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ProSoft Technology inRAx MVI56-CAS User Manual

MVI56-CAS
ControlLogix Platform
Teledyne CA Slave Module
User Manual
December 26, 2007
Please Read This Notice
This manual is provided to assist the user. Every attempt has been made to ensure that the information provided is accurate and a true reflection of the product's installation requirements. In order to ensure a complete understanding of the operation of the product, the user should read all applicable Rockwell Automation documentation on the operation of the Rockwell Automation hardware.
Under no conditions will ProSoft Technology be responsible or liable for indirect or consequential damages resulting from the use or application of the product.
Reproduction of the contents of this manual, in whole or in part, without written permission from ProSoft Technology is prohibited.
Information in this manual is subject to change without notice and does not represent a commitment on the part of ProSoft Technology Improvements and/or changes in this manual or the product may be made at any time. These changes will be made periodically to correct technical inaccuracies or typographical errors.
Warnings
UL Warnings
A Warning - Explosion Hazard - Substitution of components may impair B Warning - Explosion Hazard - When in Hazardous Locations, turn off
C Suitable for use in Class I, division 2 Groups A, B, C and D Hazardous
ATEX Warnings and Conditions of Safe Usage:
Power, Input, and Output (I/O) wiring must be in accordance with the authority having jurisdiction
A Warning - Explosion Hazard - When in hazardous locations, turn off power B Warning - Explosion Hazard - Do not disconnect equipment unless power C These products are intended to be mounted in an IP54 enclosure. The
D DO NOT OPEN WHEN ENERGIZED.
suitability for Class I, Division 2.
power before replacing or rewiring modules. Warning - Explosion Hazard - Do not disconnect equipment unless power has been switched off or the area is known to be nonhazardous.
Locations or Non-Hazardous Locations.
before replacing or wiring modules.
has been switched off or the area is known to be non-hazardous.
devices shall provide external means to prevent the rated voltage being exceeded by transient disturbances of more than 40%. This device must be used only with ATEX certified backplanes.
Electrical Ratings
Backplane Current Load: 800 mA @ 5 V DC; 3mA @ 24V DC Operating Temperature: 0 to 60°C (32 to 140°F) Storage Temperature: -40 to 85°C (-40 to 185°F) Shock: 30g Operational; 50g non-operational; Vibration: 5 g from 10 to 150
Hz
Relative Humidity 5% to 95% (non-condensing) All phase conductor sizes must be at least 1.3 mm(squared) and all earth
ground conductors must be at least 4mm(squared).
Markings:
II 3 G 0C <=Ta<= 60C EEx nA IIC T4 DEMKO 07ATEX0710717X
Your Feedback Please
We always want you to feel that you made the right decision to use our products. If you have suggestions, comments, compliments or complaints about the product, documentation or support, please write or call us.
ProSoft Technology
1675 Chester Avenue, Fourth Floor Bakersfield, CA 93301 +1 (661) 716-5100 +1 (661) 716-5101 (Fax)
http://www.prosoft-technology.com
Copyright © ProSoft Technology, Inc. 2000 - 2007. All Rights Reserved.
MVI56-CAS User Manual December 26, 2007 PSFT.CAS.MVI56.UM.07.12.26
ProSoft Technology ®, ProLinx ®, inRAx ®, ProTalk® and RadioLinx ® are Registered Trademarks of ProSoft Technology, Inc.
Contents MVI56-CAS ♦ ControlLogix Platform Teledyne CA Slave Module
Contents
PLEASE READ THIS NOTICE.............................................................................................................................. 2
Warnings ........................................................................................................................................................... 2
Your Feedback Please ...................................................................................................................................... 3
GUIDE TO THE MVI56-CAS USER MANUAL...................................................................................................... 7
1 START HERE ............................................................................................................................................... 9
1.1 System Requirements.............................................................................................................................. 9
1.2 Package Contents ..................................................................................................................................10
1.3 Setting Jumpers......................................................................................................................................11
1.4 Install the Module in the Rack.................................................................................................................12
1.5 Connect your PC to the Processor .........................................................................................................13
1.6 Download the Sample Program to the Processor...................................................................................14
1.6.1 Configuring RSLinx .......................................................................................................................15
1.7 Connect your PC to the Module..............................................................................................................17
2 INSTALLING AND CONFIGURING THE MODULE....................................................................................19
2.1 Module Configuration..............................................................................................................................23
2.1.1 Power Up ......................................................................................................................................24
2.1.2 Changing Parameters During Operation .......................................................................................24
2.1.3 Module Data Object (CASModuleDef)...........................................................................................24
2.1.4 User Data Objects.........................................................................................................................27
2.1.5 TCA Message Data.......................................................................................................................28
3 LADDER LOGIC..........................................................................................................................................29
4 DIAGNOSTICS AND TROUBLESHOOTING..............................................................................................31
4.1 Reading Status Data From the Module...................................................................................................31
4.1.1 The Configuration/Debug Menu ....................................................................................................31
4.1.2 Required Hardware .......................................................................................................................32
4.1.3 Required Software.........................................................................................................................33
4.1.4 Using the Configuration/Debug Port..............................................................................................33
4.1.5 Main Menu ....................................................................................................................................34
4.1.6 Data Analyzer................................................................................................................................37
4.1.7 Data Analyzer Tips........................................................................................................................39
4.1.8 Database View Menu ....................................................................................................................42
4.2 LED Status Indicators.............................................................................................................................44
4.2.1 Clearing a Fault Condition.............................................................................................................45
4.2.2 Troubleshooting.............................................................................................................................45
5 REFERENCE...............................................................................................................................................47
5.1 Product Specifications ............................................................................................................................47
5.1.1 Features and Benefits ...................................................................................................................47
5.1.2 General Specifications ..................................................................................................................47
5.1.3 Hardware Specifications................................................................................................................48
5.1.4 Functional Specifications...............................................................................................................48
5.2 Functional Overview ...............................................................................................................................49
5.2.1 General Concepts .........................................................................................................................49
5.2.2 Normal Data Transfer....................................................................................................................52
5.2.3 Configuration Data Transfer ..........................................................................................................53
5.2.4 Write Configuration........................................................................................................................54
5.2.5 Pass-Through Control Blocks........................................................................................................55
5.2.6 Data Flow Between MVI56-CAS Module and ControlLogix Processor..........................................56
5.3 Cable Connections .................................................................................................................................57
5.3.1 RS-232 Configuration/Debug Port.................................................................................................57
5.3.2 RS-232 ..........................................................................................................................................59
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5.3.3 RS-422..........................................................................................................................................61
5.3.4 RS-485..........................................................................................................................................62
5.3.5 DB9 to RJ45 Adaptor (Cable 14)...................................................................................................62
5.4 MVI56-CAS Database Definition ............................................................................................................63
5.5 MVI56-CAS Status Data Definition.........................................................................................................63
5.6 MVI56-CAS Configuration Data Definition..............................................................................................65
5.6.1 Port 1 ............................................................................................................................................65
5.6.2 Port 2 ............................................................................................................................................67
5.6.3 Status............................................................................................................................................68
5.7 MVI56-CAS Command Control...............................................................................................................70
5.8 Protocol Commands ...............................................................................................................................70
5.8.1 Data Read Functions ....................................................................................................................70
5.8.2 Control Commands From Master..................................................................................................71
5.8.3 Freeze Data Commands ...............................................................................................................72
5.8.4 Exception Data Commands...........................................................................................................73
6 SUPPORT, SERVICE & WARRANTY.........................................................................................................75
6.1 How to Contact Us: Sales and Support ..................................................................................................76
6.2 Return Material Authorization (RMA) Policies and Conditions................................................................77
6.2.1 All Product Returns .......................................................................................................................77
6.3 Procedures for Return of Units Under Warranty.....................................................................................77
6.4 Procedures for Return of Units Out of Warranty.....................................................................................78
6.4.1 Un-repairable Units .......................................................................................................................78
6.4.2 Purchasing Warranty Extension....................................................................................................79
6.5 LIMITED WARRANTY............................................................................................................................79
6.5.1 What Is Covered By This Warranty...............................................................................................79
6.5.2 What Is Not Covered By This Warranty ........................................................................................80
6.5.3 DISCLAIMER REGARDING HIGH RISK ACTIVITIES..................................................................81
6.5.4 DISCLAIMER OF ALL OTHER WARRANTIES.............................................................................81
6.5.5 LIMITATION OF REMEDIES**......................................................................................................81
6.5.6 Time Limit for Bringing Suit ...........................................................................................................81
6.5.7 No Other Warranties .....................................................................................................................82
6.5.8 Intellectual Property ......................................................................................................................82
6.5.9 Additional Restrictions Relating To Software And Other Intellectual Property ..............................82
6.5.10 Allocation of risks ..........................................................................................................................83
6.5.11 Controlling Law and Severability...................................................................................................83
INDEX...................................................................................................................................................................85
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Start Here MVI56-CAS ♦ ControlLogix Platform Teledyne CA Slave Module
Guide to the MVI56-CAS User Manual
Function Section to Read Details
Introduction (Must Do)
Verify Communication, Diagnostic and Troubleshooting
Reference Product Specifications Functional Overview Glossary
Support, Service, and Warranty
Index
→
→
→
→
Start Here (page 9)
Verifying Communication (page 31)
Diagnostics and Troubleshooting (page 31)
Reference
47) Functional
Overview (page 49) Product
Specifications (page 47)
Support, Service and Warranty (page 75)
(page
This Section introduces the customer to the module. Included are: package contents, system requirements, hardware installation, and basic configuration.
This section describes how to verify communications with the network. Diagnostic and Troubleshooting procedures.
These sections contain general references associated with this product, Specifications, and the Functional Overview.
This section contains Support, Service and Warranty information.
Index of chapters.
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Page 8 of 86 ProSoft Technology, Inc.
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Start Here MVI56-CAS ♦ ControlLogix Platform Teledyne CA Slave Module

1 Start Here
In This Chapter
¾ System Requirements.............................................................. 9
¾ Package Contents.................................................................. 10
¾ Setting Jumpers ..................................................................... 11
¾ Install the Module in the Rack ................................................ 12
¾ Connect your PC to the Processor......................................... 13
¾ Download the Sample Program to the Processor ..................14
¾ Connect your PC to the Module ............................................. 17
Installing the MVI56-CAS module requires a reasonable working knowledge of the Rockwell Automation hardware, the MVI56-CAS Module and the application in which they will be used.
Caution: It is important that those responsible for implementation can complete
the application without exposing personnel, or equipment, to unsafe or inappropriate working conditions. Safety, quality and experience are key factors in a successful installation.
1.1 System Requirements
The MVI56-CAS module requires the following minimum hardware and software components:
Rockwell Automation ControlLogix™ processor, with compatible power
supply and one free slot in the rack, for the MVI56-CAS module. The module requires 800mA of available power.
Rockwell Automation RSLogix 5000 programming software version 2.51 or
higher.
Rockwell Automation RSLinx communication software Pentium® II 450 MHz minimum. Pentium III 733 MHz (or better)
recommended
Supported operating systems:
o Microsoft Windows XP Professional with Service Pack 1 or 2 o Microsoft Windows 2000 Professional with Service Pack 1, 2, or 3 o Microsoft Windows Server 2003
128 Mbytes of RAM minimum, 256 Mbytes of RAM recommended
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100 Mbytes of free hard disk space (or more based on application
requirements)
256-color VGA graphics adapter, 800 x 600 minimum resolution (True Color
1024 × 768 recommended)
CD-ROM drive HyperTerminal or other terminal emulator program.
Note: You can install the module in a local or remote rack. For remote rack installation, the module requires EtherNet/IP or ControlNet communication with the processor.
1.2 Package Contents
The following components are included with your MVI56-CAS module, and are all required for installation and configuration.
Important: Before beginning the installation, please verify that all of the following items are present.
Qty. Part Name Part Number Part Description
1
1 Cable
3 Cable
2 Adapter 1454-9F
1
MVI56-CAS Module
ProSoft Solutions CD
MVI56-CAS Teledyne CA Slave Module
RS232 Null Modem
Cable #14, RJ45 to DB9 Male Adapter
For RS232 Connection to the CFG Port
For DB9 Connection to Module's Port
Two Adapters, DB9 Female to Screw Terminal. For RS422 or RS485 Connections to Port 1 and 2 of the Module
Contains sample programs, utilities and documentation for the MVI56-CAS module.
If any of these components are missing, please contact ProSoft Technology Support for replacement parts.
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1.3 Setting Jumpers
If you use an interface other than RS-232 (default), you must change the jumper configuration to match the interface. There are three jumpers located at the bottom of the module.
The following illustration shows the MVI56-CAS jumper configuration:
1 Set the PRT 2 (for application port 1) and PRT 3 (for application port 2)
jumpers for RS232, RS422 or RS485 to match the wiring needed for your application. The default jumper setting for both application ports is RS-232.
2 The Setup Jumper acts as "write protection" for the module's flash memory.
In "write protected" mode, the Setup pins are not connected, and the module's firmware cannot be overwritten. Do not jumper the Setup pins together unless you are directed to do so by ProSoft Technical Support.
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1.4 Install the Module in the Rack

If you have not already installed and configured your ControlLogix processor and power supply, please do so before installing the MVI56-CAS module. Refer to your Rockwell Automation product documentation for installation instructions.
Warning: You must follow all safety instructions when installing this or any other electronic devices. Failure to follow safety procedures could result in damage to hardware or data, or even serious injury or death to personnel. Refer to the documentation for each device you plan to connect to verify that suitable safety procedures are in place before installing or servicing the device.
After you have checked the placement of the jumpers, insert MVI56-CAS into the ControlLogix chassis. Use the same technique recommended by Rockwell Automation to remove and install ControlLogix modules.
Warning: When you insert or remove the module while backplane power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Verify that power is removed or the area is non-hazardous before proceeding. Repeated electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance that can affect module operation.
1 Turn power OFF. 2 Align the module with the top and bottom guides, and slide it into the rack
until the module is firmly against the backplane connector.
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3 With a firm but steady push, snap the module into place. 4 Check that the holding clips on the top and bottom of the module are securely
in the locking holes of the rack.
5 Make a note of the slot location. You will need to identify the slot in which the
module is installed in order for the sample program to work correctly. Slot numbers are identified on the green circuit board (backplane) of the ControlLogix rack.
6 Turn power ON.
Note: If you insert the module improperly, the system may stop working, or may
behave unpredictably. Note: If you are installing MVI56-CAS with other modules connected to the PCI bus, the peripheral modules will not have holding clips. Make sure all of the modules are aligned with their respective slots before you snap them into place.

1.5 Connect your PC to the Processor

7 Connect the right-angle connector end of the cable to your controller at the
communications port.
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8 Connect the straight connector end of the cable to the serial port on your
computer.

1.6 Download the Sample Program to the Processor

¾ To download the sample program from RSLogix 5000 to the
ControlLogix processor:
Note: The key switch on the front of the ControlLogix module must be in the REM position.
1 If you are not already online to the processor, open the Communications
menu, and then choose Download. RSLogix will establish communication with the processor.
2 When communication is established, RSLogix will open a confirmation dialog
box. Click the Download button to transfer the sample program to the processor.
3 RSLogix will compile the program and transfer it to the processor. This
process may take a few minutes.
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4 When the download is complete, RSLogix will open another confirmation
dialog box. Click OK to switch the processor from Program mode to Run mode.
Note: If you receive an error message during these steps, refer to your RSLogix documentation to interpret and correct the error.
1.6.1 Configuring RSLinx
¾ If RSLogix is unable to establish communication with the processor,
follow these steps:
1 Open RSLinx. 2 Open the Communications menu, and choose Configure Drivers.
This action opens the Configure Drivers dialog box.
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Note: If the list of configured drivers is blank, you must first choose and configure a driver from the Available Driver Types list. The recommended driver type to choose for serial communication with the processor is "RS-232 DF1 Devices".
3 Click to select the driver, and then click Configure. This action opens the
Configure Allen-Bradley DF1 Communications Device dialog box.
4 Click the Auto-Configure button. RSLinx will attempt to configure your serial
port to work with the selected driver.
5 When you see the message "Auto Configuration Successful", click the OK
button to dismiss the dialog box.
Note: If the auto-configuration procedure fails, verify that the cables are connected correctly between the processor and the serial port on your computer, and then try again. If you are still unable to auto-configure the port, refer to your RSLinx documentation for further troubleshooting steps.
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1.7 Connect your PC to the Module

With the module securely mounted, connect your PC to the Configuration/Debug port using an RJ45-DB-9 Serial Adapter Cable and a Null Modem Cable.
1 Attach both cables as shown. 2 Insert the RJ45 cable connector into the Configuration/Debug port of the
module.
3 Attach the other end to the serial port on your PC or laptop.
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Installing and Configuring the Module MVI56-CAS ♦ ControlLogix Platform Teledyne CA Slave Module

2 Installing and Configuring the Module

In This Chapter
¾ Module Configuration .............................................................23
This chapter describes how to install and configure the module to work with your application. The configuration process consists of the following steps.
1 Use RSLogix 5000 to identify the module to the processor and add the
module to a project.
Note: The RSLogix 5000 software must be in "offline" mode to add the module to a project.
2 Modify the example ladder logic to meet the needs of your application, and
copy the ladder logic to the processor. Example ladder logic files are provided on the CD-ROM.
Note: If you are installing this module in an existing application, you can copy the necessary elements from the example ladder logic into your application.
The rest of this chapter describes these steps in more detail. The first step in installing and configuring the module is to define the module to
the system. Right-click the mouse button on the I/O Configuration option in the Controller Organization window to display a pop-up menu. Select the New Module… option from the I/O Configuration menu:
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This action opens the following dialog box:
Select the 1756-Module (Generic 1756 Module) from the list and click OK. The following dialog box is displayed:
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Fill in the dialog boxes as shown adjusting the Name, Description and Slot options for your application. You must select the Comm Format as Data - INT in the dialog box. Failure to set the Assembly Instance and Size values correctly will result in a module that will not communicate over the backplane of the ControlLogix rack. Click Next to display the next dialog box.
Select the Request Packet Interval value for scanning the I/O on the module. This value represents the minimum frequency the module will handle scheduled events. This value should not be set to less than 1 millisecond. Values between 1 and 10 milliseconds should work with most applications.
After completing the module setup, the Controller Organization window will display the module's presence. The data required for the module will be defined to the application, and objects will be allocated in the Controller Tags data area. An example of the Controller Organization window is shown below:
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The next step in the module's setup is to define the User Defined Data Types to be used with the module. Copy these data types from the example ladder logic if you are not using the example. They will be defined if you are starting from the example ladder logic. The Controller Organization window should display the User Defined Data Types shown below:
The next step in module setup is to define the data to be used to interface with the module and the ladder logic. Open the Controller Tags Edit Tags dialog box and enter the values shown in the following example. The MVI56-CAS module is defined in the example as CAS1. You can set the tag name to any valid tag name you desire. If you are using the example ladder logic, this step has already been performed.
At this point, take the time to fill in the configuration values in the CAS1 data table and adjust array sizes. Refer to the Module Data Object section of this document for information on configuring the module.
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The last step in the module setup is to add the ladder logic. If you are using the example ladder logic, adjust the ladder to fit your application. If you are not using the ladder example, copy the ladder logic shown in the Controller Organization window below to your application.
The module is now set up and ready to be used with your application. Insert the module in the rack and attach the TCA serial communication cables. Download the new application to the controller and place the processor in run mode. If all the configuration parameters are set correctly and the module is attached to a TCA network, the module's Application LED (APP LED) should remain off and the backplane activity LED (BP ACT) should blink very rapidly. Refer to the Diagnostics and Troubleshooting section of this manual if you encounter errors. Attach a computer or terminal to Debug/Configuration port on the module and look at the status of the module using the Configuration/Debug Menu in the module.
2.1 Module Configuration
In order for the MVI56-CAS module to function, a minimum amount of configuration data must be transferred to the module. The following table provides an overview of the different types of configuration data that the module will require, depending on the operating modes to be supported.
Module Register Address
5000 to 5009 Data Transfer General Module
5010 to 5039 and 5040 to 5069
Refer to the Installing and Configuring the Module section for a description of the configuration of the module. The MVI56-CAS module must be configured at least once when the card is first powered, and any time thereafter when the parameters must be changed.
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Functional Modes Affected
Master and Slave Port Configuration These sections define the characteristics of each of
Name Description
This section of the configuration data contains the
Configuration
module configuration data that defines the data transfer between the module and the ControlLogix processor.
the TCA serial communication ports on the module. These parameters must be set correctly for proper module operation.
MVI56-CAS ♦ ControlLogix Platform Installing and Configuring the Module Teledyne CA Slave Module
2.1.1 Power Up
On power up, the module enters into a logical loop waiting to receive configuration data from the processor. Upon receipt, the module will begin execution of the command list if it is present.
2.1.2 Changing Parameters During Operation
A copy of the module's configuration data is mapped in the module's database as displayed in the table above. These values are initialized when the module first receives its configuration from the ControlLogix processor. Any node on the network can change this data. The module will not use this data until it is commanded. Ladder logic can be written to issue a Write Configuration command block (9997) to the module. A remote device can set a value of 9997 at address 6800 in the module to download the configuration to the processor. Alternatively, the configuration/debug port on the module can be used to issue the command directly to the module. All three of these methods will force the module to download the configuration to the ControlLogix processor. Ladder logic must exist in the processor to accept the blocks sent by the module. If everything is configured correctly, the module can receive its configuration from a remote device.
2.1.3 Module Data Object (CASModuleDef)
All data related to the MVI56-CAS is stored in a user defined data type. An instance of the data type is required before the module can be used. This is done by declaring a variable of the data type in the Controller Tags Edit Tags dialog box. The structure of the object is displayed in the following figure.
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This object contains objects that define the configuration, user data, status and command control data related to the module. Each of these object types is discussed in the following topics of the document.
Configuration Objects
Configuration of the module is performed by filling in the values in the module object defined in the Controller Tags Edit Tags dialog. Each parameter required by the module has a defined location in the object. The tables and discussions below describe the parameters set in the dialog box. You can view these tables by opening the data type under the User Defined Data Type option in the Controller Organization window.
Data Transfer Parameters (CASModule)
This object defines the parameters for data movement between the module and the processor. Values entered determine the ladder logic and data size required in the application. The ReadData and WriteData arrays must be sized to or larger than the count values entered. The ladder logic must process the number of blocks of data to be transferred. The number of blocks is computed as follows:
BlockCnt = INT(RegCnt/200) + if(MOD(RegCnt,200), 1,0) If the register count is evenly divisible by 200, the number of blocks is easy to
compute and the ladder is much simpler to write. If the number is not evenly divisible by 200, special handling of the last block of data must developed, as it must transfer less than 200 words. It is recommended that the count values always be set to values evenly divisible by 200.
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The BPFail parameter determines if the module should continue communicating on the TCA network when the backplane transfer operation fails. A value of zero indicates that the module should continue communicating when the backplane is not operational. If the value is greater than zero, the backplane will be retried the entered number of times before a failure will be reported and communication will cease on the ports. When backplane communication is restored, the module will start communicating on the network. For example, if you enter a value of 10 for the parameter, the module will stop all TCA communications if 10 successive backplane errors are recognized. When a successful transfer is recognized, the module will resume communications on the network.
TCA Port Parameters (CASPort)
This object defines the parameters for the operation of each of the TCA ports on the module. Refer to the Reference chapter for the definition of each parameter.
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