be established with the 1771 adapter. The non-discrete connections can be established by the owner processor and/or non-owner processors. The Run/Program mode for all modules in a 1771 ATTENTION chassis is controlled by the owning discrete rack connection. You must consider this when configuring non-discrete connections from other processors. ! 1747 Modules ControlNet 1747 discrete I/O data-transfer mapping requires one map-table entry per node. ControlNet 1747 non-discrete I/O data-transfer mapping requires one map-table entry per module. The ControlNet scheduled I/O data-transfer mechanism makes it possible to map 1747 modules. For a complete list of these modules, refer to RSNetWorx for ControlNet documentation. 1794 Modules ControlNet 1794 Flex discrete I/O data-transfer mapping requires one map-table entry per node. ControlNet 1794 non-discrete I/O data-transfer mapping requires one map-table entry per module. The ControlNet scheduled I/O data-transfer mechanism makes it possible to map 1794 modules. For a complete list of these modules, refer to RSNetWorx for ControlNet documentation. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-21 Other ControlNet Processors ControlNet scheduled peer-to-peer communications between ControlNet processors require one map-table entry per message. You can set up ControlNet peer-to-peer communications between any two processors on a ControlNet network. The ControlNet transfer mechanism makes it possible to map the scheduled peer-to-peer messages listed in the following table. Table 2.F Peer-to-Peer Communications Mapping 1 Message Type Valid Sizes Description Receive Data Scheduled Message From 1-240 words Send Data Scheduled Message 1 RPI Default = 4 x NUT To communicate between any ControlNet PLC-5 processors on the ControlNet network, you can include MSG instructions in your ladder-logic program. See Chapter 4 and Appendix C for more information. Using I/O Mapping Techniques Discrete I/O interfaced to a PLC-5 processor is typically mapped to the I/O image table. You can map discrete I/O to the DIF and DOF, but you lose the ability to force the I/O if the DIF or DOF is used. Each version of the PLC-5 processor has a specific amount of I/O image table available, and therefore, a limit on the amount of I/O that can be mapped to the I/O image table. Traditionally, each slot in an I/O chassis is assigned a location in the input image table and the output image table. While this provides very easy mapping of I/O to the image table, it is not the most efficient way to use it. For example, if a slot contains an input module, the corresponding location in the output image table goes unused. With the introduction of the ControlNet network to the PLC-5 processor family, new techniques are available to map discrete I/O into the I/O image table in a more efficient manner. Input and output data can be mapped to offsets within the I/O image tables and need not be the same size. 1785-UM022B-EN-P - February 2002 2-22 Planning to Use Your ControlNet PLC-5 Processor Understanding Discrete Mapping Each version of a PLC-5 processor has a fixed amount of I/O image space. For example: This processor: Has: PLC-5/20C 32 words of input image table and 32 words of output image table PLC-5/40C 128 words of input image table and 128 words of output image table PLC-5/46C 128 words of input image table and 128 words of output image table PLC-5/80C 192 words of input image table and 192 words of output image table The I/O image table is used for all discrete I/O connected to the PLC-5 processor, regardless of where it is located (local I/O, Remote I/O, ControlNet network). Since the local chassis reserves a minimum of eight words of input and output, a PLC-5/20C processor has a maximum of 24 words of inputs and 24 words of outputs available for the ControlNet network. Some applications may find that the use of I/O image space needs to be optimized to insure that the I/O requirements can be met. A node address on a ControlNet network does not directly map to a location in the I/O image table like it does on a Remote I/O network. For example, If you have an 8-slot chassis in 1-slot addressing and set the node address to two, and: If the node is on a: Then: Remote I/O network the inputs in that chassis automatically map to I:020-I:027 if the node is on a remote I/O network ControlNet network you can map the inputs to any location available in the input image table, and the outputs to any location available in the output image table. The input and output locations can be in two totally different rack numbers. For example, you can specify I:024 as the input location and O:032 as the output location. The only restriction is that you must map the input and output words contiguously. If you mapped eight words of inputs you must map it to a location with eight words available. In this example, words I:024-I:033 must be available. The ControlNet network also allows the size of the chassis to be set based on what is needed. Using the previous example, the chassis on the Remote I/O network uses eight words of inputs and eight words of outputs, regardless of what modules are actually in the chassis. On the ControlNet network, you can set the sizes to what is actually needed. For example, you can set the input size to six and the output size to three. If no outputs are in the chassis you can set the output size to zero. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-23 Optimizing the I/O Image Table You may find that you are close to the I/O image table limits in a PLC-5 processor and need to optimize the use of the I/O image table in order to insure that the application will fit in the processor. This section discusses techniques that make optimal use of the I/O image table available in a PLC-5 processor. The use of these techniques is not required, they merely demonstrate methods which can be used to make maximum use of the available I/O image table. Proceed with caution when using these techniques. Important: You need to understand the ramifications of how you map the I/O before proceeding, as the method you use may make future expansion extremely difficult. There are two methods to optimize the use of I/O image table in a ControlNet PLC-5 processor. • optimizing without slot complementary • optimizing with slot complementary — where you set the I/O chassis backplane switches to a lower density than the modules you are actually using, and then staggering the modules: input, output, input, output, etc. For example, you can set the backplane switches to 2-slot addressing and then place 16-point I/O modules in the rack: input, output, input, output, etc. See Configuring Complementary I/O for PLC-5 Processors, publication number 1785-6.8.3, for information about slot complementary I/O. Both methods make use of arranging the I/O modules in the most efficient manner within the chassis. In many cases, the optimal solution for a system is a combination of both the methods. Optimizing the I/O Image Table without Slot Complementary The techniques used for I/O image optimization are best illustrated using examples. The following examples all assume 1-slot addressing for all chassis and that the local rack is using rack 0 image table (I:000-007 and O:000-007). Example 1 Examine the following chassis: ACN I O O I O O XX I = Discrete Input Module O = Discrete Output Module ACN = ControlNet adapter X = Empty Slot 1785-UM022B-EN-P - February 2002 2-24 Planning to Use Your ControlNet PLC-5 Processor If you perform an automap on this system, the map table appears like this: Input file Input size Output file Output size I:010 8 O:010 8 The automap feature reserves the maximum size of inputs and outputs. It is up to you to manually change the sizes if desired. If you optimize the chassis as shown, the sizes adjust to the following: Input file Input size Output file Output size I:010 4 O:010 6 There are two input modules and four output modules in the chassis. However, you cannot set the sizes to two and four because the address you specify is the starting address of the chassis. It identifies the address of the leftmost slot. The size you specify determines how many slots in the chassis written to or read from. (In 1-slot addressing, words equals slots. The concept is the same for any addressing mode. Words are read/written from left to write. In 1/2- slot addressing there are two words per slot.) In this example, the first slot in the chassis is I:010/O:010, the second slot, I:011/O:011, and so on. The fifth slot is O:014 only. You cannot place an input module in this slot since no input word is mapped to it. The seventh slot has no I/O image table mapped to it. You cannot place a discrete input or output module in the last two slots since there is no I/O image table allocated to it. Example 2 Take another look at the chassis. By moving the modules you can optimize this chassis further. Move all the input modules to the left of the chassis: ACN I I O O O O XX I = Discrete Input Module O = Discrete Output Module ACN = ControlNet adapter X = Empty Slot Now if you optimize, the map table looks like this: Input file Input size Output file Output size I:010 2 O:010 6 By placing the input modules first, you only have to map two input words to the chassis and do not lose any by having to pass over output modules. The outputs only lose two words by passing over the inputs. This example shows the first rule of module optimization. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-25 First Rule of When placing discrete modules, put the type (input or output) you Module Optimization have the least of to the left in the chassis. Example 3 Some chassis may contain analog modules, communication cards, or power supplies. Examine the following chassis: I IO II ACN A O PS I = Discrete Input Module O = Discrete Output Module ACN = ControlNet adapter A = Analog Module PS = Power Supply This chassis contains an analog module and a power supply. Assume all analog modules on a ControlNet network are mapped to an integer table in the PLC-5 processor. Power supplies do not require any I/O image table. Therefore, the optimal configuration of this chassis is: I = Discrete Input Module ACN O O I I I I APS O = Discrete Output Module ACN = ControlNet adapter A = Analog Module PS = Power Supply Input file Input size Output file Output size I:010 6 O:010 2 Since analog modules and power supplies do not need any I/O image space you should place them to the right so that you don’t have to waste any inputs or outputs passing over these modules. This leads to the second important module placement rule of optimization. 1785-UM022B-EN-P - February 2002 2-26 Planning to Use Your ControlNet PLC-5 Processor Second Rule of Place modules that do not require I/O image table space to the right Module Optimization in the chassis. Example 4 To understand how optimization with a ControlNet network preserves I/O image space, look at the following example system: I = Discrete Input Module ACN I O O O O O O PS O = Discrete Output Module Chassis 1 ACN = ControlNet adapter A = Analog Module PS = Power Supply ACN O I I I I I I PS Chassis 2 A ACN A A A A A a A APS Chassis 3 The following chart shows how a Remote I/O system compares to one optimized with a ControlNet network. Remote I/O ControlNet Network Input Output Input Output Chassis Address Size Address Size Address Size Address Size 1 I:010 8 O:010 8 I:010 1 O:010 7 2 I:020 8 O:010 8 I:011 7 O:017 1 3 I:030 8 O:030 8 n/a 0 n/a 0 Total Used 24 (3 racks) 24 (3 racks) 8 (1 rack) 8 Remaining 0 0 16 (2 racks) 16 If you install the system on a PLC-5/20C processor, the Remote I/O network option would be out of I/O image space, while the ControlNet network option would have used only one-third of the available I/O image space. You must take into account future expansion when optimizing the I/O. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-27 Example 4 Examine the following system: ACN IO O I I O OO I = Discrete Input Module O = Discrete Output Module Chassis 1 ACN = ControlNet adapter A = Analog Module PS = Power Supply X = Empty Slot ACN IA O A X X A I Chassis 2 ACN OO O I I I I A Chassis 3 Input file Input size Output file Output size Chassis 1 I:010 5 O:010 8 Chassis 2 I:015 8 O:020 3 Chassis 3 I:025 7 O:023 3 Assume you want to add an additional output module in one of the empty slots in the second chassis. Only three words of output are mapped to the second chassis. You have to change the output size in the second chassis to five to get to the first empty slot. However, this example started mapping the third chassis at O:023. If you try to set the second chassis size to five, you get an overlap error because words O:023 and O:024 are being used in the third chassis. You can always change the starting address of the third chassis, but then you must change any references to the outputs in your program. It may be better to start mapping the third chassis at O:027 to allow for output expansion. You can add input modules in the empty slots without changing anything since there are already eight words of inputs mapped to the chassis. Optimizing the I/O Image Table with Slot Complementary Slot complementary makes use of the ability of a chassis to share inputs or outputs between adjacent slots. This allows you to set the density of the chassis to a lower value than the modules used in the chassis and then share the I/O between the slots. For example, you can set a chassis to 2-slot addressing and then place 16-point modules in the chassis, alternating input and output modules. 1785-UM022B-EN-P - February 2002 2-28 Planning to Use Your ControlNet PLC-5 Processor Example 1 Examine the following chassis: I = Discrete Input Module ACN IO I O I O IO O = Discrete Output Module 2-slot addressing ACN = ControlNet adapter 16-point modules In this example the first input module uses eight inputs from the first slot and eight inputs from the second slot (not used by the output module in the second slot). The first output module uses eight outputs from the first slot and eight outputs from the second slot, and so on. Given an 8-slot chassis in 2-slot addressing, there are four words of inputs and four words of outputs used in this chassis. On a ControlNet network, you can map four words of inputs and four words of outputs to this chassis and no I/O image space is wasted. If you set the addressing mode to 1-slot addressing and use the methods described in the previous section you waste either four words of input or four words of output image table. This method works extremely well for cases where there are equal numbers of input and output cards. However, in most cases there are not the same number of each module. Example 2 Examine the following chassis: ACN IO I O X O XO I = Discrete Input Module O = Discrete Output Module 2-slot addressing ACN = ControlNet adapter 16-point modules X = Empty Slot In this case you can map two words of input and four words of output to the chassis and not waste any I/O image table. However, you waste physical space (note the two empty slots). Look at the case where you have 14 input modules and two output modules. If you use slot complementary, you have to purchase an additional chassis, and therefore an additional adapter and power supply, since you can only put eight of the input modules in one chassis (one module every other slot). If you do not use slot complementary, you can fit all the cards in one chassis and only sacrifice two output image table words. With the slot-complementary method you cannot just put any module anywhere. If you wish to add an output module to the chassis shown above you cannot since there are no output slots available; you have to start a new chassis. 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-29 Summary There are two methods to optimize the use of I/O image table in a ControlNet PLC-5 processor. There are tradeoffs in using each method which are summarized in the following table. Method: Tradeoffs: optimize without slot • allows optimization of I/O image table, but complementary not to the extent if using slot complementary • does not waste chassis slots • can put any module anywhere (provided I/O table exists for that slot) optimize with slot complementary • allows complete optimization of the I/O image table • can waste chassis slots and require additional chassis • can only put modules in odd or even slots, depending on the module type The best solution in most cases is to combine the two methods. Examine the module requirements at any given chassis or location and see which method fits best. You may find in some areas you have an equal number of input and output modules, and slot complementary optimizing works well. However, you may find in other areas there are space limitations which require the use of the smallest possible chassis, and therefore, you cannot waste slots using slot complementary. A final point to be aware of is that each system is unique and you must apply these techniques accordingly. For example, you may have the following chassis: I = Discrete Input Module ACN II O I I I OI O = Discrete Output Module 2-slot addressing ACN = ControlNet adapter 16-point modules Using strict rules of optimization you might immediately arrange the chassis like this: I = Discrete Input Module ACN OO I I I I II O = Discrete Output Module 2-slot addressing ACN = ControlNet adapter 16-point modules 1785-UM022B-EN-P - February 2002 2-30 Planning to Use Your ControlNet PLC-5 Processor However, the overall system may be heavy on inputs, and there are no concerns about the output image table. In this case you may want to conserve the input image table for this chassis and arrange it as follows: I = Discrete Input Module ACN II I I I I OO O = Discrete Output Module 2-slot addressing ACN = ControlNet adapter 16-point modules When deciding when, where, and what type of optimization to use, you have to balance: • space limitations • additional costs (extra chassis, adapters, etc.) • I/O image table availability • future expansion 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-31 Using the ControlNet There can be multiple ControlNet PLC-5 processors updating I/O adapters on a ControlNet network. PLC-5 Processor in a ControlNet I/O System • any processor can own adapters on the network • any processor is allowed to send CIO instructions to I/O modules • additional processors can do scheduled transfers to any other processor on the ControlNet network by using peer-to-peer communications through the scan configuration list The following table describes various ControlNet devices that you can add to your network. For a complete listing, contact your local Rockwell Automation sales office. Catalog Number(s) Device(s) Function 1785-L20C15, ControlNet Programmable Controllers Communicate with other ControlNet nodes using scheduled or unscheduled -L40C15, -L46C15, peer-to-peer communication. -L80C15 1784-KTC15, ControlNet ISA Communication Cards Allows other computer platforms to communicate with the ControlNet network. -KTCX15, -KTCS 1784-PCC ControlNet PCMCIA Communication Card Allows other computer platforms to communicate with the ControlNet network. 1770-KFC15, ControlNet Serial/Parallel Communication Connects a serial or parallel device to a ControlNet network. Interface -KFCD15 1747-ACN15, 1747 ControlNet SLC I/O Adapters Allows the ControlNet processor remote access to Allen-Bradley’s family of -ACNR15 SLC-designated I/O modules via a ControlNet network. 1771-ACN15, 1771 ControlNet I/O Adapters Allows the ControlNet processor remote access to Allen-Bradley’s family of -ACNR15 1771-designated I/O modules via a ControlNet network. 1784-PCIC, -PCICS ControlNet PCI Communication Cards Allows other computer platforms to communicate with the ControlNet network. 1794-ACN15, 1794 ControlNet Flex I/O Adapters Allows the ControlNet processor remote access to Allen-Bradley’s family of -ACNR15 1794-designated I/O modules via a ControlNet network. 1797-ACN15 1797 ControlNet Ex I/O Adapter Allows the ControlNet processor remote access to Allen-Bradley’s family of 1797-designated I/O modules via a ControlNet network. 1788-CN2DN, 1788 ControlNet Linking Devices Allows the ControlNet processor to link to DeviceNet or Foundation Fieldbus -CN2FF networks. 1756-CNBR ControlLogix ControlNet Bridge Allows the ControlNet processor remote access to Allen-Bradley’s family of 1756-designated I/O modules via a ControlNet network. PV 550, 600, 900, Panel View ControlNet products with Allows the ControlNet processor remote access to Allen-Bradley’s PanelView 1000, 1400, 1000e ControlNet comm option ControlNet operator interfaces via a ControlNet network. You can find actual and 1400e PanelView catalog numbers at: http://www.ab.com/catalogs/b113/oi/pv900550.html#550 1203-CN1 Any scan port drive or device that Allows the ControlNet processor remote access to Allen-Bradley’s scan port communicates thru 1203-CN1 drives or devices that communicate through a 1203-CN1 via a ControlNet network. 1336T AC Vector Drives with direct fiber ControlNet Allows the ControlNet processor remote access to Allen-Bradley’s AC Vector Drive, 1395 Digital connections and Digital DC drives via a ControlNet network. DC Drive 1785-UM022B-EN-P - February 2002 2-32 Planning to Use Your ControlNet PLC-5 Processor Example of a ControlNet Network without Redundant Media Personal computer Personal computer or with 1784-KTCX15 card Personal computer Laptop computer with other serial device (ISA-based) and with PCIC card (PCI-based) 1784-PCC card (PCMCIA-based) your HMI or and your HMI and your HMI or and your HMI or programming software or programming software programming software programming software PLC-5/40C 1784-PCC1 to PLC-5 (NAP port or any other NAP port)* Serial connection 1770-KFC15 Tap (4 choices) Interface 1786-TPR Remote I/O link Tap (4 choices) Tap (4 choices) Data Highway Plus link 1786-TPR PLC-5/40C 1786-TPR ControlNet Network 1747-ACNR15 1794-ACNR15 Adapter Flex I/O Adapter 1771-ACNR15 Adapter Example of a ControlNet Network with Redundant Media Personal computer with 1784-KTCX15 card Personal computer Personal computer or Laptop computer with (ISA-based) and with PCIC card (PCI-based) other serial device 1784-PCC card (PCMCIA-based) your HMI or and your HMI and your HMI or and your HMI or programming software or programming software programming software programming software PLC-5/40C 1784-PCC1 to PLC-5 (NAP port or any other NAP port)* Serial connection 1770-KFC15 Tap (4 choices) Interface 1786-TPR Remote I/O link Tap (4 choices) Tap (4 choices) Data Highway Plus link 1786-TPR 1786-TPR PLC-5/40C ControlNet Network 1794-ACNR15 Flex I/O Adapter 1747-ACNR15 Adapter 1771-ACNR15 Adapter 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-33 When used in a Class I, Division 2, hazardous WARNING location, this equipment must be mounted in a suitable enclosure with proper wiring method that complies with the governing electrical codes. ! Distributed Keeper Functionality All ControlNet processors now keep the ControlNet configuration. The processor with the lowest node address acts as the master keeper, while the other processors serve as backups. If the master keeper drops off the network, the next-lowest numbered processor takes over as the master keeper. No user intervention is required. Important: ControlNet PLC-5 programmable controllers with firmware revision E/B, D/C, or C/L are single keeper devices. All later releases are distributed keeper devices. There are two rules you must follow when combining single keeper devices and distributed keeper devices on the same network: • if there is a single keeper device at node 1, there can be no distributed keeper devices on the network • if there are distributed keeper devices on the network, single keeper devices can also be allowed on the network. However, there cannot be a single keeper device at node 1. If you plan to have distributed keeper devices on the network, we recommend that you flash upgrade the single keeper devices to be distributed keeper devices. 1785-UM022B-EN-P - February 2002 2-34 Planning to Use Your ControlNet PLC-5 Processor Converting from a Non-ControlNet When you download archived files to a ControlNet PLC-5 processor, the programming software ignores Channel 2 configuration Remote I/O System to a ControlNet information from anything other than a ControlNet-processor I/O System program because Channel 2 is reserved for ControlNet communication on the ControlNet processors. The software sets Channel 2 to the default ControlNet configuration. Can be run on a 1 ControlNet Program files Archived from a: On channel: PLC-5 channel: If they fit and are: for this process: •PLC-5/11 • PLC-5/40L 0 0 downloaded unchanged Messaging and I/O •PLC-5/20 •PLC-5/60 • PLC-5/20C15 • PLC-5/60L • PLC-5/20E •PLC-5/80 •PLC-5/30 • PLC-5/80C15 1A 1A •PLC-5/40 • PLC-5/80E • PLC-5/40C15 • PLC-5/46C15 • PLC-5/40E •PLC-5/20 • PLC-5/40L 1B 1B • PLC-5/20C15 •PLC-5/60 • PLC-5/20E • PLC-5/60L •PLC-5/30 •PLC-5/80 •PLC-5/40 • PLC-5/80C15 • PLC-5/40C15 • PLC-5/80E • PLC-5/46C15 • PLC-5/40E • PLC-5/20C15 • PLC-5/46C1522 • PLC-5/40C15 • PLC-5/80C15 1785-UM022B-EN-P - February 2002 Planning to Use Your ControlNet PLC-5 Processor 2-35 Can be run on a 1 ControlNet Program files Archived from a: On channel: PLC-5 channel: If they fit and are: for this process: Messaging and I/O •PLC-5/11 • PLC-5/40L 1A 2 performed by the ControlNet network—you continued must make these changes manually by •PLC-5/20 • PLC-5/46C15 2,3,4 • PLC-5/20C15 •PLC-5/60 reprogramming • PLC-5/20E • PLC-5/60L •PLC-5/30 •PLC-5/80 •PLC-5/40 • PLC-5/80C15 • PLC-5/40C15 • PLC-5/80E • PLC-5/40E •PLC-5/20 • PLC-5/40L 1B 2 • PLC-5/20C15 • PLC-5/46C15 • PLC-5/20E •PLC-5/60 •PLC-5/30 • PLC-5/60L •PLC-5/40 •PLC-5/80 • PLC-5/40C15 • PLC-5/80C15 • PLC-5/40E • PLC-5/80E •PLC-5/40 • PLC-5/80 2A or 2B 2 •PLC-5/60 1A or 1B performed by DH+ or remote I/O—you must make these changes manually by 5 reprogramming • PLC-5/20E • PLC-5/60L 2 1A or 1B performed by DH+ or remote I/O—you must make these changes manually by • PLC-5/40E • PLC-5/80E 5 reprogramming • PLC5/40L 2 performed by the ControlNet network—you must make these changes manually by 3,4,5 reprogramming 1 These include processor files, data-table files, and port configurations. 2 If you do not update the program, the ControlNet processor will fault. 3 You must change block-transfer instructions for the ControlNet system from the standard block transfer read (BTR) and block transfer write (BTW) instructions to scheduled transfers or to unscheduled CIO instructions. 4 You must edit non-ControlNet PLC-5 programs containing references to the I/O Status File for use with I/O connected via the ControlNet network. Information regarding ControlNet status is stored in a separate data file that you specify through the programming software. 5 If you do not update the program, the data-table locations corresponding to the “missing” I/O devices will not be updated. Converting from ControlNet Phase ControlNet phase 1.0 or 1.25 products will not work in a ControlNet 1.5 system. 1.0 or 1.25 to ControlNet Phase 1.5 To convert ControlNet phase 1.0 or 1.25 to ControlNet phase 1.5, contact your local Rockwell Automation sales office or distributor. 1785-UM022B-EN-P - February 2002 2-36 Planning to Use Your ControlNet PLC-5 Processor Notes 1785-UM022B-EN-P - February 2002 Chapter 3 Understanding the ControlNet System Software Using This Chapter This chapter describes the configuration and programming software that you use with your ControlNet PLC-5 processor and specific details about their maintenance. Although the software packages are separate tools, they have specific interdependencies that must be met in order to keep projects synchronized between one another. Configuring and Programming Use the following software packages to configure and program your ControlNet system. Your ControlNet System Use: To: TM RSNetWorx for ControlNet define ControlNet network parameters, such as: (henceforth RSNetWorx) • network update time • media redundancy • physical media configuration • maximum scheduled nodes • maximum unscheduled nodes • monitor I/O map entry status TM RSLogix 5 • enter user program files • create/delete/monitor data table files • enter module configuration • enter channel 0, 1A, 1B, and 3 configuration • administer passwords and privileges TM RSLinx provide the ControlNet network interfaces to: • poll the network for active devices • monitor station diagnostics Additionally, use: • RSNetWorx to configure the individual scheduled connections for the ControlNet PLC-5. RSNetWorx creates a project (.xc) file on your personal computer when you save the project. RSNetWorx writes to the Channel 2 configuration memory during an online save to the ControlNet PLC-5. • RSLogix 5 to configure and program all other parameters within the ControlNet PLC-5. RSLogix 5 creates a project (.rsp) file on your personal computer when you save the project. These two software packages are separate tools because RSNetWorx is used to configure the entire ControlNet network and RSLogix 5 is used to configure node-specific information. 1785-UM022B-EN-P - February 2002 3-2 Understanding the ControlNet System Software Also, the ControlNet network requires that the entire network be configured at one time to make sure all scheduled connections are performed at their configured packet rates. Two interdependencies exist between RSNetWorx and RSLogix 5: • the I/O configuration utility invoked in RSLogix 5 • the ControlNet configuration information is created and saved in RSNetWorx, but is also saved and downloaded in RSLogix 5 I/O Configuration Utility The I/O configuration utility in RSLogix 5 is used to simplify the configuration of intelligent I/O modules. It is important to understand the difference between I/O configuration over remote I/O vs. I/O configuration over ControlNet: • over remote I/O, the information displayed and entered in the configuration applet is always read and written to the data table. Thus, all of the I/O configuration functionality over remote I/O is contained with the RSLogix 5 application. • over ControlNet, the information displayed and entered in the configuration applet is read and written to both the data table and the RSNetWorx project (.xc) file. The I/O configuration data must be read and written to the RSNetWorx project (.xc) file so that the user can download the I/O configuration data from RSNetWorx. If the RSNetWorx project (.xc) file was not updated with the I/O configuration edits done within the I/O configuration utility, the edits would be lost when that RSNetWorx project file was downloaded. You must configure the association to the RSNetWorx project (.xc) file in RSLogix 5 so that RSLogix 5 knows which RSNetWorx project (.xc) file to access the I/O configuration information. You can do this within the Controller Properties window in RSLogix 5. If you don’t use the I/O configuration utility to edit or monitor ControlNet scheduled connections, the association to the RSNetWorx project (.xc) file in RSLogix 5 is unnecessary. Certain circumstances can cause the data table configuration information to differ from what is stored in the RSNetWorx project (.xc) file. This can occur when program logic is used to modify the contents of the data table for purposes of reconfiguring a module via a path other than the I/O configuration utility. If such “on the fly” reconfiguration is necessary for your application, consider that subsequently launching the I/O configuration utility applet will result in outdated information being displayed, unless that information has been imported into the RSNetWorx project (.xc) file. 1785-UM022B-EN-P - February 2002 Understanding the ControlNet System Software 3-3 Under these circumstances, consider the following guidelines: • when configuring intelligent modules over ControlNet, any configuration changes should be performed via a module’s respective applet in the I/O configuration utility. This will ensure that the edits are written to both the data table and the RSNetWorx project (.xc) file. • if you must configure an intelligent module over ControlNet via program logic, you must then upload the online network configuration in RSNetWorx to synchronize the contents of the data table with the RSNetWorx project (.xc) file. This will ensure that the I/O configuration utility applet will contain current information the next time it is launched. Uploading and Downloading Software Projects Considering that both RSLogix 5 and RSNetWorx can upload and download the ControlNet configuration information, you must make sure that both the RSLogix 5 project (.rsp) file and the RSNetWorx project (.xc) file contain the same ControlNet configuration information. For example, if outdated ControlNet configuration information is present in the RSLogix 5 project (.rsp) file, a download of the RSLogix 5 project may download ControNet configuration information that does not match the current ControlNet network. There are two reasons why the RSLogix 5 project (.xc) file contains ControlNet configuration information: • the RSNetWorx tool can only download to the entire ControlNet network. For example, in an application where a single ControlNet PLC-5 needs to have its program downloaded, RSNetWorx will attempt to download all nodes on the ControlNet network. This will be time-consuming and require that all ControlNet PLC-5 processors on the ControlNet network be placed in PROGRAM mode. • the RSLogix 5 download can download everything to a ControlNet PLC-5 in a single download. If the ControlNet configuration information was not contained within the RSLogix 5 project, both an RSLogix 5 project download and an RSNetWorx project download would be required. Verify that ControlNet PLC-5 Configuration Matches Network Information To make sure that the ControlNet configuration information downloaded to the ControlNet PLC-5 processor matches the current ControlNet network information, follow one of these procedures: Download from both RSNetWorx and RSLogix 5 You can download the ControlNet configuration information from RSNetWorx and the remaining controller information from RSLogix 5. 1785-UM022B-EN-P - February 2002 3-4 Understanding the ControlNet System Software When downloading the project from RSLogix 5, a dialog box appears and asks whether the ControlNet configuration information stored in the RSLogix 5 project should be downloaded. With this approach, you will want to keep the existing ControlNet configuration that is currently on the ControlNet PLC-5 processor. Download from RSLogix 5 Only You can download the entire program from RSLogix 5 while keeping the ControlNet configuration information up to date. When downloading the ControlNet configuration information from RSLogix 5, a dialog box appears and asks whether the ControlNet configuration information stored in the RSLogix 5 project should be downloaded. With this approach, you will want to overwrite the existing ControlNet configuration that is currently on the ControlNet PLC-5 processor with the ControlNet configuration information that is stored in the RSLogix 5 project (.rsp) file. The ControlNet configuration information in RSLogix 5 is kept up to date by uploading from the ControlNet PLC-5 processor and by saving a new RSLogix 5 project (.rsp) file following every save performed in RSNetWorx, or following an RSNetWorx project download if a save was performed off-line. Important: This approach simplifies the download to a single operation, however it requires the maintenance of keeping the RSLogix 5 project (.rsp) file up to date with the current ControlNet network configuration information for every PLC-5 processor on the ControlNet network. To do this, you must perform the RSLogix 5 upload and save for each and every save performed in RSNetWorx, even if no ControlNet configuration information changed for any ControlNet PLC-5 processor. This is required because a network keeper signature is reevaluated every save and is unique for every save. The network keeper signature is downloaded to every keeper-capable device on the ControlNet network. Using RSNetWorx to Perform Verification Activities After a Download or Save in RSNetWorx We recommend that you perform two verification activities following a download or save operation in RSNetWorx: • Verify Keeper Signatures • Verify Scanner Signatures 1785-UM022B-EN-P - February 2002 Understanding the ControlNet System Software 3-5 To verify keeper signatures: 1. In Network menu, choose Keeper Status 2. If any keepers are invalid, select the node(s) and click Update Keeper To verify scanner signatures: 1. In Network menu, choose Scanner Signature Status 2. If any scanners are invalid, download the RSNetWorx project to the processors that indicate a scanner signature mismatch (you may have to follow additional troubleshooting procedures in RSNetWorx to correct the scanner signature mismatch). Merge-Save Functionality When you add or delete nodes or when you add, modify, or delete I/O map table entries, only those processors on the network whose ControlNet schedules need to change are required to be in Program mode. This feature requires RSNetWorx for ControlNet version 1.6 or later. During the save operation, RSNetWorx gives you two options: • Optimize schedule for all connections: RSNetWorx recalculates the ControlNet schedule for all the nodes on the ControlNet network. The new schedule is downloaded to all the processors. The processors close all of their existing connections and then reopen their connections according to the new schedule. This option requires that all the processors be in Program mode. • Merge changes into existing schedule: RSNetWorx merges the pending changes into the current ControlNet schedule. The new schedule is only downloaded to those processors that are affected by the change. Only those processors that are affected by the change have to be in Program mode. All other processors on the network can remain in Run mode and their connections remain open. This option is only available if the current schedule can accommodate the pending changes and if the ControlNet network parameters (such as NUT, maximum scheduled address, maximum unscheduled address, or media redundancy) do not change. Important: Performing a download via RSNetWorx may require all the processors to be in Program mode. For More Information For more information about using these software packages, see the online help systems included with RSNetWorx for ControlNet and RSLogix 5 software. 1785-UM022B-EN-P - February 2002 3-6 Understanding the ControlNet System Software Notes 1785-UM022B-EN-P - February 2002 Chapter 4 Programming Your ControlNet System Using This Chapter If you want to read about using: Go to page: ControlNet message instructions 4-1 ControlNet I/O transfer instructions 4-3 ControlNet immediate data input and output instructions 4-6 Using Selectable Timed Interrupts (STIs) in a program on a 4-9 ControlNet network Recovering from Major Fault Codes 200 and 201 4-9 Using ControlNet You can use the Message (MSG) instruction and the MG data type to send message commands over the ControlNet system within the local Message Instructions ControlNet link: • PLC-5 TYPED WRITE • PLC-5 TYPED READ • PLC-3 WORD RANGE READ • PLC-3 WORD RANGE WRITE • PLC-2 UNPROTECTED READ • PLC-2 UNPROTECTED WRITE Use your programming software to go to the instruction entry for message block screen. If you want to: Do this: change the command Select one of the following: type • PLC-5 TYPED WRITE—to select a write operation to another PLC-5 processor • PLC-5 TYPED READ—to select a read operation from another PLC-5 processor • PLC-3 WORD RANGE READ—to select a write operation to another PLC-3 processor • PLC-3 WORD RANGE WRITE—to select a read operation from another PLC-3 processor • PLC-2 UNPROTECTED READ—to select a write operation to another PLC-2 processor • PLC-2 UNPROTECTED WRITE—to select a read operation from another PLC-2 processor enter a PLC-5 data Type the PLC-5 data table address. table address 1785-UM022B-EN-P - February 2002 4-2 Programming Your ControlNet System If you want to: Do this: enter the size in Type a number of elements from 1 to 1000. elements enter the destination Type a number from 1 to 99. network address enter a destination Type the destination data table address. data table address The fields of the MG data type that you can directly address are: Field Definition Location Enabled-waiting flag bit word 0, bit 02 .EW Continuous control bit word 0, bit 03 .CO Errored flag bit word 0, bit 04 .ER Done flag bit word 0, bit 05 .DN Started flag bit word 0, bit 06 .ST Enabled flag bit word 0, bit 07 .EN Abort (Time out) control bit word 0, bit 08 .TO No-response flag bit—not used word 0, bit 09 .NR No-cache bit word 0, bit 10 .NC Error-code word word 1 .ERR Requested length word word 2 .RLEN Done length word word 3 .DLEN Remaining words words 4 through 55 .DATA[0] through.DATA[51] For more detailed information about writing ladder programs and using message instructions, see your programming software documentation. Multihop Messaging Via the MSG Instruction 1756-CNB You can use the MSG instruction to communicate from a processor on one ControlNet link to a processor on another ControlNet link via ControlBus using 1756-CNB ControlNet bridge modules. You can also configure a ControlNet ladder MSG instruction to: • a Data Highway Plus device by bridging across the 1756-CNB(R) and 1756-DHRIO modules • an Ethernet device by bridging across the 1756-CNB(R) and ControlBus 1756-ENET modules Refer to your programming software documentation for information ControlNet Link 1 ControlNet Link 2 about configuring multihop messages. 1785-UM022B-EN-P - February 2002 Programming Your ControlNet System 4-3 Option to Close Communication Connection when MSG is Done This feature allows you to configure the ControlNet ladder MSG instruction to close its communication connection when the message operation is done - thus conserving ControlNet resources on low duty rate messages. Do this by setting the .NC configuration bit in the ladder MSG control file. Understanding the ControlNet PLC-2 Compatibility File When a PLC-2 command is received from the ControlNet network, the ControlNet PLC-5 processor uses the user-specified file as the PLC-2 compatibility file. All PLC-2 commands received from the ControlNet network use the same PLC-2 compatibility file. The ControlNet PLC-5 processor uses the value stored in S:73 of the processor status file as the PLC-2 compatibility file number. The PLC-2 file number must be between 3 and 999, inclusive. The corresponding data table file must exist and be large enough to accommodate the PLC-2 requests. You can use a MOV instruction in the ladder program to update S:73. The PLC-2 type MSG instructions error if the PLC-2 compatibility file on the target PLC-5 processor is invalid. Condition Error Code Returned Corrective Action PLC-2 Compatibility file number is: less than 3 or greater than 999 0x8000 Set S:73 to a value between 3 and 999, inclusive. between 3 and 999, but file does 0x8000 Create the data not exist table file referred by S:73. between 3 and 999, exists, but file is 0x5000 Increase the size of not large enough the data table file referred by S:73. Using the ControlNet I/O You can use the ControlNet I/O Transfer (CIO) instruction and the ControlNet Transfer (CT) data type to make ControlNet I/O transfers Transfer Instruction within the local ControlNet link. Use your programming software to go to the instruction entry for ControlNet I/O transfer block screen. 1785-UM022B-EN-P - February 2002 4-4 Programming Your ControlNet System If you want to: Do this: change the command Select one of the following: type • 1771 READ - reads input data from 1771 non-discrete I/O module • 1771 WRITE - writes output data to 1771 non-discrete I/O module • 1794 READ - reads data from a 1794 I/O module • 1794 WRITE - writes data to a 1794 I/O module • 1794 FAULT ACTION - changes the action that a module takes when it faults • 1794 IDLE ACTION - changes the action that a module takes when it is idle • 1794 CONFIG DATA - changes a module’s configuration data • CIP GENERIC - sends user-specified CIP service • 1794 CONFIG DATA - changes a module’s configuration data • 1794 SAFE STATE DATA - changes a module’s safe-state data • CIP GENERIC - sends user-specified CIP service • GENERIC BI-DIRECTIONAL - sends user-specified CIP service which requires reply data • 1747 READ INPUT - reads data from SLC I/O module input file • 1747 WRITE OUTPUT - writes data to SLC I/O module output file • 1747 READ M0 FILE - reads data from SLC I/O module M0 file • 1747 WRITE M0 FILE - writes data to SLC I/O module M0 file • 1747 READ M1 FILE - reads data from SLC I/O module M1 file • 1747 WRITE M1 FILE - writes data to SLC I/O module M1 file • 1747 SAFE STATE - change SLC I/O module safe state DATA data • 1747 WRITE FLAGS - change action SLC I/O module take when it faults and/or goes to idle • 1747 CONFIG DATA - change SLC module configuration data enter a PLC-5 data table Type the data table address. address enter the size in Type the number of elements: elements 1 • 0 to 64 for 1771 READ or 1771 WRITE • 1 for 1794 FAULT ACTION or 1794 IDLE ACTION • 1 to 15 for 1794 CONFIG DATA or 1794 SAFE STATE DATA • 1 to 16 for 1794 READ or 1794 WRITE • 1 to 32 for 1747 READ INPUT or 1747 WRITE INPUT • 1 to 138 for 1747 READ M0 FILE, 1747 WRITE M0 FILE 1747 READ M1 FILE, 1747 WRITE M1 FILE • 1 to 138 for 1747 SAFE STATE DATA • 1 for 1747 WRITE FLAGS • 1 to 138 for 1747 CONFIG DATA enter the destination Type a number from 1 to 99. network address enter the destination Type the number of the slot that holds the I/O device - number from 0 to 15. slot number 1 If you enter a 0, the module determines the size of the transfer. In this case, you must make sure that your data table can accommodate up to 64 words. 1785-UM022B-EN-P - February 2002 Programming Your ControlNet System 4-5 The fields of the CT data type that you can directly address are: Field Definition Location Enabled-waiting flag bit word 0, bit 02 .EW Continuous control bit word 0, bit 03 .CO Errored flag bit word 0, bit 04 .ER Done flag bit word 0, bit 05 .DN Started flag bit word 0, bit 06 .ST Enabled flag bit word 0, bit 07 .EN Abort (Time out) control bit word 0, bit 08 .TO Error-code word word 1 .ERR Requested length word word 2 .RLEN Done length word word 3 .DLEN Transfer file number word 4 .FILE Transfer element number word 5 .ELEM Remaining words words 6 through 21 .DATA[0] through.DATA[15] The CIP Generic and Generic Bi-directional CIO command types allow you to enter any possible CIP command over the ControlNet network. This allows the processor to send commands to devices not listed in the command type list, or to send special CIP commands to devices. Use of these command types requires specific details of the device to which the command is being sent. For more detailed information about writing ladder programs, see your programming software documentation. Sending Continuous Messages If you use continuous mode message instructions, do not toggle the rung condition unless the continuous message is done or errored. Once enabled, the continuous message will only stop under the following conditions: • if a message error is detected • if you reset the message CO bit • if you set the TO status bit You can change the CO and TO bits through the message block configuration screen or with ladder logic. 1785-UM022B-EN-P - February 2002 4-6 Programming Your ControlNet System 1771 ControlNet Transfers in PIIs and STIs When a 1771 Read or 1771 Write CIO instruction is encountered in a PII or STI, the processor resumes execution of lower priority ladder programs (main logic programs) until the CIO is completed. If you want the PII or STI to run to completion before returning to your main logic program, place the CIO instruction inside of a UID/UIE pair in your PII or STI program file. Using ControlNet You can use two instructions for immediate data input and output on a ControlNet network—Immediate Data Input (IDI) and Immediate Immediate Data Input and Data Output (IDO). Output Instructions IDI IMMEDIATE DATA INPUT Data file offset 232 Length 10 Destination N11:232 ID0 IMMEDIATE DATA OUTPUT Data file offset 175 Length 24 Source N12:175 1785-UM022B-EN-P - February 2002 Programming Your ControlNet System 4-7 In the previous example, an IDI is initiated that updates the destination file from the private buffer before the next normal input-image update. The Data File Offset (232) is the offset into the buffer where the data is stored. The Length (10) identifies the number of words in the transfer—it can be an immediate value ranging from 1 to 64 or a logical address that specifies the number of words to be transferred. The Destination (N11:232) is the destination of the words to be transferred. The Destination should be the matching data table address in the DIF except when you use the instruction to ensure data-block integrity in the case of Selectable Timed Interrupts (STIs). See page 4-9. IDI IMMEDIATE DATA INPUT Data file offset 232 Length 10 Destination N11:232 Data Table Private DIF Buffer N11:0 0 N11:232 232 IDI copies from Inputs arrive from the private DIF the ControlNet buffer to the network data table 1785-UM022B-EN-P - February 2002 4-8 Programming Your ControlNet System An IDO is initiated that updates the private memory output buffer from the source file before the next normal output-image update. The Data File Offset (175) is the offset into the buffer where the data is stored. The Length (24) identifies the number of words in the transfer or a logical address that specifies the number of words to be transferred. The Source (N12:175) is the source of the words to be transferred. The Source should be the matching data table address in the DOF except when you use the instruction to ensure data-block integrity in the case of Selectable Timed Interrupts (STIs). See page 4-9. IDO IMMEDIATE DATA OUTPUT Data file offset 175 Length 24 Source N12:175 Data Table Private DOF Buffer N12:0 0 N12:175 175 IDO instruction Outputs transmitted copies from the to the ControlNet data table to the network on next private opportunity DOF buffer For more detailed information about writing ladder programs and programming ControlNet I/O transfers using Immediate Input (IIN) and Immediate Output (IOT) instructions, see your programming software documentation. 1785-UM022B-EN-P - February 2002 Programming Your ControlNet System 4-9 Using Selectable Timed You must be careful when using Selectable Timed Interrupts (STIs) with a program on a ControlNet network. Interrupts with a Program on a ControlNet Network A Selectable Timed Interrupt (STI) periodically interrupts primary program execution in order to run a subprogram to completion. If an STI occurs while a normal ControlNet non-discrete I/O data transfer or a ControlNet Immediate Data I/O instruction (IDO or IDI) is in progress and they both operate on the same set of data, the integrity of that block of data is jeopardized. To ensure data-block integrity, write your STI routine so that it operates on its own copy of the data block that it needs. Use ControlNet Immediate Data I/O instructions (IDO and IDI) within your STI to copy the needed block of data out to and back from a temporary location that is different from that used by the normal data table. For detailed information about STIs, see your programming software documentation. Recovering from Major Fault 200 A Major Fault with error code 200 and 201 means that the processor was unable to transmit the scheduled data it is configured to transmit. and 201 This is typically caused by disturbances on the ControlNet channel because of missing terminators, bad connectors, or noisy conditions. These disturbances may cause the processor to fall off the network while its trying to transmit its scheduled data. If you consistently get these faults, you may want to check and repair the cable. This fault can also occur when the processor falls behind and did not have the scheduled data ready to send on time. Depending on the requirements of the application, you may consider adding a fault routine to the application to clear an occurrence of a Major Fault with error code 200 and 201. For detailed information about creating fault routines, refer to chapter 16 of the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12. Note: To monitor for ControlNet noise via ladder logic or HMI, declare a ControlNet diagnostic file using RSNetWorx. Refer to Appendix F: ControlNet Diagnostic File Layout for definitions. You can also monitor for ControlNet noise via RSWho’s station diagnostics in RSLinx. 1785-UM022B-EN-P - February 2002 4-10 Programming Your ControlNet System Notes 1785-UM022B-EN-P - February 2002 Chapter 5 Monitoring and Troubleshooting Your ControlNet System Using This Chapter If you want to read about: See page: Using the general status indicators 5-1 Using the ControlNet status indicators 5-3 Using the Data Highway Plus and Remote I/O Status Indicators 5-5 Monitoring the ControlNet configuration and status 5-5 Using the DH+/RIO Status Indicators 5-6 Using the General Status The general status indicators inform you of the general operational state of the processor. Indicators Indicator Color Description Probable Cause Recommended Action BATT BATT Red Battery low Battery low Replace battery within 10 days PROC Off Battery is good Normal operation No action required FORCE COMM 1785-UM022B-EN-P - February 2002 5-2 Monitoring and Troubleshooting Your ControlNet System Indicator Color Description Probable Cause Recommended Action PROC Green Processor is in run Normal operation No action required (steady) mode and fully operational Green Processor memory is Normal operation No action required (blinking) being transferred to EEPROM Red Major fault • RSLogix 5 During RSLogix 5 download, this is (blinking) download in normal operation - wait for progress download to complete. • Run-time error If not during RSLogix 5 download: • Check major fault bit in status file (S:11) for error definition • Clear fault, correct problem, and return to run mode Alternating Processor in Normal operation if No action required - allow flash Red and FLASH-memory processor's FLASH update to complete Green programming mode memory is being reprogrammed Red Power cycle with Battery is low, Properly replace or install battery problem battery disconnected or not (see Chapter 1 for more (steady) installed information) Red Fault with memory • New processor • Use programming software to loss clear and initialize memory (steady) • Invalid ControlNet • Verify that ControlNet address network address switch is not set to 0 •Processor has • Install battery (to preserve failed internal failure diagnostics), then power diagnostics down, reseat processor and power up; then reload your program. If you are unable to reload your program, replace the processor. If you are able to reload your program and fault persists, contact Technical Support at 440.646.6800 to diagnose the problem. Off Processor is in Check power supply and program load or test connections mode or is not receiving power FORCE Amber SFC and/or I/O forces Normal operation No action required (steady) enabled Amber SFC and/or I/O forces (blinking) present but not enabled Off SFC and/or I/O forces not present COMM Off No transmission on Normal operation if channel 0 channel is not being used Green Transmission on Normal operation if (blinking) channel 0 channel is being used 1785-UM022B-EN-P - February 2002 Monitoring and Troubleshooting Your ControlNet System 5-3 Using the ControlNet The ControlNet status indicators inform you of the operational state of the ControlNet network. Status Indicators Indicator Color Description Probable Cause Recommended Action I/O Off ControlNet I/O not Normal operation if No action required present or not Channel 2 not being used I/O operating Steady All nodes configured Normal operation No action required Green in the ControlNet map table present and operating properly AB Flashing At least one node Cable(s) or connector(s) Repair or replace cable(s) or Green/Off configured for the broken or not connected connector(s), and reconnect ControlNet network Destination module(s) bad Repair or replace module(s) not present or not or missing operating properly Node(s) not on network Connect node to network Flashing All nodes configured Cable(s) or connector(s) Repair or replace cable(s) or Red/Off for ControlNet not broken or not connected connector(s), and reconnect present or not Nodes not on network Connect nodes to network operating properly 1 Indicator Probable Cause Recommended Action Color Off Internal diagnostics failed 1. Turn power off, make sure ControlNet address is not 00, reseat processor, then power up and 2. Clear memory and reload your program A B 3. Replace EEPROM with new program 4. If still an error, replace the processor No power Check power supply Steady Red Faulted unit Cycle power or reset unit If fault persists, contact your Rockwell Automation representative or distributor Flashing Normal operation if processor is in No action required Green FLASH memory program mode Flashing The processor's ControlNet address Configure the ControlNet network so that UMAX is at Red/Green is above UMAX least as high as the processor's ControlNet address. Set the processor's ControlNet address at or below UMAX. Alternating Self-test No action required Red/Green Alternating Incorrect node configuration Check network address and other ControlNet Red/Off configuration parameters 1785-UM022B-EN-P - February 2002 5-4 Monitoring and Troubleshooting Your ControlNet System 1 Indicator Probable Cause Recommended Action Color Off Channel disabled No action required or Configure for ControlNet communication A B Steady Normal operation No action required Green Flashing Temporary errors Make sure that the processor is connected to the Green/Off ControlNet network with an Allen-Bradley tap. Check media for broken cables, loose connectors, missing terminators, etc. Flashing Media fault Make sure that the processor is connected to the Red/Off ControlNet network with an Allen-Bradley tap. Check media for broken cables, loose connectors, missing terminators, etc. No other nodes present on network Add other nodes to the network Flashing Incorrect network configuration Cycle power or reset unit Red/Green If fault persists, contact your Rockwell Automation representative or distributor 1 Definition of terms: • alternating–the two indicators alternate between the two defined states at the same time (applies to both indicators viewed together); the two indicators are always in opposite states, out of phase • flashing–the indicator alternates between the two defined states (applies to each indicator viewed independent of the other); if both indicators are flashing, they flash together, in phase • steady–indicator is on continuously in the defined state 1785-UM022B-EN-P - February 2002 Monitoring and Troubleshooting Your ControlNet System 5-5 Using the DH+/RIO Status Indicators Indicator Color Channel Mode Description Probable Cause Recommended Action Green Remote I/O Active Remote I/O link, all Normal No action required (steady) Scanner adapter modules are operation or present and not faulted A B Remote I/O Communicating with Adapter scanner DH+ Processor is transmitting or receiving on DH+ link Green Remote I/O At least one adapter is • Power off at • Restore power to the (blinking Scanner faulted or has failed remote rack rack rapidly or • Cable broken •Repair cable slowly) DH+ No other nodes on network Red Remote I/O Hardware fault Hardware error • Turn power off, then (steady) Scanner on. Remote I/O •Check that the Adapter software DH+ configurations match the hardware set-up. • Replace the processor. Red Remote I/O Faulted adapters detected • Cable not •Repair cable (blinking Scanner connected or rapidly or is broken slowly) • Power off at • Restore power to remote racks racks DH+ Bad communication on Duplicate node Correct station address DH+ detected Off Remote I/O Channel offline Channel is not Place channel online if Scanner being used needed Remote I/O Adapter DH+ 1785-UM022B-EN-P - February 2002 5-6 Monitoring and Troubleshooting Your ControlNet System Monitoring ControlNet Use the following software packages to monitor ControlNet configuration and status information. Configuration and Status Use: To: RSNetWorx for ControlNet define ControlNet network parameters, such as: • network update time • media redundancy • physical media configuration • maximum scheduled nodes • maximum unscheduled nodes • monitor I/O map entry status 1 RSLogix5 • monitor ControlNet diagnostic file • enter user program files • create/delete/monitor data table files • enter module configuration • enter channel 0, 1A, 1B, and, 3 configuration • administer passwords and privileges RSLinx to provide the ControlNet network interfaces to: • poll the network for active devices • monitor station diagnostics 1 It is highly recommended that you declare an extended ControlNet diagnostic file (63 words) using RSNetWorx. This file will allow you to monitor for noise (via ladder and HMI query), to monitor the overall health of scheduled connections (words 40 and 41), and to monitor ControlNet buffer usage. For information about using these software packages, see the online help systems for RSNetWorx for ControlNet and RSLogix5 software. 1785-UM022B-EN-P - February 2002 Appendix A Processor Specifications Backplane Current 1785-L20C15: 2.7A @ 5Vdc 1785-L40C15, -L46C15, -L80C15: 3.3A @ 5Vdc Heat Dissipation 1785-L20C15: 54 BTU/hour 1785-L40C15, -L46C15, -L80C15: 59 BTU/hour Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): o o 0-60 C (32–140 F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bc, Un-packaged Non-operating Dry Heat), IEC 60068-2-14 (Test Na, Un-packaged Non-operating Thermal Shock): o o –40 to 85 C (–40 to 185 F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5–95% non condensing Vibration IEC60068-2-6 (Test Fc, Operating): 2g @10–500Hz Shock IEC60068-2-27:1987, Test Ea (Unpackaged shock, ES#002) Operating - 30g Non-operating - 50g Emissions CISPR 11: Group 1, Class A ESD Immunity IEC 61000-4-2: 4kV contact discharges Radiated RF Immunity IEC 61000-4-3: 10V/m, 3V/m Broadcast Bands, with 1kHz sine-wave 80% AM from 30MHz to 1000Mhz EFT/B Immunity IEC 61000-4-4: +2kV at 5kHz on communications ports Surge Transient Immunity IEC 61000-4-5: +2kV line-earth(CM) on signal ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 30MHz Enclosure Type Rating None (open style) Time-of-Day Maximum Variations at 60° C: ± 5 min per month 1 Clock/Calendar Typical Variations at 20° C: ± 20 s per month Timing Accuracy: 1 program scan 2 Available Cartridges 1785-CHBM ControlNet Hot Backup Cartridge (required for each processor used in a hot backup system) 1785-RC Relay Cartridge Battery Allen-Bradley 1770-XYC 3 • 1785-ME32 Memory Modules • 1785-ME64 • 1785-M100 I/O Modules Bulletin 1771 I/O, 1794 I/O, 1746 I/O, and 1791 I/O including 8-, 16-, 32-pt, and intelligent modules 1 The clock/calendar will update appropriately each year. 2 The 1785-CHBM cannot be used with the 1785-5/60C processor. 3 The 1785-ME16 cannot be used with ControlNet PLC-5 processors. 4 For more information, refer to publication 1770-4.1, Industrial Automation Wiring and Grounding Guidelines. 5 See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. 1785-UM022B-EN-P - February 2001 A-2 Processor Specifications Hardware Addressing 2-slot • Any mix of 8-pt modules • 16-pt modules must be I/O pairs • No 32-pt modules 1-slot • Any mix of 8- or 16-pt modules • 32-pt modules must be I/O pairs 1/2-slot—Any mix of 8-,16-, or 32-pt modules 4 Communication •Serial Wire Category 2 •DH+ • DH using 1785-KA • Remote I/O • ControlNet 4 • Relay Cartridge Wire Category 1 Location 1771-A1B, -A2B, A3B, -A3B1, -A4B chassis; left-most slot Weight PLC-5/20C15: 3 lbs, 3 oz (1.45 kg) PLC-5/40C15: 3 lbs, 2 oz (1.42 kg) PLC-5/46C15: 3 lbs, 2 oz (1.42 kg) PLC-5/80C15: 3 lbs, 2 oz (1.42 kg) Keying • Between 40 and 42 • Between 54 and 56 Certifications UL UL Listed Industrial Control Equipment (when product is marked) CSA CSA Certified Process Control Equipment CSA CSA Certified Process Control Equipment for Class I, Division 2 Group A,B,C,D Hazardous Locations 5 CE European Union 89/336/EEC EMC Directive, compliant with: EN 50081-2; Industrial Emissions EN 50082-2; Industrial Immunity European Union 73/23/EEC LVD Directive, compliant with: EN 61131-2; Programmable Controllers 5 C-Tick Australian Radiocommunications Act, compliant with: AS/NZS 2064; Industrial Emissions 1 The clock/calendar will update appropriately each year. 2 The 1785-CHBM cannot be used with the 1785-5/60C processor. 3 The 1785-ME16 cannot be used with ControlNet PLC-5 processors. 4 For more information, refer to publication 1770-4.1, Industrial Automation Wiring and Grounding Guidelines. 5 See the Product Certification link at www.ab.com for Declarations of Conformity, Certificates, and other certification details. 1785-UM022B-EN-P - February 2002 Processor Specifications A-3 PLC-5/20C15 PLC-5/40C15 PLC-5/46C15 PLC-5/80C15 1 1 2 Maximum User Memory Words 16K 48K 48K 100K Maximum Total Any Mix 512 2048 2048 3072 I/O Complimentary 512 in and 512 2048 in and 2048 in and 3072 in and out 2048 out 2048 out 3072 out Program Scan Time 0.5 ms per K word (bit logic) 2 ms per K word (typical) 3 Transmission Rate 5M bit/s ControlNet I/O Network Update Time (NUT) 2-100 ms (user selectable) Number of ControlNet Ports 1 (redundant) Maximum Number of Nodes per Link without a Repeater 48—with 250 m (approx. 820 ft) cable length Maximum Number of Nodes per Link with Repeaters 99 Maximum Link Cable Length without a Repeater 1,000 m (approximately 3,280 ft)—with 2 nodes 500 m (approximately 1,640 ft)—with 32 nodes 250 m (approximately 820 ft)—with 48 nodes Maximum Number of I/O Map Entries 64 96 96 128 Maximum DIF/DOF Size 2000 words 3000 words 3000 words 4000 words Maximum Link Cable Length with Repeaters 6,000 m (approximately 19,680 ft)—with 2 nodes 3,000 m (approximately 9,840 ft)—typical Remote I/O and Transmission Rate 57.6K bit/s DH+ 115.2K bit/s 230.4K bit/s I/O Scan Time (Typical) 10 ms per rack @ 57.6K bit/s 7 ms per rack @ 115.2K bit/s 3 ms per rack @ 230K bit/s Maximum Number of Remote I/O Racks 3 15 15 23 Maximum Number of Remote I/O Devices 12 60 60 92 Number of Ports Configurable for DH+ or Remote I/O 1 2 2 2 (Adapter or Scanner) Number of Dedicated DH+ Ports 1 0 0 0 Number of Serial Ports 1 Number of Coprocessor Ports 1 Maximum Number of MCPs 16 1 The PLC-5/40C15 and -5/46C15 processors have a limit of 32K words per data-table file. 2 The PLC-5/80C15 processor has a limit of 56K words per program file and 32 K words per data table file. The PLC-5/80C processor has 64K words of total data table space. 3 For more information, see the ControlNet Cable System Planning and Installation Manual, publication 1786-6.2.1. 1785-UM022B-EN-P - February 2002 A-4 Processor Specifications The following information applies when operating this Informations sur l’utilisation de cet équipement en equipment in hazardous locations: environnements dangereux : Products marked “CL I, DIV 2, GP A, B, C, D” are suitable Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne for use in Class I Division 2 Groups A, B, C, D, Hazardous conviennent qu’à une utilisation en environnements de Locations and nonhazardous locations only. Each product is Classe I Division 2 Groupes A, B, C, D dangereux et non supplied with markings on the rating nameplate indicating dangereux. Chaque produit est livré avec des marquages sur the hazardous location temperature code. When combining sa plaque d’identification qui indiquent le code de products within a system, the most adverse temperature code température pour les environnements dangereux. Lorsque (lowest “T” number) may be used to help determine the plusieurs produits sont combinés dans un système, le code de overall temperature code of the system. Combinations of température le plus défavorable (code de température le plus equipment in your system are subject to investigation by the faible) peut être utilisé pour déterminer le code de local Authority Having Jurisdiction at the time of température global du système. Les combinaisons installation. d’équipements dans le système sont sujettes à inspection par les autorités locales qualifiées au moment de l’installation. EXPLOSION HAZARD RISQUE D’EXPLOSION WARNING AVERTISSMENT • Do not disconnect equipment • Couper le courant ou s’assurer unless power has been que l’environnement est classé removed or the area is known non dangereux avant de to be nonhazardous. débrancher l'équipement. ! ! • Do not disconnect connec- • Couper le courant ou s'assurer tions to this equipment unless que l’environnement est classé power has been removed or non dangereux avant de the area is known to be non- débrancher les connecteurs. hazardous. Secure any external Fixer tous les connecteurs connections that mate to this externes reliés à cet équipe- equipment by using screws, ment à l'aide de vis, loquets sliding latches, threaded con- coulissants, connecteurs filetés nectors, or other means pro- ou autres moyens fournis avec vided with this product. ce produit. • Substitution of components • La substitution de composants may impair suitability for peut rendre cet équipement Class I, Division 2. inadapté à une utilisation en environnement de Classe I, • If this product contains batter- Division 2. ies, they must only be changed in an area known to be non- • S’assurer que l’environne- hazardous. ment est classé non dangereux avant de changer les piles. 1785-UM022B-EN-P - February 2002 Appendix B Processor Status File S:0 - S:2 Processor status data is stored in data-file 2. This word of Stores: the status file: S:0 Arithmetic flags • bit 0 = carry • bit 1 = overflow • bit 2 = zero • bit 3 = sign S:1 Processor status and flags S:1/00 RAM checksum is invalid at power-up S:1/01 Processor in run mode S:1/02 Processor in test mode S:1/03 Processor in program mode S:1/04 Processor uploading to memory module S:1/05 Processor in download mode S:1/06 Processor has test edits enabled S:1/07 Mode select switch in REMOTE position S:1/08 Forces enabled S:1/09 Forces present S:1/10 Processor successfully uploaded to memory module S:1/11 Performing online programming S:1/12 Not defined S:1/13 User program checksum calculated S:1/14 Last scan of ladder or SFC step S:1/15 Processor running first program scan or the first scan of the next step in an SFC S:2 Switch setting information S:2/00 Channel 1A DH+ station number through S:2/05 S:2/06 Channel 1A DH+ baud rate 0 57.6 kbps 1 230.4 kbps 1785-UM022B-EN-P - February 2001 B-2 Processor Status File This word of Stores: the status file: S:2/07 Not defined S:2/08 S:2/09 Last state 0 outputs are turned off 1 outputs retain last state S:2/11 I/O chassis addressing S:2/12 bit 12 bit 11 0 0 illegal 101/2-slot 011-slot 112-slot S:2/13 Memory module transfer S:2/14 bit 14 bit 13 0 0 memory module transfers to processor memory if processor memory is not valid 0 1 memory module does not transfer to processor memory 1 1 memory module transfers to processor memory at powerup S:2/15 Processor memory protection 0 enabled 1 disable S:3-10 This word of Stores: the status file: S:3 to S:6 Active Node table for channel 1A Word Bits DH+ Station # 3 0-15 00-17 4 0-15 20-37 5 0-15 40-57 6 0-15 60-77 S:7 Global status bits: (See also S:27, S:32, S:33, S:34, and S:35) • S:7/0-7 rack fault bits for racks 0-7 • S:7/8-15 unused S:8 Last program scan (in ms) S:9 Maximum program scan (in ms) S:10 Minor fault (word 1) See also S:17 S:10/00 Battery is low (replace in 1-2 days) S:10/01 DH+ active node table has changed S:10/02 STI delay too short, interrupt program overlap S:10/03 memory module transferred at power-up 1785-UM022B-EN-P - February 2002 Processor Status File B-3 This word of Stores: the status file: S:10/04 Edits prevent SFC continuing; data table size changed during program mode; reset automatically in run mode S:10/05 Invalid I/O status file S:10/06 reserved S:10/07 No more command blocks exist to execute block-transfers S:10/08 Not enough memory on the memory module to upload the program from the processor S:10/09 No MCP is configured to run S:10/10 MCP not allowed S:10/11 PII word number not in local rack S:10/12 PII overlap S:10/13 no command blocks exist to get PII S:10/14 Arithmetic overflow S:11 This word of Stores: the status file: S:11 major fault word S:11/00 Corrupted program file (codes 10-19). See major fault codes (S:12). S:11/01 Corrupted address in ladder program (codes 20-29). See major fault codes (S:12). S:11/02 Programming error (codes 30-49). See major fault codes (S:12). S:11/03 Processor detected an SFC fault (codes (71-79). See major fault codes (S:12). S:11/04 Processor detected an error when assembling a ladder program file (code 70); duplicate LBLs found. S:11/05 Start-up protection fault. The processor sets this major fault bit when powering up in Run mode if the user control bit S:26/1 is set. S:11/06 Peripheral device fault S:11/07 User-generated fault; processor jumped to fault routine (codes 0-9). See major fault codes (S:12). S:11/08 Watchdog faulted S:11/09 System configured wrong (codes 80 - 82, 84 - 88, 200 - 208). See major fault codes (S:12). S:11/10 Recoverable hardware error S:11/11 MCP does not exist or is not a ladder or SFC file 1785-UM022B-EN-P - February 2002 B-4 Processor Status File This word of Stores: the status file: S:11/12 PII file does not exist or is not a ladder file S:11/13 STI file does not exist or is not a ladder file S:11/14 Fault routine does not exist or is not a ladder file S:11/15 Faulted program file does not contain ladder logic S:12 This word stores the following fault codes: This fault code: Indicates this fault: And the fault is: 00-09 Reserved for user-defined fault codes. Recoverable: You can use user-defined fault codes to identify different types of faults or error conditions in your the fault routine can instruct program by generating your own recoverable fault. To use these fault codes, choose an input condition the processor to clear the that decides whether to jump to a fault routine file, then use the JSR instruction as the means to jump to fault and then resume the fault routine file. scanning the program. To use the JSR instruction, enter the fault code number 0-9 (an immediate value) as the first input parameter of the instruction. Any other input parameters are ignored (even if you have an SBR instruction A fault routine executes at the beginning of your fault routine file. You cannot pass parameters to the fault routine file using when any of these faults JSR/SBR instructions). occur. You do not have to use the user-defined fault codes to generate your own fault. If you program a JSR with no input parameters, the processor will write a zero to the Fault Code field. The purpose of using the user-defined fault codes is to allow you to distinguish among different types of faults or error codes based on the 0-9 fault code numbers. When the input condition is true, the processor copies the fault code number entered as the first input parameter of the JSR instruction into word 12 of the processor status file (S:12), which is the Fault Code field. The processor sets a Major Fault S:11/7 “User-Generated Fault.” The processor then faults unless you clear the Major Fault word (S:11) or the specific fault bit via ladder logic in the fault routine. 1785-UM022B-EN-P - February 2002 Processor Status File B-5 This fault code: Indicates this fault: And the fault is: 10 Run-time data table check failed Recoverable: the fault routine can instruct 11 Bad user program checksum the processor to clear the fault and then resume 12 Bad integer operand type, restore new processor memory file scanning the program. 13 Bad mixed mode operation type, restore new processor memory file A fault routine executes 14 Not enough operands for instruction, restore new processor memory file when any of these faults occur. 15 Too many operands for instructions, restore new processor memory file 16 Corrupted instruction, probably due to restoring an incompatible processor memory file (bad opcode) 17 Can’t find expression end; restore new processor memory file 18 Missing end of edit zone; restore new processor memory file 19 Download aborted 20 You entered too large an element number in an indirect address 21 You entered a negative element number in an indirect address 22 You tried to access a non-existent program file 23 You used a negative file number, you used a file number greater than the number of existing files, or you tried to indirectly address files 0, 1, or 2 24 You tried to indirectly address a file of the wrong type Recoverable 30 You tried to jump to one too many nested subroutine files Non-recoverable: the fault routine will be 31 You did not enter enough subroutine parameters executed but cannot clear major fault bit 2. 32 You jumped to an invalid (non-ladder) file 33 You entered a CAR routine file that is not 68000 code 34 You entered a negative preset or accumulated value in a timer instruction Recoverable 35 You entered a negative time variable in a PID instruction 36 You entered an out-of-range setpoint in a PID instruction 37 You addressed an invalid module in a block-transfer, immediate input, or immediate output instruction 38 You entered a RET instruction from a non-subroutine file Non-recoverable the fault routine will be 39 FOR instruction with missing NXT executed but cannot clear major fault bit 2. 40 The control file is too small for the PID, BTR, BTW, or MSG instruction Recoverable 1785-UM022B-EN-P - February 2002 B-6 Processor Status File This fault code: Indicates this fault: And the fault is: 41 NXT instruction with missing FOR Non-recoverable the fault routine will be 42 You tried to jump to a non-existent label executed but cannot clear major fault bit 2. 43 File is not an SFC 44 Error using SFR. This error occurs if: • you tried to reset into a simultaneous path • you specified a step reference number that is not found or is not tied to a step (it is a transition) • the previous SFR to a different step is not complete 45 Invalid channel number entered Recoverable 46 Length operand of IDI or IDO instruction is greater than the maximum allowed 47 SFC action overlap. An action was still active when the step became re-activated Non-recoverable 48-69 Reserved Recoverable 70 The processor detected duplicate labels 71 The processor tried to start an SFC subchart that is already running 72 The processor tried to stop an SFC subchart that isn’t running 73 The processor tried to start more than the allowed number of subcharts 74 SFC file error detected 75 The SFC has too many active functions 76 SFC step loops back to itself. 77 The SFC references a step, transition, subchart, or SC file that is missing, empty or too small 78 The processor cannot continue to run the SFC after power loss 79 You tried to download an SFC to a processor that cannot run SFCs 80 You have an I/O configuration error Recoverable 81 You illegally set an I/O chassis backplane switch by setting both switch 4 and 5 on 82 Illegal cartridge type for selected operation. This error also occurs if the processor doesn’t have a memory module, but the backplane switches are set for a memory module. Make sure the backplane switches are correct (set switch 6 ON and switch 7 OFF if the processor doesn’t have a memory module). 1785-UM022B-EN-P - February 2002 Processor Status File B-7 This fault code: Indicates this fault: And the fault is: 83 User watchdog fault Recoverable 84 Error in user-configured adapter mode block-transfer 85 Memory module bad 86 Memory module is incompatible with host 87 Scanner rack list overlap 88 Scanner channels are overloading the remote I/O buffer; too much data for the processor to process. If you encounter fault code 88, be sure you followed the design guidelines listed on page ___. Specifically, make sure you: • group together 1/4-racks and 1/2-racks of each logical rack. Do not intersperse these with other rack numbers • if using complementary I/O addressing, treat complementary rack addresses individually when grouping racks; primary rack numbers are separate from complement rack numbers 90 Sidecar module extensive memory test failed. Call your Rockwell Automation representative for service 91 Sidecar module undefined message type 92 Sidecar module requesting undefined pool 93 Sidecar module illegal maximum pool size 94 Sidecar module illegal ASCII message 95 Sidecar module reported fault, which may be the result of a bad sidecar program or of a hardware failure 96 Sidecar module not physically connected to the PLC-5 processor 3 97 Sidecar module requested a pool size that is too small for PC command (occurs at power-up) 98 Sidecar module first/last 16 bytes RAM test failed 99 Sidecar module-to-processor data transfer faulted 100 Processor-to-sidecar module transfer failed 101 Sidecar module end of scan transfer failed 102 The file number specified for raw data transfer through the sidecar module is an illegal value 103 The element number specified for raw data transfer through the sidecar module is an illegal value 104 The size of the transfer requested through the sidecar module is an illegal size 105 The offset into the raw transfer segment of the sidecar module is an illegal value 106 Sidecar module transfer protection violation; for PLC-5/26, -5/46, and -5/86 processors only 200 ControlNet scheduled output data missed. Recoverable The processor is unable to transmit the scheduled data it is configured to transmit. Check your network for missing terminators or other sources of electrical noise (see the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1) 1785-UM022B-EN-P - February 2002 B-8 Processor Status File This fault code: Indicates this fault: And the fault is: 201 ControlNet input data missed. Recoverable The processor is unable to process incoming data from the network. Check your network for missing terminators or other sources of electrical noise (see the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1). 202 ControlNet diagnostic data missed. Recoverable Contact your local Rockwell Automation representative if you get this message. 203 ControlNet schedule transmit data overflow. Recoverable Contact your local Rockwell Automation representative if you get this message. 204 Too many output connections per NUI. Recoverable Make scheduled outputs with short Requested Packet Intervals longer and reaccept edits for the ControlNet configuration. 1785-UM022B-EN-P - February 2002 Processor Status File B-9 This fault code: Indicates this fault: And the fault is: 205 ControlNet configuration exceeds processor bandwidth. Recoverable IMPORTANT: Scheduled connections will be closed. You must cycle power, save with RSNetWorx, Reduce the number of or download the program to reopen the connections. ControlNet I/O map table entries. Possible ways: Because the configuration software is unable to accurately predict all the resources that the processor will require to execute your ControlNet configuration software (based on the relative loading on the • using a discrete rack processor), this fault code is used if the processor determines that your configuration (typically when you connection instead of accept Channel 2 edits) exceeds the processor’s available bandwidth. multiple discrete module connections Typical causes of this error code include: • combining multiple I/O • receiving data from the ControlNet network faster than the ControlNet PLC-5 processor can parse it racks into a single I/O • performing I/O updates too frequently rack • performing immediate ControlNet I/O ladder instructions too frequently • putting peer-to-peer data in contiguous blocks in See S:74 and S:75 for additional information. the data table so that less send and receive scheduled messages are required Increase your Network Update Time and/or increase the Requested Packet Intervals for scheduled data transfers in your I/O map table. Increase your ladder program scan by either adding more logic or by increasing the Communications Time Slice (S:77). Reduce the number or frequency of immediate ControlNet I/O ladder instructions that are performed. 206 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 207 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 208 Too many pending ControlNet I/O connections. Recoverable Delete one or more I/O map table entries and reaccept edits for the ControlNet configuration. 230 System attempted transition to Run mode with processor in Invalid backup state. Change from the Invalid backup state to the No Control backup state before transitioning into Run mode. Refer to the Invalid backup state troubleshooting table later in this chapter. 1785-UM022B-EN-P - February 2002 B-10 Processor Status File This fault code: Indicates this fault: And the fault is: 231 Bypassed qualification (may occur during race condition when both processors attempt to go into Run Transition the PLC-5 mode at the same time). processors into Run mode one at a time. 232 Both processors attempted to be primaries. Check all media for broken cables, loose connectors, missing terminators, etc. 233 ControlNet configuration invalid on transition into Run mode. Reconfigure the ControlNet channel. 234 Failed Qualification. Refer to the qualification major faults troubleshooting table later in this chapter. Illegal invalid backup state Cycle power to the 235 processor. If the fault reoccurs, contact Rockwell Automation Technical Support at 440-646-6800 Illegal No Control backup state Cycle power to the 236 processor. If the fault reoccurs, contact Rockwell Automation Technical Support at 440-646-6800 Illegal Primary/Secondary backup state Cycle power to the 237 processor. If the fault reoccurs, contact Rockwell Automation Technical Support at 440-646-6800 Incompatible firmware revisions Install the same series and 238 revision of firmware into both hot backup PLC-5 processors ControlNet keeper mismatch Use RSNetworx to make the 239 PLC-5 processor a valid keeper 1785-UM022B-EN-P - February 2002 Processor Status File B-11 S:13-S:24 This word of Stores: the status file: S:13 Program file where fault occurred S:14 Rung number where fault occurred S:15 VME status file S:16 I/O status File S:17 Minor fault (word 2) See also S:10. S:17/00 BT queue full to remote I/O S:17/01 Queue full - channel 1A; maximum remote block-transfers used S:17/02 Queue full - channel 1B; maximum remote block-transfers used S:17/03 Queue full - channel 2A; maximum remote block-transfers used S:17/04 Queue full - channel 2B; maximum remote block transfers used S:17/05 No modem on serial port S:17/06 • Remote I/O rack in local rack table or • Remote I/O rack is greater than the image size. This fault can also be caused by the local rack if the local rack is set for octal density scan and the I/O image tables are smaller than 64 words (8 racks) each. S:17/07 Firmware revision for channel pairs 1A/1B or 2A/2B does not match processor firmware revision S:17/08 ASCII instruction error S:17/09 Duplicate node address S:17/10 DF1 master poll list error S:17/11 Protected processor data table element violation S:17/12 Protected processor file violation S:17/13 Using all 32 ControlNet MSGs S:17/14 Using all 32 ControlNet 1771 CIOs S:17/15 Using all 8 1794 ControlNet Flex I/O CIOs S:18 Processor clock year S:19 Processor clock month S:20 Processor clock day S:21 Processor clock hour S:22 Processor clock minute 1785-UM022B-EN-P - February 2002 B-12 Processor Status File This word of Stores: the status file: S:23 Processor clock second S:24 Indexed addressing offset S:25 Reserved S:26-S:35 This word of Stores: the status file: S:26 User control bits S:26/00 Restart/continuous SFC: when reset, processor restarts at first step in SFC. When set, processor continues with active step after power loss or change to RUN S:26/01 Start-up protection after power loss: when reset, no protection. When set, processor sets major fault bit S:11/5 when powering up in run mode. S:26/02 Define the address of the local rack: when reset, local rack address is 0. When set, local rack address is 1. S:26/03 Set complementary I/O (series A only): when reset, complementary I/O is not enabled. When set, complementary I/O is enabled. S:26/04 Local block-transfer compatibility bit: when reset, normal operation. When set, eliminates frequent checksum errors to certain BT modules. S:26/05 PLC-3 scanner compatibility bit: when set (1), adapter channel response delayed by 1 ms; when reset (0) operate in normal response time. S:26/06 Data table-modification inhibit bit. When set (1), user cannot edit the data table or modify forces while the processor keyswitch is in the RUN position. You control this bit with your programming software S:26/07 Reserved through S:26/15 S:27 Rack control bits: (See also S:7, S:32, S:33, S:34, and S:35) • S:27/0-7 - - I/O rack inhibit bits for racks 0-7 • S:27/8-15 - - I/O rack reset bits for racks 0-7 S:28 Program watchdog setpoint S:29 Fault routine file S:30 STI setpoint S:31 STI file number S:32 Global status bits: (See also S:7, S:27, S:33, S:34, and S:35) • S:32/0-7 rack fault bits for racks 10-17 (octal) • S:32/8-15 unused 1785-UM022B-EN-P - February 2002 Processor Status File B-13 This word of Stores: the status file: S:33 Rack control bits: (See also S:7, S:27, S:32, S:34, and S:35) • S:33/0-7 I/O rack inhibit bits for racks 10-17 • S:33/8-15 I/O rack reset bits for racks 10-17 S:34 Global status bits: (See also S:7, S:27, S:32, S:33, and S:35) • S:34/0-7 rack fault bits for racks 20-27 (octal) • S:34/8-15 unused S:35 Rack control bits: (See also S:7, S:27, S:32, S:33, and S:34) • S:35/0-7 I/O rack inhibit bits for racks 20-27 • S:35/8-15 I/O rack reset bits for racks 20-27 Important: Setting inhibit bits in the processor status file (S:27, S:33, or S:35) does not update inhibit bits in the I/O status file. S:36-S:78 This word of Stores: the status file: S:36 - S:45 Reserved S:46 PII program file number S:47 PII module group S:48 PII bit mask S:49 PII compare value S:50 PII down count S:51 PII changed bit S:52 PII events since last interrupt S:53 STI scan time (in ms) S:54 STI maximum scan time (in ms) S:55 PII last scan time (in ms) S:56 PII maximum scan time (in ms) S:57 User program checksum S:58 Reserved S:59 Extended-local I/O channel discrete transfer scan (in ms) S:60 Extended-local I/O channel discrete maximum scan (in ms) S:61 Extended-local I/O channel block-transfer scan (in ms) S:62 Extended-I/O channel maximum block-transfer scan (in ms) S:63 Protected processor data table protection file number 1785-UM022B-EN-P - February 2002 B-14 Processor Status File This word of Stores: the status file: S:64 The number of remote block-transfer command blocks being used by channel pair 1A/1B. S:65 The number of remote block-transfer command blocks being used by channel pair 2A/2B. S:66 Reserved. S:68 Installed memory card type. The four most-significant bits indicate memory card type: Value: Memory card type: 0 No memory card installed 1 1785-ME16 installed 2 1785-ME32 installed 3 1785-ME64 installed 4 1785-ME100 installed 5 1785-CHBM installed 6 1785-RC installed 7-15 Reserved When the 1785-RC module is installed, the eight least-significant bits indicate the memory card’s status: Bit: Is set when: 3 the 1785-RC memory card is installed in the processor 2 contact is detected closed. The bit resets when contact is detected open 1 the relay is driven open. The bit resets when the relay is closed. 0 120Vac is present on the memory card. The bit resets when 120Vac is not present on the card. When any other memory card is installed, the bits are undefined S:72 ControlNet node number of this processor. S:73 ControlNet PLC-2 compatibility file When a PLC-2 command is received from the ControlNet network, the processor uses this file number. The PLC-2 file number must be between 3 and 999, inclusive. S:74 Time (in milliseconds) between iterations of the ControlNet subsystem diagnostics When this value exceeds 2000, the processor may major fault with error code 205. See Appendix E, “Fault Codes”. S:75 Maximum amount of time (in milliseconds) between iterations of the ControlNet subsystem diagnostics S:76 Number of slots in processor-resident local rack 0 Illegal 14 slots 2 12 slots 38 slots 4 16 slots S:77 Communication time slice for communication housekeeping functions (in ms) S:78 MCP I/O update disable bits Bit 0 for MCP A Bit 1 for MCP B etc. 1785-UM022B-EN-P - February 2002 Processor Status File B-15 S:79-S127 This word of Stores: the status file: S:79 MCP inhibit bits Bit 0 for MCP A Bit 1 for MCP B etc. S:80-S:127 MCP file number MCP scan time (in ms) MCP max scan time (in ms) The above sequence applies to each MCP; therefore, each MCP has 3 status words. For example, word 80: file number for MCP A word 81: scan time for MCP A word 82: maximum scan time for MCP A word 83: file number for MCP B word 84: scan time for MCP B etc. 1785-UM022B-EN-P - February 2002 B-16 Processor Status File Notes 1785-UM022B-EN-P - February 2002 Appendix C ControlNet Instruction Set For detailed information about the instruction set for programming PLC-5 processors, see the Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12, and the PLC-5 Instruction Set Reference, publication 1785-6.1. ControlNet I/O Transfer Instruction Instruction Description ControlNet I/O Transfer If the input conditions go from false to true, the data is CIO CT transferred according to the instruction parameters you set when you enter the ControlNet I/O transfer instruction. CNET I/O TRANSFER The Control Block (CT21:50) contains status and instruction Control block CT21:50 parameters. Status Bits You cannot use N (integer) control blocks on the TO–Time-Out Bit ControlNet network. EW–Enabled-Waiting Bit CO–Continuous Bit For continuous CIOs, condition the rung to be true for only ER–Error Bit one scan. DN–Done Bit ST–Start Bit EN–Enable Bit Message Instructions on a ControlNet Network Instruction Description Message If the input conditions go from false to true, the data is MSG MSG transferred according to the instruction parameters you set when you enter the message instruction. The Control Block SEND/RECEIVE MESSAGE (MG10:10) contains status and instruction parameters. Control block MG10:10 Status Bits You cannot use N (integer) control blocks on the ControlNet TO–Time-Out Bit network. EW–Enabled-Waiting Bit CO–Continuous Bit For continuous MSGs, condition the rung to be true for only ER–Error Bit one scan. DN–Done Bit ST–Start Bit EN–Enable Bit NC–No Cache Bit 1785-UM022B-EN-P - February 2002 C-2 ControlNet Instruction Set Immediate Data I/O Instructions Instruction Description Immediate Data If the input conditions are true, an immediate data input is initiated that IDI Input updates the destination file from the private buffers before the next normal IDI input-image update. The Data file offset (232) is where the data is stored. IMMEDIATE DATA INPUT The Length (10) identifies the number of words in the transfer–it can be an Data file offset 232 immediate value ranging from 1 to 64 or a logical address that specifies the number of words to be transferred. The Destination (N11:232) is the Length 10 destination of the words to be transferred. The Destination should be the matching data-table address in the DIF except when you use the instruction Destination N11:232 to ensure data-block integrity in the case of Selectable Times Interrupts (STIs). See page 4-8. Immediate Data If the input conditions are true, an immediate data output is initiated that IDO Output updates the private memory output buffers from the source file before the IDO next normal output-image update. The Data file offset (175) is the offset into IMMEDIATE DATA OUTPUT the buffer where the data is stored. The Length (24) identifies the number of Data file offset 175 words in the transfer–it can be an immediate value ranging from 1 to 64 or a logical address that specifies the number of words to be transferred. The Length 24 Source (N12:175) is the source of the words to be transferred. The Source should be the matching data-table address in the DOF except when you use Source N12:175 the instruction to ensure data-block integrity in the case of Selectable Timed Interrupts (STIs). See page 4-8. Immediate I/O Execution Times Execution Time (μs) Instruction: Processor: Words of Memory True: False: INN - Immediate Input PLC-5/20 C15 389 1.1 2 PLC-5/40C15, -5/46C15 and 347 -5/80C15 IOT - Immediate Output PLC-5/20 C15 323+(14.5 x dis)+(6.7 x DOF) 1.1 2 PLC-5/40C15, -5/46C15 and 330+(27.5 x dis)+(13.25 x DOF) -5/80C15 IDI - Immediate Data PLC-5/20 C15 538+(0.65 x words) 1.1 4-7 Input PLC-5/40C15, -5/46C15 and 488+(0.65 x words) -5/80C15 IDO - Immediate Data PLC-5/20 C15 286+(1.23 x words)+(14.5 x 1.1 4-7 Output DOF)+(6.7 x dis) PLC-5/40C15, -5/46C15 and 270+(1.6 x words)+(27.5 x -5/80C15 DOF)+(13.25 x dis) words - IDI or IDO transfer length dis - Total number of ControlNet connections using the discrete Output image file DOF - Total number of ControlNet connections using the Data Output File 1785-UM022B-EN-P - February 2002 Appendix D ControlNet I/O Map-Entry Status Words and Error Codes I/O Map-Entry The ControlNet status file is an integer data-table file that you specify and configure with the I/O map for scheduled-I/O usage. It contains Status Words status information about all of the ControlNet network’s scheduled I/O connections. Each I/O map-table entry has a status-file offset field pointing to three status words associated with the connection. Immediate Inhibit Bit PCSC Overflow Bit PCSC New Data Bit PCSC Enable Bit First Word 15 14 013 12 11 10 009 08 07 06 0 05 04 03 0 02 01 000 Reset Data Data Run Mode Reserved Bit Underrun Overrun Data Invalid Bit Reserved Inhibit Bit Connection Error Bit System Bits User Bits 15 14 013 12 11 10 009 08 07 06 0 05 04 03 0 02 01 000 Error Messages 15 14 013 12 11 10 009 08 07 06 0 05 04 03 0 02 01 000 For critical I/O points, always condition your logic with bits 8 and 9 of the first ControlNet status word. 1785-UM022B-EN-P - February 2002 D-2 ControlNet I/O Map-Entry Status Words and Error Codes The following table explains the bits in the first word of the ControlNet I/O status file: Bit Number Description Use 00 Reset Bit Set this bit to put the associated connection into PROGRAM mode, even if the processor is in Run mode. Clear this bit to set the mode of the associated connection according to the processor’s mode. This bit has no effect for 1771 block transfer modules. 01 Inhibit Bit Set this bit to perform an orderly shutdown of the associated connection. If the target node is a ControlNet adapter, the adapter will go into idle mode. The processor will not attempt to reopen the connection as long as this bit is set. The processor will also set the Data Invalid Bit and Connection Error Bit. Clear this bit to allow the processor to attempt to open the associated connection. 02 PCSC Enable Bit Set this bit to enable Process Control Sample Complete for the associated I/O map entry. Clear this bit to disable Process Control Sample Complete for the associated I/O map entry. 03 PCSC New Data Bit The processor sets this bit when the PCSC Enable Bit is set and new data arrives from the associated connection. Clear this bit when you are finished processing the current sample of data. 04 PCSC Overflow Bit The processor sets this bit when the PCSC Enable Bit and the PCSC New Data Bits are set and new data arrives from the associated connection. This means that PCSC data is arriving faster than your ladder program is processing it. Clear this bit after you modify your ladder program to handle the incoming PCSC data. 05 Immediate Inhibit Bit Set this bit to immediately stop communicating on the associated connection. This has the same effect as if you disconnected the target node from the ControlNet network. If the target node is a ControlNet adapter and the adapter is setup for Processor Restart Lockout, the adapter will go into Processor Restart Lockout mode. The processor will not attempt to reopen the connection as long as this bit is set. The processor will also set the Data Invalid Bit and Connection Error Bit. Clear this bit to allow the processor to attempt to open the associated connection. 08 Data Invalid Bit The processor sets this bit when data is not received from the associated target node. The error code in second and third words of the ControlNet I/O status tells you why the data is invalid. Also, if either the Inhibit Bit or Immediate Inhibit Bit is set, the Data Invalid Bit will be set. The processor clears this bit when valid data is received from the associated target node. In your program, make sure that this bit is clear before you use the associated data. 09 Connection Error Bit The processor sets this bit when the associated connection is not made to the target node. The error code in second and third words of the ControlNet I/O status tells you why the connection is not made. Also, if either the Inhibit Bit or Immediate Inhibit Bit is set, the Connection Invalid Bit will be set. The processor clears this bit when the associated connection is made to the target node. 10 Data Underrun This bit it set whenever the length of data received for the associated connection is smaller than expected. The Data Invalid Bit will also set if the length of data received is less than the value configured in the Input Data Size field for the connection in RSNetworx. 11 Data Overrun This bit it set whenever the length of data received for the associated connection is larger than expected. The Data Invalid Bit will not be set. 15 Run Mode This bit it set to give the Run/Idle status of the target device for connections that support Run/Idle notification (such as Peer-to-Peer Receive Data connections). 1785-UM022B-EN-P - February 2002 ControlNet I/O Map-Entry Status Words and Error Codes D-3 The following table explains the second and third status words in the ControlNet I/O status file. ControlNet I/O Connection Bit 9 of First Word Second Word Third Word Type of I/O Status File Entry of I/O Status File Entry of I/O Status File Entry (Connection Error) All Set 0 Error code (see the “Error Messages” section) Receive Data Clear 0 0 = peer processor is in PROGRAM mode 1 = peer processor is in RUN mode Send Data Clear 0 Number of peer listeners 1747 Discrete Clear If bit x is clear, then the module in slot x is OK. If bit x is set, then the module in slot x is missing, bad, or is the wrong type. 1747 Analog Clear 0 0 1771 Discrete Clear 0 0 1771 Analog Read Clear 0 Error code from read 1771 Analog Write Clear Error code from write 0 1771 Analog Read/Write Clear Error code from write Error code from read 1794 Discrete Clear 0 If bit x is clear, then the module in slot x is OK. If bit x is set, then the module in slot x is missing, bad, or is the wrong type. 1794 Analog Read Clear 0 If bit x is clear, then the module in slot x is OK. If bit x is set, then the module in slot x is missing, bad, or is the wrong type. 1794 Analog Write Clear 0 0 1794 Analog Read/Write Clear 0 If bit x is clear, then the module in slot x is OK. If bit x is set, then the module in slot x is missing, bad, or is the wrong type. 1785-UM022B-EN-P - February 2002 D-4 ControlNet I/O Map-Entry Status Words and Error Codes Error Codes The following is a list of ControlNet error codes, messages, possible causes, and possible corrective actions. These errors can originate in either the PLC-5 programmable controller or the target device: Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code VARIOUS VARIOUS CONFIGURATION DATA The ControlNet configuration is Reenter the map entry that is failing. CORRUPTED corrupted. Reenter the ladder instruction that is failing. 1 0x0001 CONNECTION FAILED The ControlNet cable from the Fix and/or reconnect the ControlNet originating node to the target node is cable. broken or disconnected. The target node is not powered. Supply power to the target node. The target’s node number is greater Reconfigure the ControlNet network than SMAX. so that the target’s node number is less than or equal to SMAX. 5 0x0005 UNKNOWN DESTINATION The slot addressed does not exist. Use a rack with more slots. ADDRESS Correct the I/O map table. The map table is corrupted. Reenter the I/O map entry that is failing. The target node of the MSG Edit the ladder program so that the instruction is not a processor or the correct target node is used. target node of the CIO instruction is not the correct I/O adapter. Replace the target node with the correct type of node. 12 0x000C OBJECT IN WRONG STATE The target Scheduled Peer Output Clear the inhibit and immediate map entry is inhibited. inhibit bits for the target Scheduled Peer Output map entry. 14 0x000E ATTRIBUTE CANNOT BE SET A CIO instruction attempted to set an Insert a module that can have this attribute that cannot be set at the attribute set into the correct slot. destination module. For example, a CIO tried to send safe-state data to a Flex module that does not support safe-state data. Edit the ladder program so that it does not attempt to set this attribute. 19 0x0013 NOT ENOUGH DATA The transfer length is zero. Increase the transfer length. The processor data table is too small Increase the size of the data table to to hold the data to be transferred. accommodate the transfer length. 21 0x0015 TOO MUCH DATA The transfer length is too large. Decrease the transfer length. 1785-UM022B-EN-P - February 2002 ControlNet I/O Map-Entry Status Words and Error Codes D-5 Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 38 0x0026 INVALID DESTINATION The map table is corrupted. Reenter the I/O map entry that is ADDRESS SIZE failing. The target node of the MSG Edit the ladder program so that the instruction is not a processor or the correct target node is used. target node of the CIO instruction is not the correct I/O adapter. Replace the target node with the correct type of node. 256 0x0100 CONNECTION IN USE The connection at the target node is No action is required. The already in use. connection can be re-established after the target node times out the old connection. 262 0x0106 CONNECTION USED BY OTHER The originating node attempted to Delete or inhibit any other node’s NODE use a connection that is already connection so that the preferred being used by another node. node can establish the connection. A non-discrete connection is setup Replace the target module with the to a discrete module. correct non-discrete module. Correct the I/O map table. 263 0x0107 CONNECTION NOT FOUND The connection at the target node Make sure I/O map entries exist in does not exist. the I/O map tables of both the originating and target nodes. 265 0x0109 INVALID CONNECTION SIZE The originating node requested a Correct the connection size in the connection size that the target node map table. If it is a listen-only cannot accommodate. connection, make sure that the connection size is not larger that the size of the controlling connection. Set the addressing mode switches of the 1771 rack dip correctly. Use a rack with the correct number of slots. 273 0x0111 INVALID RPI The target node cannot produce the Increase the requested packet data at or faster than the requested interval (RPI) entered in the map packet interval (RPI) entered in the table. map table. 275 0x0113 OUT OF CONNECTIONS The maximum number of Reduce the number of I/O connections to/from this node has connections, MSG instructions, or been exceeded. CIO instructions to/from this node. 276 0x0114 PRODUCT CODE MISMATCH The target node/module does not Replace the target node/module match the node/module entered in with the correct node/module. the map table. 277 0x0115 PRODUCT TYPE MISMATCH Correct the I/O map table. 278 0x0116 REVISION MISMATCH The series/revision of the target Replace the target node/module node/module does not match the with the correct node/module. series/revision entered in the map table. Correct the I/O map table. 1785-UM022B-EN-P - February 2002 D-6 ControlNet I/O Map-Entry Status Words and Error Codes Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 279 0x0117 INVALID CONNECTION POINT The PLC-5C is requesting data from Change the PLC-5C I/O map entry to a ControlLogix tag that does not use the correct tag. exist. Change or add the tag to the ControlLogix processor. The PLC-5C does not support Verify that the PLC-5C is a Series F ControlNet hot backup. Refer to PLC-5/40C or -5/80C. publication 1785-6.5.24 for more Verify that the 1785-CHBM Hot information. Backup module is properly installed. The target node does not support Replace the target node with one ControlNet Hot Backup. that supports ControlNet Hot Backup. 280 0x0118 INVALID CONFIGURATION The target node/module does not Replace the target node/module FORMAT match the node/module entered in with the correct node/module. the map table. Verify that the target node/module is powered up. Correct the map table. 281 0x0119 OWNER CONNECTION NOT The originating node attempted to Correct any connection errors OPEN open a listen-only connection before associated with the owner the owner connection was opened. connection. The CIO instruction failed because In the I/O map table, add a discrete the 1771 discrete rack has no connection for the 1771 I/O rack. owner. The ControlNet cable from the Fix and/or reconnect the ControlNet controlling node to the target node is cable. broken or disconnected. The controlling node is not powered. Supply power to the controlling node. The target 1771 adapter is in Press the reset button on the target Processor Restart Lockout. 1771 adapter. Cycle power to the target 1771 adapter. 282 0x011A OUT OF APPLICATION The maximum number of • If this is an I/O connection, reduce CONNECTIONS connections to/from this node has the number of I/O connections. been exceeded. • If this is a MSG instruction, reduce the number of MSG instructions. • If this is a CIO instruction, reduce the number of CIO instructions. 515 0x0203 CONNECTION TIMED OUT The ControlNet cable from the Fix and/or reconnect the ControlNet originating node to the target node is cable. broken or disconnected. The target node is not powered. Supply power to the target node. 1785-UM022B-EN-P - February 2002 ControlNet I/O Map-Entry Status Words and Error Codes D-7 Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 516 0x0204 UNCONNECTED REQUEST The ControlNet cable from the Fix and/or reconnect the ControlNet TIMED OUT originating node to the target node is cable. broken or disconnected. The target node is not powered. Supply power to the target node. The originator’s and/or the target’s Reconfigure the ControlNet network node number is greater than UMAX. so that the originator’s and target’s node numbers are less than or equal to UMAX. The target node is too busy to Reduce the number of unconnected respond. requests to the target node. 769 0x0301 OUT OF BUFFER MEMORY The maximum number of • If this is an I/O connection, reduce connections to/from this node has the number of I/O connections. been exceeded. • If this is a MSG instruction, reduce the number of MSG instructions. • If this is a CIO instruction, reduce the number of CIO instructions. 770 0x0302 SCHEDULED BANDWIDTH NOT There are too many words Edit the I/O map table to reduce the AVAILABLE scheduled for transmission. number of scheduled words. The network update time (NUT) is Increase the network update time too small. (NUT). The originator’s and/or the target’s Reconfigure the ControlNet network node number is greater than SMAX. so that the originator’s and target’s node numbers are less than or equal to SMAX. 772 0x0304 NO SCHEDULED The ControlNet cable from the Fix and/or reconnect the ControlNet CONFIGURATION originating node to the keeper was cable and reconfigure the ControlNet broken or disconnected when the network. ControlNet network was configured. The keeper was not powered when Supply power to the keeper and the ControlNet network was reconfigure the ControlNet network. configured. The originating and/or target node is Edit the I/O map table of the not properly configured to send originating and/or target nodes to scheduled data. send scheduled data. 773 0x0305 SCANNER SIGNATURE The ControlNet cable from the Fix and/or reconnect the ControlNet MISMATCH originating node to the keeper was cable. Reconfigure the ControlNet broken or disconnected when the network by enabling and accepting ControlNet network was configured. edits with RSNetWorx. The ControlNet processor was not Reconfigure the ControlNet network configured on the current network. by enabling and accepting edits with RSNetWorx. The ControlNet network was formed Reconfigure the new ControlNet by joining two existing ControlNet network by enabling and accepting networks. edits with RSNetWorx. 1785-UM022B-EN-P - February 2002 D-8 ControlNet I/O Map-Entry Status Words and Error Codes Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 774 0x0306 KEEPER NOT AVAILABLE The ControlNet cable from the Fix and/or reconnect the ControlNet originating node to the keeper is cable. broken or disconnected. The keeper is not powered. Supply power to at least one ControlNet processor. No keeper exists on the ControlNet Add at least one ContolNet network. processor to the network. Reconfigure the ControlNet network by enabling and accepting edits with RSNetWorx. 789 0x0315 INVALID PATH SEGMENT TYPE The map table is corrupted. Reenter the I/O map entry that is failing. The target node of the CIO Edit the ladder program so that the instruction is not the correct I/O correct target node is used. adapter. Replace the target node with the correct adapter. 791 0x0317 INVALID SCHEDULE DATA The ControlNet cable from the Fix and/or reconnect the ControlNet originating node to the programming cable and reconfigure the ControlNet terminal was broken or network. disconnected when the ControlNet network was configured. The originating node was not Supply power to the originating node powered when the ControlNet and reconfigure the ControlNet network was configured. network. 797 0x31D INVALID TARGET TAG The PLC-5C is requesting data from Change the PLC-5C I/O map entry to a ControlLogix tag that is not use the correct tag. configured as a producer. Reconfigure the tag in the ControlLogix processor to be a producer. REDUNDANT CONNECTION Configuration for this redundant Change the PLC-5C I/O map and MISMATCH connection does not match the module configuration data to match configuration used by the Hot the Hot Backup partner. Backup partner. 798 0x31E TAG IS ALREADY PRODUCED The PLC-5C is requesting data from In the ControlLogix processor, THE MAXIMUM NUMBER OF a ControlLogix tag that is already increase the number of times this TIMES being producted the maximum tag can produce data. number of times. 65522 0xFFF2 CONFIGURATION FROM MAP The ControlNet cable from the Fix and/or reconnect the ControlNet ENTRY FAILED originating node to the target node is cable. broken or disconnected. The target node is not powered. Supply power to the target node. The target slot is empty. Insert the proper module in the correct slot of the target node. The target slot contains the wrong module type. An incorrect module or slot was Edit the I/O map table to show the entered in the map table. correct module type and slot. 1785-UM022B-EN-P - February 2002 ControlNet I/O Map-Entry Status Words and Error Codes D-9 Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 65523 0xFFF3 CONTROLNET TRANSFER The immediate CIO instruction could Edit the ladder program so that the QUEUE FULL not be executed because the queue number of active 1771 READ/WRITE is full. CIO instructions is equal to or less than the maximum of 32. 65527 0xFFF7 MODULE TIMED OUT The target slot is empty. Insert the proper module in the correct slot of the target node. The target slot contains the wrong module type. An incorrect module or slot was Edit the I/O map table to show the entered in the map table. correct module type and slot. 65529 0xFFF9 COMMUNICATION ERROR A communication error between the Make sure that the module is CAUSED LOSS OF DATA adapter and the module caused the properly seated in the correct slot of transfer to be aborted. the target node. Make sure that the adapter’s power supply is providing the proper voltage. The target slot contains the wrong Insert the proper module in the module type. correct slot of the target node. An incorrect module or slot was Edit the I/O map table to show the entered in the I/O map table. correct module type and slot. 1785-UM022B-EN-P - February 2002 D-10 ControlNet I/O Map-Entry Status Words and Error Codes Decimal Hex. Code Error Message Explanation/Possible Cause(s) Possible Corrective Action(s) Code 65530 0xFFFA MODULE DECLARED INVALID A communication error between the Make sure that the module is LENGTH adapter and the module caused the properly seated in the correct slot of transfer to be aborted. the target node. Make sure that the adapter’s power supply is providing the proper voltage. The target slot contains the wrong Insert the proper module in the module type. correct slot of the target node. An incorrect module or slot was Edit the I/O map table to show the entered in the map table. correct module type and slot. 65531 0xFFFB INVALID READ DATA A communication error between the Make sure that the module is adapter and the module caused the properly seated in the correct slot of transfer to be aborted. the target node. Make sure that the adapter’s power supply is providing the proper voltage. The target slot contains the wrong Insert the proper module in the module type. correct slot of the target node. An incorrect module or slot was Edit the I/O map table to show the entered in the map table. correct module type and slot. 65532 0xFFFC INVALID WRITE DATA A communication error between the Make sure that the module is adapter and the module caused the properly seated in the correct slot of transfer to be aborted. the target node. Make sure that the adapter’s power supply is providing the proper voltage. The target slot contains the wrong Insert the proper module in the module type. correct slot of the target node. An incorrect module or slot was Edit the I/O map table to show the entered in the map table. correct module type and slot. 65533 0xFFFD DATA TABLE TOO SMALL The processor data table is too small Increase the size of the data table to to hold the data to be transferred. accommodate the transfer length. 1785-UM022B-EN-P - February 2002 Appendix E Fault Codes Fault routines execute when a PLC-5 processor encounters a run-time error (major fault) during program execution. 3. A fault routine processes the major fault bit found in S:11 and determines the course of program execution based on the fault bit present. Fault routines provide a means to either: • systematically shut down a process or control operation • log and clear the fault and continue normal operation For more information about fault routines, see Enhanced and Ethernet PLC-5 Programmable Controllers User Manual, publication 1785-6.5.12. Clearing Faults When a major fault occurs, you need to clear faults before your process can continue. ATTENTION: Clearing a major fault does not correct the cause of the fault. Be sure to examine the fault bit ! and correct the cause of the fault before clearing it. For example, if a major fault is encountered that causes bit S:11/2 to be set, which indicates a programming error, do not use a routine to clear the fault until you correct your program. Additional Major Fault Codes The processor stores fault codes in word 12 of the processor status file (S:12). The following table lists new major fault codes specific to the ControlNet processor. This fault code: Indicates this fault: Take this corrective action: 200 ControlNet scheduled output data missed. Check your network for missing terminators or other sources of electrical noise (see the Industrial The processor is unable to transmit the scheduled data it is configured to Automation Wiring and Grounding Guidelines, transmit. publication 1770-4.1) 201 ControlNet input data missed. Check your network for missing terminators or other sources of electrical noise (see the Industrial The processor is unable to process incoming data from the network Automation Wiring and Grounding Guidelines, publication 1770-4.1). 202 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 203 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 204 Too many output connections per NUI. Make scheduled outputs with short Requested Packet Intervals longer and reaccept edits for the ControlNet configuration. 1785-UM022B-EN-P - February 2002 E-2 Fault Codes This fault code: Indicates this fault: Take this corrective action: 205 ControlNet configuration exceeds processor resources. • Reduce the number of ControlNet I/O map table entries. Possible ways to do this include: IMPORTANT: Scheduled connections will be closed. You must cycle power, save with RSNetWorx, or download the program to reopen - using a discrete rack connection instead of the connections. multiple discrete module connections Because the configuration software is unable to accurately predict all - combining multiple I/O racks into a single the resources that the processor will require to execute your ControlNet I/O rack configuration software (based on the relative loading on the processor), - putting peer-to-peer data in contiguous this fault code is used if the processor determines that your blocks in the data table so that less send configuration (typically when you accept Channel 2 edits) exceeds the and receive scheduled messages are processor’s available bandwidth. required Typical causes of this error code include: • Increase your Network Update Time and/or • receiving data from the ControlNet network faster than the ControlNet increase the Requested Packet Intervals for PLC-5 processor can parse it scheduled data transfers in your I/O map table. • performing I/O updates too frequently • Increase your ladder program scan by either • performing immediate ControlNet I/O ladder instructions too adding more logic or by increasing the frequently. Communications Time Slice (S:77). • Reduce the number or frequency of immediate See S:74 and S:75 for more information. ControlNet I/O ladder instructions that are performed. 206 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 207 This error code is reserved. Contact your local Rockwell Automation representative if you get this message. 208 Too many pending ControlNet I/O connections. Delete one or more I/O map table entries and reaccept edits for the ControlNet configuration. 230 System attempted transition to Run mode with processor in Invalid Change from the Invalid backup state to the No backup state. Control backup state before transitioning into Run mode. Refer to the Invalid backup state troubleshooting table later in this chapter. 231 Bypassed qualification (may occur during race condition when both Transition the PLC-5 processors into Run mode processors attempt to go into Run mode at the same time). one at a time. 232 Both processors attempted to be primaries. Check all media for broken cables, loose connectors, missing terminators, etc.. 233 ControlNet configuration invalid on transition into Run mode. Reconfigure the ControlNet channel. 234 Failed Qualification. Refer to the qualification major faults troubleshooting table later in this chapter. Illegal invalid backup state Cycle power to the processor. If the fault reoccurs, 235 contact Rockwell Automation Technical Support at 440-646-6800 Illegal No Control backup state Cycle power to the processor. If the fault reoccurs, 236 contact Rockwell Automation Technical Support at 440-646-6800 Illegal Primary/Secondary backup state Cycle power to the processor. If the fault reoccurs, 237 contact Rockwell Automation Technical Support at 440-646-6800 Incompatible firmware revisions Install the same series and revision of firmware 238 into both hot backup PLC-5 processors ControlNet keeper mismatch Use RSNetworx to make the PLC-5 processor a 239 valid keeper 1785-UM022B-EN-P - February 2002 Appendix F ControlNet Diagnostics File Layout When you specify a Control Diagnostic File in RSNetWorx for the ControlNet network, the PLC-520C, -5/40C, -5/46C or -5/80C processor copies the 40 words of diagnostic counters into the specified integer file. Twenty-three additional diagnostic counters are available in the ControlNet diagnostic file. To access these counters, you must first use RSLogix5 to increase the size of the ControlNet diagnostic integer file to 63 words. The layout of the ControlNet diagnostic file is described in the following table. The processor updates this file once every second. 1 File Offset Field Names (word;bits) Buffer Errors 0;15-00 Last 8 Nodes from which bad packets were received 1-4; Good Frames Transmitted (center significant byte) 5;07-00 Good Frames Transmitted (least significant byte) 5;15-08 Good Frames Received (least significant byte) 6;07-00 Good Frames Transmitted (most significant byte) 6;15-08 Good Frames Received (most significant byte) 7;07-00 Good Frames Received (center significant byte) 7;15-08 Channel A Errors 8;07-00 Bad Received Frames 8;15-08 Aborted Frames Transmitted 9;07-00 Channel B Errors 9;15-08 NUI Overloads 10;07-00 Highwaters/Out-of-Steps 10;15-08 Blockages 11;07-00 Slot Overloads 11;15-08 Aborted Frames Received 12;07-00 Non-Concurrences 12;15-08 Frames with Duplicate Node Address Received 13;07-00 Lonely Occurrences 13;15-08 Collisions 14;07-00 Noise Hits 14;15-08 Moderators from non-lowmen 15;07-00 1785-UM022B-EN-P - February 2002 F-2 ControlNet Diagnostics File Layout 1 File Offset Field Names (word;bits) Node Address of current Moderator 15;15-08 Cannot Hear Moderator Occurrences (i.e., Lonely) 16;07-00 Network Parameter Mismatch Occurrences 16;15-08 Reserved 17;07-00 SM Commands Received from the wire 17;15-08 Reserved 18;07-00 Reserved 18;15-08 Fault Register -- Pre Reset 19;07-00 Reserved 19;15-08 Reserved 20;07-00 Fault Register -- Post Reset 20;15-08 Dirty bits 21;7-0 SMAC version number 21;15-8 Interface mode 22;7-0 Toggle bits 22;15-8 Channel status (see following table) 23;7-0 Media bits (see following table) 23;15-8 Keeper State 24 Reserved 25-39 Current number of open scheduled connections 40 (always less than or equal to the number in Word 41) Current number of configured scheduled connections 41 Accumulated number of scheduled connection timeouts 42 Current number of active MSG instructions 43 (always less than or equal to 32) Maximum number of simultaneously active MSG instructions 44 (always less than or equal to 32) Accumulated number of MSG connection timeouts 45 Current number of active 1771 CIO instructions 46 (always less than or equal to 32) Maximum number of simultaneously active 1771 CIO 47 instructions (always less than or equal to 32) Accumulated number of 1771 CIO connection timeouts 48 Current number of active 1794 and CIP CIO instructions 49 (always less than or equal to 8) Maximum number of simultaneously active 1794 and CIP CIO 50 instructions (always less than or equal to 8) Accumulated number of 1794 and CIP CIO connection timeouts 51 Current number of open target Message Router connections 52 (always less than or equal to 32) 1785-UM022B-EN-P - February 2002 ControlNet Diagnostics File Layout F-3 1 File Offset Field Names (word;bits) Maximum number of simultaneously open target Message 53 Router connections (always less than or equal to 32) Accumulated number of target Message Router connection 54 timeouts Current number of used unconnected clients 55 (always less than or equal to 8) Maximum number of simultaneously used unconnected clients 56 (always less than or equal to 8) Accumulated number of unconnected client timeouts 57 Current number of used unconnected servers 58 (always less than or equal to 20) Maximum number of simultaneously used unconnected servers 59 (always less than or equal to 20) Accumulated number of unconnected server timeouts 60 Accumulated number of dropped unconnected requests 61 Accumulated number of JITT overruns 62 1 The file offset in the user-specified ControlNet diagnostics file. For example, if you specified N12, then the Buffer Errors would be located in N12:0, bits 15 - 00. The following table describes each bit in word 23 (Channel status and Media bits) of the diagnostic file. Bit(s): Description: Values: 2 - 0 channel A LED state 000 = off 001 = green 5 - 3 channel B LED state 010 = flashing green/off 011 = flashing red/off 100 = flashing red/green 101 = railroading red/off 110 = railroading red/green 111 = red 6 redundancy warning 0 = normal 1 = non-selected channel is unusable 7 active channel 0 = channel B active 1 = channel A active 8 repeater mode 0 = device set for normal mode 1 = device set for repeater mode 9 channel A media mode 0 = configured for Coaxial 1 = configured for fiber 10 channel B media mode 0 = configured for Coaxial 1 = configured for fiber 15 - 11 reserved Note: A value of 219 in word 23 indicates that the ControlNet network is not usable. 1785-UM022B-EN-P - February 2002 F-4 ControlNet Diagnostics File Layout Notes 1785-UM022B-EN-P - February 2002 Index Numerics A 1747 modules automatic I/O mapping 2-16 discrete I/O data transfer mapping 2-20 1770-CD 1-15, 1-23 B 1770-KFC Communication Interface 2-31 battery compartment 1771 modules location of discrete I/O data transfer mapping 2-20 on PLC-5/20C 1-3 1771-ACN and -ACNR ControlNet I/O on PLC-5/40C 1-4 Adapters 2-31 battery status 5-1 1771-AF 1-14 1771-AS 1-14 1771-ASB 1-14 C 1771-DCM 1-14 cables 1771-SN 1-14 remote I/O 1-13 1772-SD, -SD2 1-14 cabling 1-23 1775-S4A, -S4B 1-14 catalog numbers 1775-SR 1-14 ControlNet PLC-5 processors P-1 1784-CP13 1-20, 1-23 Channel 1A 2-34 1784-KTC Communication Card 2-31 Channel 1B 2-34 1784-KTx 1-20, 1-23 CIOs 2-4 1784-KTxD 1-20, 1-23 clearing faults E-1 1784-PCC Communication Card 2-31 Closing ControlNet communication 4-3 1784-PCM5 1-20, 1-23 communication 1784-PCM6 1-20, 1-23 time slice B-14 1784-PCMK 1-20, 1-23 Communication Connection, closing 4-3 1786-BNC -BNC Connector 1-24 communication connection, closing 4-3 1786-BNCJ -BNC Connector 1-24 communication ports 1786-BNCJI -BNC Connector 1-24 location of 1786-BNCP -BNC Connector 1-24 on PLC-5/20C 1-3 1786-CP 1-21 on PLC-5/40C 1-4 1786-CP ControlNet Network Access communication, option to close 4-3 Cable 1-24 configuration software 3-1 1786-CTK ControlNet Tool Kit 1-24 configuration utility 3-2 1786-RG6 Quad Shield Cable 1-24 connecting a programming terminal 1786-RPA Repeater 1-24 1-19 1786-TPR Tap 1-17, 1-24 connecting to a ControlNet network 1786-TPS Tap 1-17, 1-24 1-17 1786-TPVR Tap 1-24 connection 1786-TPVS Tap 1-24 definition of P-2 1786-TPYR Tap 1-17 connection error bit D-2 1786-TPYS Tap 1-17 Conserving ControlNet resources 4-3 1786-XT BNC Terminator 1-24 ControlNet 1794 Flex I/O data transfer mapping 2-20 diagnostics counters F-1 1794 Flex I/O data transfer mapping 2-20 diagnostics file layout F-1 1794 modules Scheduled Data Transfer 2-2 discrete I/O data-transfer mapping 2-20 ControlNet cabling 1-23 1794-ACN ControlNet Flex I/O Adapter ControlNet communication, closing 4-3 2-31 ControlNet diagnostics file layout F-1 6008-SQH1, -SQH2 1-14 Publication 1785-UM022B-EN-P - February 2002 2 Index ControlNet I/O peer-to-peer messaging instructions error messages D-4 4-1 features 2-1 programming C-1 files configured with map ControlNet I/O automatic mapping 2-16 Data Input File (DIF) 2-18, 2-19 ControlNet I/O mapping Data Output File (DOF) 2-18, 2-19 automatic 2-16 Default Configuration File 2-18 reserving rack space for remote I/O linked I/O Status File 2-18 racks before mapping 2-16 I/O forcing 2-7 understanding 2-16 immediate data transfer operations 2-8 discrete I/O data transfer mapping map table 2-19 creating 2-16 mapping data transfers 2-18 entries 2-16 non-discrete I/O data transfer mapping scheduled data transfers 2-16 mapping 2-19, 2-20 scheduled data transfer operations 2-2, ControlNet I/O status file D-2 2-4 ControlNet I/O Transfer (CIO) scheduled operations instructions 2-4, 2-6, 4-3, C-1 discrete I/O data transfer 2-4 ControlNet immediate data I/O nondiscrete I/O data transfer 2-4 instructions peer-to-peer communication 2-4 Immediate Data Input (IDI) C-2 understanding 2-1 Immediate Data Output (IDO) C-2 unscheduled data transfer operations process C-2 2-4 ControlNet immediate data I/O unscheduled non-discrete I/O data instructions transfer 2-4 process 2-9 unscheduled operations ControlNet Immediate Data Input (IDI) ControlNet I/O Transfer (CIO) instruction 2-9 instruction ControlNet Immediate Data Output (IDO) description C-1 instruction 2-9 ControlNet I/O Transfer (CIO) ControlNet network instructions definition of P-2 description 2-6 locating additional information P-4 features 2-6 ControlNet network examples 2-32 I/O transfer instructions ControlNet PLC-5 configuration programming 4-3 matches network information 3-3 immediate data I/O instructions ControlNet PLC-5/20C processor 1-3 programming 4-6 ControlNet PLC-5/40C processor 1-4 ladder rung messages 2-4 ControlNet processor messaging from programming configuring your ControlNet system 3-1 devices 2-4 installing 1-1 non-discrete I/O data transfers 2-6 planning to use 2-1 description C-1 programming your system 4-1 features C-1 ControlNet publications P-4 peer-to-peer messaging 2-4, 2-7 ControlNet status processor Publication 1785-UM022B-EN-P - February 2002 Index 3 ControlNet system definition of P-2 cabling 1-23 description 2-4 configuring 3-1 discrete I/O data transfer mapping 2-19 changing a 1794 I/O modules fault distributed keeper action 2-6, 4-4 functionality 2-33 changing a 1794 I/O modules idle DOF P-2, 2-18, 2-19 action 2-6, 4-4 download from RSLogix 5 3-3 configuring nodes 2-16 download software projects 3-3 locating additional information P-4 drop cable monitoring 5-1 definition of P-2 network maintenance 2-5 network update cycle E what happens in 2-5 error codes D-4 scheduled operations 2-5 error codes 200 and 201 4-9 selecting devices to connect 2-31 Expected Network Packet Time troubleshooting 5-1 1771 non-discrete I/O data transfer unscheduled operations 2-5 mapping 2-21 using ControlNet PLC5 processors in 2-31 ControlNet system software 3-1 F ControlNet, conserving resources 4-3 fault codes E-1 Converting fault codes 200 and 201 4-9 ControlNet phase 1.0 or 1.25 to 1.5 2-35 fault routines E-1 non-ControlNet to ControlNet system files 2-34 configured with I/O map for scheduled I/O usage 2-18 Data Input 2-18, 2-19 D Data Output 2-18, 2-19 Data Highway Plus status indicators 5-5 Default Configuration 2-18 Data Input File I/O Status 2-18, 2-35, D-1 definition P-2 I/O status 2-18 description 2-18, 2-19 processor status B-1 data invalid bit D-2 frame Data Output File definition of P-2 definition P-2 front panel description 2-18, 2-19 PLC-5/20C processor 1-3 data overrrun D-2 PLC-5/40C processor 1-4 data underrun D-2 Default Configuration File description 2-18 G diagnostics file layout global status bits ControlNet F-1 racks 07 B-2 DIF P-2, 2-18, 2-19 racks 1017 B-12 diganostics counters F-1 discrete I/O data transfer Publication 1785-UM022B-EN-P - February 2002 4 Index devices 2-4 I non-discrete I/O data transfer I/O 2-4 ControlNet 2-1 peer-to-peer messaging 2-4 automatic mapping 2-16 I/O configuration utility 3-2 discrete I/O data transfer mapping I/O forcing 2-7 2-19 I/O map table files configured with map definition of P-2 Data Input File (DIF) 2-18, 2-19 I/O map entry status words D-1 Data Output File (DOF) 2-18, I/O mapping techniques 2-21 2-19 I/O status indicator 5-3 Default Configuration File 2-18 IDI 2-9 I/O Status File 2-18 IDO 2-9 I/O forcing 2-7 IIN 2-9 immediate data transfer 2-8 Immediate Data Input (IDI) instruction map table C-2 creating 2-16 Immediate Data Output (IDO) instruction entries 2-16 C-2 maximum number of entries immediate data transfer operations 2-8 2-18 immediate I/O mapping 2-16 process 2-9 mapping data transfers 2-18 immediate inhibit bit D-2 non-discrete I/O data transfer Immediate Input (IIN) instruction 2-9 mapping 2-19, 2-20 Immediate Output (IOT) instruction 2-9 reserving rack space for remote I/O indicators linked racks before PLC-5/20C 1-3 mapping 2-16 PLC-5/40C 1-4 scheduled data transfer 2-2 inhibit bit D-2 scheduled operations installed memory card type discrete I/O data transfer 2-4 using status to determine B-14 non-discrete I/O data transfer installing keying bands for the processor 2-4 1-10 peer-to-peer communication installing your processor 2-4 checking your processor package 1-5 unscheduled connecting a programming terminal I/O datatransfer instructions 1-19 4-3 ControlNet connection 1-21 immediate data I/O instructions DH+ connection 1-19 4-6 serial channel 1-20 Message instruction 2-7, 4-1, connecting to a ControlNet network C-1 1-17 non-discrete I/O data transfers identifying the components of the 2-6, C-1 processor 1-3 non-discrete I/O data transfer installing a DH+ link 1-15 instructions 4-3 installing a remote I/O link 1-13 unscheduled data transfer 2-4 installing keying bands for the processor unscheduled non-discrete I/O data 1-10 transfer 2-4 installing the processor in the chassis unscheduled operations 1-13 messaging from programming Publication 1785-UM022B-EN-P - February 2002 Index 5 locating additional information 1-1 L removing the processor from the chassis ladder rung messaging 2-4 1-13 link selecting cables definition of P-2 ControlNet cables 1-23 DH+ programming 1-23 M remote I/O 1-23 major fault 200 and 201 4-9 serial 1-22 major fault codes E-1 selecting the ControlNet network map table 2-16 address 1-12 maptable entries 2-16 selecting the DH+ station address of maptable entry P-2 Channel 1A 1-11 memory card type setting the I/O chassis backplane using status file to determine B-14 switches 1-9 memory module space 1-3, 1-4 setting the I/O chassis configuration plug merge-save functionality 3-5 1-10 Message instructions 2-4, 2-7, 4-1, C-1 specifying the serial interface of Channel monitoring ControlNet system 5-1 0 1-12 MSGs 2-4 instructions multicast 2-14 ControlNet I/O Transfer (CIO) 2-6, C-1 multicast inputs 2-14 how to use 4-3 multicast outputs 2-14 when to use 2-20, 2-35 ControlNet Immediate Data Input (IDI) 2-9, C-2 N how to use 4-6 NAP P-2 ControlNet Immediate Data Output (IDO) Network Access Port 2-9, C-2 definition of P-2 how to use 4-6 network address ControlNet Message (MSG) definition of P-2 how to use 4-1 network examples 2-32 Immediate Input (IIN) 2-9 Network Update Interval 2-5 Immediate Output (IOT) 2-9 definition of P-2 Message (MSG) 2-7 Network Update Time how to use C-1 definition of P-3 when to use 2-21 node IOT 2-9 definition of P-3 non-discrete I/O data transfer P-3, 2-4 K non-discrete I/O data transfer mapping 2-20 keeper non-redundant media 1-17 definition P-2 NUI P-2, 2-5 keeper signature NUT P-3 verification 3-4 keyswitch location of O on PLC-5/20C 1-3 Option to Close Communication 4-3 on PLC-5/40C 1-4 owner definition of P-3 Publication 1785-UM022B-EN-P - February 2002 6 Index remote I/O P cable lengths 1-13 PCMCIA Communication Card 2-31 nonControlNet 2-17 PCSC 2-9 remote I/O status indicators 5-5 considerations 2-11 remote I/O immediate I/O transfers 2-8, PCSC enable bit D-2 4-8 PCSC new data bit D-2 repeater PCSC overflow bit D-2 definition of P-3 Peer In 2-21 replacing a non-ControlNet remote I/O Peer Out 2-21 network with a ControlNet performing verification activities 3-4 network 2-16, 2-34, 2-35 PLC-5 Requested Packet Interval using in a ControlNet system 2-31 definition P-3 PLC-5 catalog numbers P-1 reset bit D-2 PLC-5 processors P-4 RSLinx software 3-1 PLC-5 programming software P-4 RSLogix software 3-1 PLC-5 publications P-4 RSNetWorx for ControlNet software 3-1 Process Control Sample Complete 2-9 RSNetWorx to perform verification processor activities 3-4 definition P-3 front panel PLC-5/20C 1-3 S PLC-5/40C 1-4 scan list configuration specifications A-1 definition P-2 processor status file B-1 scan list entry layout B-1 definition P-2 processor resident local I/O 2-16 scanner signature processors verification 3-4 ControlNet PLC-5 programmable scheduled connection types controllers P-1 definition P-3 programming a processor Scheduled Data Transfer through Channel 0 1-20 definition 2-2 programming software 3-1 scheduled data transfer operations 2-2, programming terminal 2-4 connecting 1-19 scheduled maximum node publications definition P-3 ControlNet cabling 1-25 scheduled peer-to-peer communication ControlNet system 1-18 2-4 scheduled peer-to-peer communications 2-21 R scheduled peer-to-peer communications rack control bits mapping 2-21 racks 07 B-12 scheduled transfers racks 1017 B-13 definition of P-3 recovery screens fault codes 200 and 201 4-9 Instruction Entry for ControlNet I/O redundant media 1-17 Transfer Block 4-3 definition of P-3 Instruction Entry for Message Block 4-1 redundant media example 2-32 segment related ControlNet publications P-4 definition of P-3 related PLC-5 publications P-4 Publication 1785-UM022B-EN-P - February 2002 Index 7 terminating 1-17 definition of P-3 Selectable Timed Interrupts (STIs) troubleshooting ControlNet system 5-1 using with ControlNet system 4-9 trunk cable selecting the DH+ station address of definition of P-3 Channel 1A 1-11 trunkcable section P-3 setting the I/O chassis backplane switches 1-9 U addressing switches 1-9 UMAX EEPROM transfer switches 1-9 definition P-3 last state switch 1-9 Unscheduled Data Transfer processor memory protection switch 1-9 definition 2-4 setting the I/O chassis configuration plug unscheduled data transfer operations 1-10 2-4 SMAX unscheduled maximum node definition P-3 definition P-3 Software 3-1 unscheduled non-discrete I/O data specifications transfer 2-4 PLC-5 A-1 unscheduled transfers specifying the serial interface of definition of P-3 Channel 0 1-12 upload/download software projects 3-3 status user control bits layout for the processor B-1 processor status file B-12 Status File D-1 using ControlNet I/O Transfer (CIO) I/O instructions 4-3 description 2-18 using ControlNet Immediate Data I/O status file instructions 4-6 processor B-1 using ControlNet Message (MSG) status indicators instructions 4-1 location of using the ControlNet status indicators on PLC-5/20C 1-3 5-3 on PLC-5/40C 1-4 using the general status indicators 5-1 PLC-5 5-1 using this manual using 5-1, 5-3 conventions used P-4 status words intended audience for P-1 I/O map entry D-1 introduction to P-1 recommended preparation for P-1 T tap 1-21 V connecting 1-17 verification acitivities 3-4 definition of P-3 verify keeper signature 3-4 using 1-17 verify scanner signature 3-4 terminator Publication 1785-UM022B-EN-P - February 2002 8 Index Publication 1785-UM022B-EN-P - February 2002 How Are We Doing? Your comments on our technical publications will help us serve you better in the future. Thank you for taking the time to provide us feedback. You can complete this form and mail it back to us, visit us online at www.ab.com/manuals, or email us at RADocumentComments@ra.rockwell.com Pub. Title/Type ControlNet PLC-5 Programmable Controllers User Manual Cat. No. 1785-L20 to -L80C15 Pub. No. 1785-UM022B-EN-P Pub. Date February 2002 Part No. 957345-75 Please complete the sections below. Where applicable, rank the feature (1=needs improvement, 2=satisfactory, and 3=outstanding). Overall Usefulness 1 2 3 How can we make this publication more useful for you? 1 2 3 Can we add more information to help you? Completeness (all necessary information procedure/step illustration feature is provided) example guideline other explanation definition Technical Accuracy 1 2 3 Can we be more accurate? (all provided information text illustration is correct) Clarity 1 2 3 How can we make things clearer? 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