Rockwell Automation 1794-L34 User Manual

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FlexLogix Controller System User Manual

1794-L34

Firmware Revision 16

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

) describes some important

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you to identify a hazard, avoid a hazard, and recognize the consequences.

SHOCK HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may be dangerous temperatures.

Allen-Bradley, FlexLogix, Logix5000, RSLogix, RSLogix 5000, Rockwell Automation, RSNetWorx, and RSLinx are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Summary of Changes

Developing FlexLogix Controller Systems

Where to Start

Directly Connect to the Controller via the Serial Port

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preface

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Install Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connect the Controller via the Serial Port. . . . . . . . . . . . . . . 15

Configure the Serial Driver . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select the Controller Path . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Communicate over Networks

Manage Controller Communications

Chapter 3

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

EtherNet/IP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Connections over EtherNet/IP . . . . . . . . . . . . . . . . . . . . 24

ControlNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Connections over ControlNet . . . . . . . . . . . . . . . . . . . . . 26

DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Define Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Communicate with DF1 devices . . . . . . . . . . . . . . . . . . . 33

Communicate with ASCII devices . . . . . . . . . . . . . . . . . . 35

Modbus support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DH-485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Third Party . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Communication Format . . . . . . . . . . . . . . . . . . . . . . . . . 42

Connection Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 4

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Produce and Consume (Interlock) Data . . . . . . . . . . . . . . . . 45

Send and Receive Messages. . . . . . . . . . . . . . . . . . . . . . . . . 47

Determine whether to cache message connections . . . . . 47

Connection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Calculate Connection Use . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Connections Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4 Table of Contents

Place, Configure, and Monitor I/O

Chapter 5

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Select I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Place Local I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Selecting a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 54

Configure I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

I/O connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Configure Distributed I/O on EtherNet/IP . . . . . . . . . . . . . . 59

Configure Distributed I/O on ControlNet . . . . . . . . . . . . . . . 60

Configure Distributed I/O on DeviceNet . . . . . . . . . . . . . . . 61

Address I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Determine When Data Is Updated . . . . . . . . . . . . . . . . . . . . 63

Monitor I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Displaying fault data . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Monitor a rack-optimized connection . . . . . . . . . . . . . . . 65

Reconfigure an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . 66

Reconfigure a module via RSLogix 5000 software . . . . . . 66

Reconfigure a module via a MSG instruction . . . . . . . . . . 67

Develop Applications

Chapter 6

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Manage Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Develop Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Defining tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Defining programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Defining routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Sample controller projects . . . . . . . . . . . . . . . . . . . . . . . 74

Organize Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Select a Programming Language . . . . . . . . . . . . . . . . . . . . . 76

Add-On Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Monitor Controller Status. . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Monitor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Determine if communication has timed out with any device

Determine if communication has timed out with a specific

I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Interrupt the execution of logic and execute the fault handler

Select a System Overhead Percentage . . . . . . . . . . . . . . . . . 82

Use the Event Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Prioritizing Periodic and Event Tasks . . . . . . . . . . . . . . . 85

Triggering the Event Task. . . . . . . . . . . . . . . . . . . . . . . . 86

Programmatically Determine if an EVENT Instruction

Triggered a Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Checklist for an EVENT Instruction Task . . . . . . . . . . . . . 87

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Configure PhaseManager

Maintain the Battery

FlexLogix System Status Indicators

FlexLogix Back-Up on DeviceNet

Table of Contents 5

Chapter 7

Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

PhaseManager Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

State Model Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

How equipment changes states . . . . . . . . . . . . . . . . . . . 92

Manually change states . . . . . . . . . . . . . . . . . . . . . . . . . 94

Compare PhaseManager to Other State Models. . . . . . . . . . . 94

Minimum System Requirements . . . . . . . . . . . . . . . . . . . . . . 94

Equipment Phase Instructions . . . . . . . . . . . . . . . . . . . . . . . 95

Chapter 8

Using this Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Storing Replacement Batteries . . . . . . . . . . . . . . . . . . . . . . . 97

Estimating Battery Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Appendix A

Controller LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Appendix B

Using This Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

How the Back-up Works . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Requirements of the Back-Up. . . . . . . . . . . . . . . . . . . . 105

Power-Up and System Start-up . . . . . . . . . . . . . . . . . . . . . 106

Developing the FlexLogix Back-Up Application . . . . . . . . . 108

Back-up Heartbeat Configuration Rungs . . . . . . . . . . . . 108

Reading Back-up State Rung. . . . . . . . . . . . . . . . . . . . . 112

Reading Back-up Status . . . . . . . . . . . . . . . . . . . . . . . . 114

Using Indicators to Check Status . . . . . . . . . . . . . . . . . . . . 115

Development and Debugging Tips. . . . . . . . . . . . . . . . . . . 115

Instruction Locator Index

Appendix C

Where to Find an Instruction . . . . . . . . . . . . . . . . . . . . . . . 117

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6 Table of Contents

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Summary of Changes

Introduction

Updated Information

This release of this document contains new and updated information. To find new and updated information, look for change bars, as shown next to this paragraph.

The document contains these changes.

Topic Page

DF1 radio modem 31

Add-On Instructions 77

Where to Find an Instruction 117

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8 Summary of Changes

Notes:

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Preface

Developing FlexLogix Controller Systems

Introduction

Use this manual to become familiar with the FlexLogix controller and its features. This version of the manual corresponds to controller firmware revision 16.

This manual describes the necessary tasks to install, configure, program, and operate a FlexLogix system. In some cases, this manual includes references to additional documentation that provides the more comprehensive details.

Use This Chapter

1794 I/O modules connected to the FlexLogix controller

The FlexLogix controller offers state-of-art control, communications, and I/O elements in a distributed control package..

FlexLogix controller

For a more flexible system, use:

• multiple controllers joined across networks

• I/O from multiple platforms that is distributed in many locations

and connected over multiple I/O links

network communication cards installed in the controller

EtherNet/IP link

1794 I/O modules connected to the FlexLogix controller

remote I/O modules

drives

}

ControlNet link

EtherNet/IP link

ControlNet link

DeviceNet

computers

other controllers

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12 Where to Start

The FlexLogix controller, part of the Logix family of controllers, provides a small, powerful, cost-effective system built on the following components:

• 1794-L34 FlexLogix controller available in 512 Kbytes of user memory.

• FlexLogix controller that supports the Logix instructions.

• RSLogix 5000 programming software that supports every

Logix controller.

• FLEX I/O modules that provide a compact, DIN-rail mounted I/O system.

• 1788 communication daughtercard that provides communication over standard-based ControlNet, DeviceNet or EtherNet/IP networks. The controller allows the insertion of daughtercards for up to 2 networks (e.g., one for DeviceNet and one for EtherNet/IP).

Design

See:

• FlexLogix Selection Guide, 1794-SG001

• Logix5000 Controller Design Considerations Reference Manual,

1756-RM094

When designing a FlexLogix system, determine the network configuration and the placement of components in each location. Make these decisions as you design your system:

Design Step

o 1. o 2. o 3. o 4. o 5.

Select I/O devices

Select communication cards

Select controllers

Select power supplies

Select software

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Where to Start 13

Install Hardware

See:

• FlexLogix Controller Installation

To install a FlexLogix controller, follow these steps:

Installation Step

o 1. o 2. o 3. o 4.

o 5.

o 6. o 7. o 8.

o 9.

Install a DIN rail

Use DIN rail locks that came with your controller

Mount an appropriate power supply on the DIN rail

Install the battery in the controller

See 8 “Maintain the Battery.“

Install the communication cards in the controller

See Chapter 3 “Communicate over Networks”

Install the controller on the DIN rail

Install the extended-local adapter (optional)

Make serial connections

See Chapter 2 “Directly Connect to the Controller via the Serial Port “

Load controller firmware

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14 Where to Start

Notes:

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Chapter

Directly Connect to the Controller via the Serial Port

Use This Chapter

See:

• EtherNet/IP Modules in Logix5000 Control Systems User Manual,

ENET-UM001

• ControlNet Modules in Logix5000 Control System User Manual,

CNET-UM001

• DeviceNet Modules in Logix5000 Control System User Manual,

DNET-UM004

Connect the Controller via the Serial Port

This chapter describes how to connect to the controller via the serial port so you can configure the controller and upload and/or download a project to the controller.

For this information See

Connect the Controller via the Serial Port 15

Configure the Serial Driver 18

Select the Controller Path 20

For the FlexLogix controller to operate on a serial network, you need:

• a workstation with a serial port

• RSLinx software to configure the serial communication driver

• RSLogix5000 programming software to configure the serial port

of the controller

The RS-232 port is a non-isolated serial port built-in to the front of the FlexLogix controller.

1. Determine whether you need an isolator.

If you connect the controller to a modem or an ASCII device, consider installing an isolator between the controller and modem or ASCII device. An isolator is also recommended when connecting the controller directly to a programming workstation.

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16 Directly Connect to the Controller via the Serial Port

baud rate selector switch

One possible isolator is the 1761-NET-AIC interface converter.

port 2: mini-DIN 8 RS-232

port 1: DB-9 RS-232, DTE

dc power source selector switch

terminals for external 24V dc power supply

2. Select the appropriate cable.

If you are using an isolator: Use this cable:

yes The 1761-CBL-AP00 cable (right-angle bend connector to controller) or the 1761-CBL-PM02 cable

(straight connector to the controller) attaches the controller to port 2 on the 1761-NET-AIC isolator. The 8-pin mini-DIN connector is not commercially available, so you cannot make this cable.

DB-9 right-angle or straight cable end

Pin: DB-9 end: Mini-DIN end:

1DCD DCD

2 RxD RxD

3TxD TxD

4DTR DTR

5 ground ground

6DSR DSR

7 RTS RTS

8 CTS CTS

9na na

678

8-pin, mini-DIN cable end

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Directly Connect to the Controller via the Serial Port 17

If you are using an isolator: Use this cable:

no The 1756-CP3 cable attaches the controller directly to the RS-232 device.

1 CD

2 RDX

3 TXD

4 DTR

COMMON

6 DSR

7 RTS

8 CTS

straight cable end

1 CD

2 RDX

3 TXD

4 DTR

COMMON

6 DSR

7 RTS

8 CTS

right-angle cable end

If you make your own cable, it must be shielded and the shields must be tied to the metal shell (that surrounds the pins) on both ends of the cable.

You can also use a 1747-CP3 cable from the SLC product family. This cable has a larger right-angle connector than the 1756-CP3 cable.

3. Connect the appropriate cable to the serial port on the

controller.

isolator 1761-NET-AIC

4. If necessary, attach the controller to the isolator.

1761 cable

user-supplied modem cable

modem

24 V dc

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18 Directly Connect to the Controller via the Serial Port

Configure the Serial Driver

ATTENTION

The FlexLogix controller is grounded through its DIN rail. It is important that you understand the workstation’s grounding system before connecting it to the controller. An isolator is

recommended between the controller and the workstation.

Use RSLinx software to configure the RS-232 DF1 Device driver for serial communications. To configure the driver:

1. From the Communications menu in RSLinx software, select

Configure Drivers. Choose the RS-232 DF1 Device driver.

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2. Click Add New to add the driver.

3. Specify the driver name and click OK.

Directly Connect to the Controller via the Serial Port 19

4. Specify the serial port settings:

a. From the Comm Port drop-down list, select the serial port (on

the workstation) that the cable is connected to. b. From the Device drop-down list, select Logix 5550-Serial Port. c. Click Auto-Configure.

5. Does the dialog box display the following message:

Auto Configuration Successful!

If: Then:

Yes Click OK.

No Go to step 4. and verify that you selected the correct Comm Port.

Then click Close.

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20 Directly Connect to the Controller via the Serial Port

Select the Controller Path

In RSLogix 5000 software, select the controller path on the network.

1. Open an RSLogix 5000 project for the controller.

2. From the Communications menu, select Who Active.

3. Expand the communication driver to the level of the controller.

4. Select the controller.

To: Choose:

monitor the project in the controller Go Online

transfer a copy of the project from the controller to RSLogix 5000 software

transfer the open project to the controller Download

You may have to confirm the action.

Upload

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Communicate over Networks

Chapter

Use This Chapter

The FlexLogix controller supports additional networks so that the controller can:

Supported networks for: Example:

Control distributed (remote) I/O

• EtherNet/IP

• ControlNet

• DeviceNet

Produce/consume (interlock) data between controllers

• EtherNet/IP

• ControlNet

FlexLogix controller

control network

distributed (remote) I/O platform

FlexLogix controller

control network

other Logix5000 controller

Send and receive messages to and from other devices (this includes access to the controller via RSLogix 5000 programming software)

• EtherNet/IP

• ControlNet

• DeviceNet (to devices only)

• serial

• DH-485

21 Publication 1794-UM001G-EN-P - January 2007

control network

FlexLogix controller

other remote devices

22 Communicate over Networks

This chapter summarizes the FlexLogix controller’s communications capabilities:

For this information: See:

EtherNet/IP 22

ControlNet 25

DeviceNet 28

Serial 31

DH-485 39

Third Party 42

EtherNet/IP

See:

• EtherNet/IP Modules in Logix5000 Control Systems User Manual,

ENET-UM001

• EtherNet/IP Web Server Module User Manual, ENET-UM527

• EtherNet/IP Performance Application Guide, ENET-AP001

• Logix5000 Controllers Design Considerations Reference Manual,

1756-RM094

• EtherNet/IP Daughtercard Installation Instructions,

1788-IN054

For EtherNet/IP communications, install a 1788-ENBT communication card in your FlexLogix controller.

Use these software products when you use a FlexLogix controller on EtherNet/IP:

Software Use Required/optional

RSLogix 5000 programming software

Use this to configure the FlexLogix project and define EtherNet/IP communications.

BOOTP/DHCP Utility

This utility comes with RSLogix 5000 software. Use this utility to assign IP addresses to devices on an EtherNet/IP network.

RSNetWorx for EtherNet/IP Use this software to

configure EtherNet/IP devices by IP addresses and/or host names.

Required

Optional

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Communicate over Networks 23

The EtherNet/IP communication modules:

• support messaging, produced/consumed tags, HMI, and distributed I/O

• encapsulate messages within standard TCP/UDP/IP protocol

• share a common application layer with ControlNet and

DeviceNet

• interface via RJ45, category 5, unshielded, twisted-pair cable

• support half/full duplex 10 Mbps or 100 Mbps operation

• support standard switches

• require no network scheduling

• require no routing tables

In this example:

• The controllers can produce and consume tags among each other.

• The controllers can initiate MSG instructions that send/receive data or configure devices.

• The personal computer can upload/download projects to the controllers.

• The personal computer can configure devices on EtherNet/IP.

CompactLogix controller with integrated EtherNet/IP port

PowerFlex 700S AC drive with DriveLogix

FlexLogix controller with 1788-ENBT card

ControlLogix controller with 1756-ENBT module

switch

workstation

Distributed I/O

1756-ENBT module (as an adapter) with 1756 I/O modules

1794-AENT adapter with 1794 I/O modules

1734-AENT adapter with 1734 I/O modules

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24 Communicate over Networks

Connections over EtherNet/IP

You indirectly determine the number of connections the controller uses by configuring the controller to communicate with other devices in the system. Connections are allocations of resources that provide more reliable communications between devices than unconnected messages.

All EtherNet/IP connections are unscheduled. An unscheduled connection is a message transfer between controllers that is triggered by the requested packet interval (RPI) or the program (such as a MSG instruction). Unscheduled messaging lets you send and receive data when needed.

The 1788-ENBT card supports 32 CIP connections over an EtherNet/IP network. With these controllers, the number of end-node connections they effectively support is dependent on the RPI of the connection:

If the RPI is: The EtherNet/IP card effectively

supports a maximum of this many communication connections:

2 ms 2

For more information...

4 ms 5

8 ms 10

16 ms 18

32 ms + 25

In the table above, with an RPI of 32 ms and greater, the EtherNet/IP card effectively supports 25 communications connections. In this case, the remaining 7 connections can be used for non-I/O purposes.

The EtherNet/IP Modules in Logix5000 Control Systems User Manual, ENET-UM001 provides information on how to:

• configure an EtherNet/IP communication module

• control I/O over EtherNet/IP

• send a message over EtherNet/IP

• produce/consume a tag over EtherNet/IP

• monitor diagnostics

• calculate controller connections over EtherNet/IP

The Logix5000 Controllers Design Guidelines Reference Manual, 1756-RM094 provides guidelines on optimizing a control application on an EtherNet/IP network.

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Communicate over Networks 25

ControlNet

See:

• ControlNet Modules in Logix5000 Control Systems User Manual,

CNET-UM001

• Logix5000 Controllers Design Considerations Reference Manual,

1756-RM094

• ControlNet Daughtercard Installation Instructions,

1788-IN002

• ControlNet Daughtercard Installation Instructions,

For ControlNet communications, install a ControlNet communication card in your FlexLogix controller:

If you are using Use this card

fiber media 1788-CNF, 1788-CNFR

coaxial media 1788-CNC, 1788-CNCR

Use these software products when you use a FlexLogix controller on ControlNet:

Software Use Required/optional

RSLogix 5000 programming software

RSLinx Use this software to

RSNetWorx for ControlNet Use this software to

Use this to configure the FlexLogix project and define ControlNet communications.

configure the ControlNet communication driver.

configure the ControlNet network, define the NUT (Network update time), and schedule the ControlNet network.

Required

The ControlNet communications modules:

• support messaging, produced/consumed tags and distributed I/O

• share a common application layer with DeviceNet and EtherNet/IP

• require no routing tables

• support the use of coax and fiber repeaters for isolation and

increased distance

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26 Communicate over Networks

In this example:

• The controllers can produce and consume tags among each other.

• The controllers can initiate MSG instructions that send/receive data or configure devices.

• The personal computer can upload/download projects to the controllers.

• The personal computer can configure devices on ControlNet, and it can configure the network itself.

personal computer/workstation

CompactLogix controller with built-in Control port

FlexLogix controller with 1788-CNC card

PowerFlex 700S drive

ControlNet

PLC-5/40C controller

PanelView terminal

Distributed I/O

1756-CNB module (as an adapter) with 1756 I/O modules

1794-ACN15 adapter with 1794 I/O modules

1734-ACNR adapter with 1734 I/O modules

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Connections over ControlNet

more reliable communications between devices compared to unconnected messages.

ControlNet connections can be:

Connection method: Description:

Communicate over Networks 27

scheduled

(unique to ControlNet)

unscheduled An unscheduled connection is a message transfer between controllers that is triggered by

A scheduled connection is unique to ControlNet communications. A scheduled connection lets you send and receive data repeatedly at a predetermined interval, which is the requested packet interval (RPI). For example, a connection to an I/O module is a scheduled connection because you repeatedly receive data from the module at a specified interval. Other scheduled connections include connections to:

• communication devices

• produced/consumed tags

On a ControlNet network, you must use RSNetWorx for ControlNet to enable all scheduled connections and establish a network update time (NUT). Scheduling a connection reserves network bandwidth to specifically handle the connection.

ladder logic or the program (such as a MSG instruction). Unscheduled messaging lets you send and receive data when needed. Unscheduled messages use the remainder of network bandwidth after scheduled connections are allocated.

The FlexLogix controller supports 100 connections. However, the controller is limited by the number of connections each ControlNet communication card supports. The 1788-CNx cards support 32 total ControlNet connections, 22 of which can be scheduled and used for producing and consuming tags. With these controllers, the number of end-node connections they effectively support is dependent on the application’s NUT and RPI:

If the NUT and RPI are each: The controllers effectively support this

many communication connections

5 ms 3

10 ms 6

20 ms 13

40 ms + 22

In the table above, with a NUT and RPI of 40 ms and greater, the ControlNet card supports 22 communications connections. In this case, the remaining 10 connections can be used for unscheduled connections.

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28 Communicate over Networks

For more information...

DeviceNet

See:

• DeviceNet Modules in Logix5000 Control Systems User Manual,

DNET-UM004

• Logix5000 Controllers Design Considerations Reference Manual,

1756-RM094

• DeviceNet Daughtercard

The ControlNet Modules in Logix5000 Control Systems User Manual, CNET-UM001 provides information on how to:

• configure a ControNet communication module

• control I/O over ControlNet

• send a message over ControlNet

• produce/consume a tag over ControlNet

• calculate controller connections over ControlNet

The Logix5000 Controllers Design Guidelines Reference Manual, 1756-RM094 provides guidelines on optimizing a control application on a ControlNet network.

The DeviceNet network uses the Common Industrial Protocol (CIP) to provide the control, configuration, and data collection capabilities for industrial devices.

For DeviceNet communications, install a 1788-DNBO communication card in your FlexLogix controller.

FlexLogix system with 1788-DNBO card

PanelView terminal

CompactLogix controller with 1769-SDN

laptop

Ultra 5000 servo drive

PLC-5 controller with 1771-SDN scanner module

DeviceNet network

motor starter

input/output devices

PowerFlex ac drive

sensor

indicator lights

ControlLogix controller with 1756-DNB module

pushbutton cluster

bar code scanner

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Communicate over Networks 29

Use these software products when you use a FlexLogix controller on DeviceNet:

Software Use Required/optional

RSLogix 5000 programming software

Use this to configure the FlexLogix project and define

Required

DeviceNet communications.

RSNetWorx for DeviceNet Use this software to

Required configure DeviceNet devices and define the scan list for those devices.

The DeviceNet communications module:

• supports messaging to devices (not controller to controller)

• shares a common application layer with ControlNet and

EtherNet/IP

• offers diagnostics for improved data collection and fault detection

• requires less wiring than traditional, hardwired systems

personal computer

FlexLogix system with a 1788-DNBO card

You can use a linking device as a:

• gateway to connect information- or control-level networks to device-level networks for programming, configuration, control or data collection

• router/bridge to connect the EtherNet/IP or ControlNet network to the DeviceNet network

ControlLogix controller with 1756-ENBT module

EtherNet/IP network

FlexLogix controller

FLEX adapter and I/O

linking devices

DeviceNet network

sensor

motor starter

with a 1788-ENBT card

pushbutton cluster

input/output devices

PowerFlex ac drive

bar code

indicator lights

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scanner

30 Communicate over Networks

Define Data Blocks

How you configure the DeviceNet devices determines how many words you use per device. The 1788-DNBO card supports a maximum of:

• 124 32-bit words of input data

• 123 32-bit words of output data

• 32 32-bit words of status data

Most DeviceNet devices support 16-bit words. Take care how you map these into the 32-bit words used in RSLogix 5000 programming software. RSNetWorx for DeviceNet lets you DINT-align the device data. While this might simplify the organization of the data, it might also limit the data you have available.

For more information...

The DeviceNet Modules in Logix5000 Control Systems User Manual, DNET-UM004 provides information on how to:

• configure DeviceNet communication module

• control devices on DeviceNet

The Logix5000 Controllers Design Guidelines Reference Manual, 1756-RM094 provides guidelines on optimizing a control application on a DeviceNet network.

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Communicate over Networks 31

Serial

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

The RS-232 port is a non-isolated serial port built-in to the front of the FlexLogix controller. You can configure the serial port of the controller for these modes:

Use this mode: For:

DF1 point-to-point

DF1 master mode control of polling and message transmission between the master and

communication between the controller and one other DF1-protocol-compatible device.

This is the default system mode. Default parameters are:

• Baud Rate: 19200

• Data Bits: 8

• Parity: None

• Stop Bits: 1

• Control Line: No Handshake

• RTS send Delay: 0

• RTS Off Delay: 0

This mode is typically used to program the controller through its serial port.

slave nodes.

DF1 radio modem

The master/slave network includes one controller configured as the master node and as many as 254 slave nodes. Link slave nodes using modems or line drivers.

A master/slave network can have node numbers from 0 to 254. Each node must have a unique node address. Also, at least 2 nodes must exist to define your link as a network (1 master and 1 slave station are the two nodes).

• Compatible with SLC500 and MicroLogix1500 controllers

• This mode supports master and slave, and store and forward

modes

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32 Communicate over Networks

Use this mode: For:

DF1 slave mode using a controller as a slave station in a master/slave serial

communication network.

When there are multiple slave stations on the network, link slave stations using modems or line drivers to the master. When you have a single slave station on the network, you do not need a modem to connect the slave station to the master. You can configure the control parameters for no handshaking. You can connect 2 to 255 nodes to a single link. In DF1 slave mode, a controller uses DF1 half-duplex protocol.

One node is designated as the master and it controls who has access to the link. All the other nodes are slave stations and must wait for permission from the master before transmitting.

User mode

communicating with ASCII devices.

(channel 0 only)

This requires your program to use ASCII instructions to read and write data from and to an ASCII device.

DH-485 communicating with other DH-485 devices multi-master, token

passing network allowing programming and peer-to-peer messaging.

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Communicate over Networks 33

1. Determine whether you need an isolator.

For more information on determining if you need an isolator, see page 15.

2. Select the appropriate cable.

3. Connect the appropriate cable to the serial port.

Communicate with DF1 devices

You can configure the controller as a master or slave on a serial communication network. Use serial to get information to and from remote controllers (stations) when:

• the system contains three or more stations

• communications occur on a regular basis and require

leased-line, radio, or power-line modems

EtherNet/IP

RS-232

modem

Isolator

RS-232

modem

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34 Communicate over Networks

On this tab Do this

To configure the controller for DF1 communications:

1. Select System Mode

2. Specify communication settings

1. Select DF1 protocol

For more information...

2. Specify DF1 settings

The Logix5000 Controllers General Instructions Reference Manual, 1756-RM003 defines the instructions you can use to manipulate ASCII characters.

The SCADA System Application Guide, AG-UM008 provides information on how to:

• select a polling mode

• configure controllers, modems, and software

• troubleshoot basic DF1 protocol issues

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Communicate over Networks 35

Communicate with ASCII devices

When configured for user mode, you can use the serial port to interface with ASCII devices. For example, you can use the serial port to:

• read ASCII characters from a weigh scale module or bar code reader

• send and receive messages from an ASCII triggered device, such as a MessageView terminal.

connection from the serial port of the controller to the ASCII device

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36 Communicate over Networks

On this tab Do this

To configure the controller for ASCII communications:

1. Select User Mode

2. Specify communication settings

1. Select ASCII protocol

2. Specify ASCII character settings

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Communicate over Networks 37

The controller supports several instructions to manipulate ASCII characters. The instructions are available in ladder diagram (LD) and structured text (ST).

Read and write ASCII characters

If you want to: Use this instruction:

determine when the buffer contains termination characters ABL

count the characters in the buffer ACB

clear the buffer ACL

clear out ASCII Serial Port instructions that are currently executing or are in the queue

obtain the status of the serial port control lines AHL

turn on or off the DTR signal

turn on or off the RTS signal

read a fixed number of characters ARD

read a varying number of characters, up to and including the first set of termination characters

send characters and automatically append one or two additional characters to mark the end of the data

ARL

AWA

send characters AWT

Create and modify strings of ASCII characters

If you want to: Use this instruction:

add characters to the end of a string CONCAT

delete characters from a string DELETE

determine the starting character of a sub-string FIND

insert characters into a string INSERT

extract characters from a string MID

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38 Communicate over Networks

Convert data to or from ASCII characters

If you want to: Use this instruction:

convert the ASCII representation of an integer value to a SINT, INT, DINT, or REAL value

STOD

For more information...

convert the ASCII representation of a floating-point value to a REAL value

convert a SINT, INT, DINT, or REAL value to a string of ASCII characters

convert a REAL value to a string of ASCII characters RTOS

convert the letters in a string of ASCII characters to upper case UPPER

convert the letters in a string of ASCII characters to lower case LOWER

STOR

DTOS

The Logix5000 Controllers General Instructions Reference Manual, 1756-RM003 defines the instructions you can use to manipulate ASCII characters.

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• communicate with an ASCII device

• transmit/receive ASCII characters

Modbus support

See:

• Logix5000 Controllers as Masters or Slaves on Modbus Application Solution, CIG-AP129

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To use Logix5000 controllers on Modbus, you connect through the serial port and execute specific ladder logic routines. A sample controller project is available with RSLogix 5000 Enterprise programming software. From RSLogix 5000 software, select Help

→

Vendor Sample Projects to display a list of available, sample projects.

Communicate over Networks 39

DH-485

For DH-485 communication, use the serial port of the controller. However, when using a FlexLogix controller, it is recommended that you use NetLinx networks (EtherNet/IP, ControlNet, or DeviceNet) because excessive traffic on a DH-485 network may make it impractical to connect to a controller with RSLogix 5000 programming software.

If your application uses: Select:

• connections to existing DH-485 networks

built-in serial port

The DH-485 protocol uses RS-485 half-duplex as its physical interface. (RS-485 is a definition of electrical characteristics; it is not a protocol.) You can configure the RS-232 port of the FlexLogix controller to act as a DH-485 interface. By using a 1761-NET-AIC and the appropriate RS-232 cable (1756-CP3 or 1747-CP3), a FlexLogix controller can send and receive data on a DH-485 network.

FlexLogix controller

1747-CP3

1761-NET-AIC+

1761-CBL-AP00

connection from FlexLogix controller to port 1 or port 2

DH-485 network

1747-CP3

1747-AIC

SLC 5/03 controller

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40 Communicate over Networks

On the DH-485 network, the FlexLogix controller can send and receive messages to and from other controllers on the network.

IMPORTANT

A DH-485 network consists of multiple cable segments. Limit the total length of all the segments to 1219m (4000 ft.).

For the controller to operate on a DH-485 network, you need:

• a 1761-NET-AIC interface converter for each controller you want to put on the DH-485 network.

You can have two controllers for each 1761-NET-AIC converter, but you need a different cable for each controller.

a. Connect the serial port of the controller to either port 1 or

port 2 of the 1761-NET-AIC converter.

b. Use the RS-485 port to connect the converter to the DH-485

network.

The cable you use to connect the controller depends on the port you use on the 1761-NET-AIC converter.

If you connect to this port: Use this cable:

port 1

1747-CP3

DB-9 RS-232, DTE connection

port 2

mini-DIN 8 RS-232 connection

1761-CBL-AC00

1761-CBL-AP00

1761-CBL-PM02

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Communicate over Networks 41

• RSLogix 5000 programming software to configure the serial port of the controller for DH-485 communications.

Specify these characteristics on the Serial Port tab (default values are shown in bold):

Characteristic: Description:

Baud Rate Specifies the communication rate for the DH-485 port. All devices

Node Address Specifies the node address of the controller on the DH-485

Token Hold Factor Number of transmissions (plus retries) that a node holding a

Maximum Node Address

on the same DH-485 network must be configured for the same baud rate. Select 9600 or 19200 Kbps.

network. Select a number 1-31 decimal, inclusive.

To optimize network performance, assign node addresses in sequential order. Initiators, such as personal computers, should be assigned the lowest address numbers to minimize the time required to initialize the network.

token can send onto the data link each time that it receives the token. Enter a value between 1-4. The default is 1.

Specifies the maximum node address of all the devices on the DH-485 network. Select a number 1-31 decimal, inclusive.

For more information...

To optimize network performance, make sure:

• the maximum node address is the highest node number being used on the network

• that all the devices on the same DH-485 network have the same selection for the maximum node address.

The Data Highway/Data Highway Plus/Data Highway II/Data Highway-485 Cable Installation Manual, 1770-6.2.2 describes how to

plan and install a DH-485 network.

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42 Communicate over Networks

Third Party

The FlexLogix controller can operate on third-party networks. To operate on a third-party network, install the 1788-MODULE generic module communication card in the controller.

Use these software products when you use a FlexLogix controller on third-party network:

Software Use Required/optional

RSLogix 5000 programming software, Version 12 or later

Third-party software Software that configures

Use this to configure the 1788-MODULE card as part of the FlexLogix system

the 1788-MODULE card on the third-party network

Required

Use RSLogix 5000 programming software to map the 1788-MODULE card as part of the FlexLogix system. In the Controller Organizer, add the card to the I/O Configuration folder.

Communication Format

The Communication Format field chooses a data type for information transmitted between the controller and a remote device connected to the 1788-MODULE communication card. This format creates an array in the controller of whatever data type you choose for the input and output data.

Connection Parameters

You must set connection parameters to define data identification and connection size. An Assembly Instance and Data Size must be assigned for input, output and configuration data.

Assembly Instance

The Assembly Instance is a number that identifies what data transferred between the owner-controller and I/O module looks like. You must create a map that defines your assembly instance entries.

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Communicate over Networks 43

Size

The size field determines how large the connections are between the owner-controller and the I/O module. Connections are sent in sizes matching the communications format data type selected. The default, DINT, results in 32-bit quantities.

Complete your system configuration and develop your program logic. Then download the project to the controller.

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44 Communicate over Networks

Notes:

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Use This Chapter

Chapter

Manage Controller Communications

For this information See

Produce and Consume (Interlock) Data 45

Send and Receive Messages 47

Connection Overview 49

Calculate Connection Use 50

Connections Example 52

Produce and Consume (Interlock) Data

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

The controller supports the ability to produce (broadcast) and consume (receive) system-shared tags over ControlNet or EtherNet/IP networks. Produced and consumed tags each require connections. Over ControlNet, produced and consumed tags are scheduled connections.

controller_1

produced tag

controller_2

consumed tag

controller_3

consumed tag

controller_4

consumed tag

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46 Manage Controller Communications

This type of tag Description

produced

consumed Each consumed tag requires one connection for the controller that is consuming the tag.

A produced tag allows other controllers to consume the tag, which means that a controller can receive the tag data from another controller. The producing controller uses one connection for the produced tag and one connection for each consumer. The controller’s communication device uses one connection for each consumer.

As you increase the number of controllers that can consume a produced tag, you also reduce the number of connections the controller and communication device have available for other operations, like communications and I/O.

The controller’s communication device uses one connection for each consumer.

For two controllers to share produced or consumed tags, both controllers must be attached to the same control network (such as a ControlNet or Ethernet/IP network). You cannot bridge produced and consumed tags over two networks.

The total number of tags that can be produced or consumed is limited by the number of available connections. If the controller uses all of its connections for I/O and communication devices, no connections are left for produced and consumed tags.

For more information...

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• produce a tag

• consume a tag

• produce a large array

The Logix5000 Controllers Design Considerations Reference Manual, 1756-RM094 provides guidelines on how to:

• create produced and consumed tags

• specify an RPI

• manage connections

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Manage Controller Communications 47

Send and Receive Messages

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

Messages transfer data to other devices, such as other controllers or operator interfaces. Messages use unscheduled connections to send or receive data. Connected messages can leave the connection open (cache) or close the connection when the message is done transmitting.

This message type: With this

communication method:

CIP data table read or write 33

PLC2, PLC3, PLC5, or SLC (all types)

CIP generic block-transfer read or write 33

(1)

You can connect CIP generic messages. But for most applications we recommend you leave CIP generic messages unconnected.

(2)

Consider caching only if the target module requires a connection.

CIP

CIP with Source ID DH+ 33

Is a connected message:

your option

(1)

The message can be cached:

(2)

Connected messages are unscheduled connections on both ControlNet and EtherNet/IP networks.

Each message uses one connection, regardless of how many devices are in the message path. You can programmatically change the target of a MSG instruction to optimize message transfer time.

Determine whether to cache message connections

When you configure a MSG instruction, you have the option of whether or not to cache the connection.

If the message executes Then

repeatedly Cache the connection.

This keeps the connection open and optimizes execution time. Opening a connection each time the message executes increases execution time.

infrequently Do not cache the connection.

This closes the connection upon completion of the message, which frees up that connection for other uses.

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48 Manage Controller Communications

The controller has the following limits on the number of connections that you can cache:

For more information...

If you have this software and firmware revision:

11.x or earlier • block transfer messages for up to 16 connections

12.x or later up to 32 total connections

Then you can cache:

• other types of messages up to 16 connections

The Logix5000 Controllers General Instructions Reference Manual, 1756-RM003 describes how to use the MSG instruction.

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• execute a MSG instruction

• get and set the number of unconnected buffers

• convert INT data to DINT data

• manage multiple MSG instructions

• send one MSG to multiple devices

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Manage Controller Communications 49

Connection Overview

See:

• Logix5000 Controllers Design Considerations Reference Manual,

1756-RM094

A Logix5000 system uses a connection to establish a communication link between two devices. Connections can be:

• controller to local I/O modules or local communication modules

• controller to remote I/O or remote communication modules

• controller to remote I/O (rack-optimized) modules

• produced and consumed tags

• messages

• controller access by RSLogix 5000 programming software

• controller access by RSLinx software for HMI or other

applications

The limit of connections may ultimately reside in the communication module you use for the connection. If a message path routes through a communication module, the connection related to the message also counts towards the connection limit of that communication module.

This device Supports this many connections

FlexLogix controller 100

1788-CNx communication card 32

1788-DNBO communication card 2

For more information...

1788-ENBT communication card 32

Other controllers and communication modules support different maximum numbers of connections.

The Logix5000 Controllers Design Considerations Reference Manual, 1756-RM094 describes how to optimize connection use.

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50 Manage Controller Communications

Calculate Connection Use

Connection Type: Device

rack-optimized connection for the local DIN rail and the extended-local DIN rail

I/O module (rack-optimized connection) on local rail 0

I/O module (direct connection) on local rail 1

I/O module (rack-optimized connection) on extended-local rail 0

I/O module (direct connection) on extended-local rail 1

1788-CNx ControlNet communication card 0 0

1788-DNBO DeviceNet communication card (direct connection)

1788-ENBT Ethernet/IP communication card 0 0

(1)

FlexLogix controller connection to remote DeviceNet devices are accounted for in the 2 connections to the 1788-DNBO card.

To calculate the total number of local connections the controller uses:

Connections

Quantity:

212

(1)

per Device:

total

Remote connections depend on the communication module. The number of connections the module itself supports determines how many connections the controller can access through that module. To calculate the total number of remote connections the controller uses:

Tota l Connections:

Remote Connection Type Device

Quantity

remote ControlNet communication module

I/O configured as direct connection (none)

I/O configured as rack-optimized connection

remote I/O module over ControlNet (direct connection) 1

remote EtherNet/IP communication module

I/O configured as direct connection (none)

I/O configured as rack-optimized connection

remote I/O module over EtherNet/IP (direct connection) 1

remote device over DeviceNet

(accounted for in rack-optimized connection for optional 1788-DNBO card) 0

other remote communication adapter 1

produced tag

each consumer

consumed tag 1

Connections per Device

0 or

Tota l Connections

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Manage Controller Communications 51

Remote Connection Type Device

Quantity

message (depending on type) 1

block-transfer message 1

Connections per Device

Tota l Connections

total

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52 Manage Controller Communications

Connections Example

FlexLogix with 1788-DNBO and 1788-ENBT cards installed

In this example system the FlexLogix controller:

• controls local (in the same chassis) digital I/O modules

• controls remote I/O devices on DeviceNet

• sends and receives messages to/from a ControlLogix controller

on EtherNet/IP

• produces one tag that the the CompactLogix controller consumes

• is programmed via RSLogix 5000 programming software

1769-ADN adapter with Compact I/O modules

Redistation

Series 9000 photoeye

DeviceNet network

ControlLogix controller with 1756-ENBT module

EtherNet/IP network

1769-L35E CompactLogix controller

personal computer

The FlexLogix controller in this example uses these connections:

Connection Type: Device

Quantity:

controller to local I/O modules (rack-optimized) 2 1 2

controller to installed DeviceNet communication card 1 2 2

controller to installed EtherNet/IP communication card 1 0 0

controller to RSLogix 5000 programming software 1 1 1

message to ControlLogix controller 2 1 2

produced tag consumed by CompactLogix controller 2 1 2

Connections per Device:

Tota l Connections:

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total 9

Use This Chapter

Chapter

Place, Configure, and Monitor I/O

For this information: See:

Select I/O Modules 53

Place Local I/O Modules 54

Configure I/O 55

Configure Distributed I/O on EtherNet/IP 59

Configure Distributed I/O on ControlNet 60

Configure Distributed I/O on DeviceNet 61

Address I/O Data 62

Select I/O Modules

See:

• FLEX I/O and FLEX EX Selection Guide, 1794-SG002

Determine When Data Is Updated 63

Reconfigure an I/O Module 66

When selecting 1794 FLEX I/O modules, select:

• Select a communication adapter - Choose the network for your operating system

• Select I/O modules based on field devices

• Select a terminal base - Choose an appropriate terminal base for

your modules

• Select power supplies and make sure there is sufficient power for the communication adapter and modules

53 Publication 1794-UM001G-EN-P - January 2007

54 Place, Configure, and Monitor I/O

Place Local I/O Modules

See:

• FLEX I/O Analog Modules User Manual, 1794-6.5.2

• FLEX I/O Digital Modules User

The FlexLogix controller supports a local DIN rail of as many as 8 I/O modules and an extended-local DIN rail of as many as 8 I/O modules. The second DIN rail is optional.

local DIN rail

extended-local DIN rail

Selecting a Power Supply

In a FlexLogix system, select an Allen-Bradley power supply. In applications that must be compliant with CSA requirements, use a Separated Extra-Low Voltage (SELV) power supply that is compliant with IEC 61010.1, Annex H.

When selecting power supplies:

• Provide power for the controller separately from the power for the FLEX I/O modules. To provide power for FLEX I/O modules, follow the guidelines in the documentation for those modules.

• When providing power for the 1794-FLA extended-local I/O adapter, treat the adapter as a communication adapter, not as an I/O module.

1794 FLEX power supplies

The following power supplies available for use with the FlexLogix system.

Catalog number Nominal

input voltage

1794-PS3 120/230V ac 85-265V ac 86W 205VA 250VA 3.0A @ 24V dc (horizontal

1794-PS13 36W 53VA 90VA 1.3A @ 24V dc

Input voltage range

Maximum real input power

Maximum apparent input power

Maximum transformer load

Output current

mount)

2.8A @ 24Vdc (non-horizontal mount)

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Place, Configure, and Monitor I/O 55

The FlexLogix controller also supports distributed (remote) I/O via these networks:

• EtherNet/IP

• ControlNet

• DeviceNet

Configure I/O

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

1756-RM094

To communicate with an I/O module in your system, you add the module to the I/O Configuration folder of the controller.

Add I/O modules to the FlexBus Local or Local2

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56 Place, Configure, and Monitor I/O

Configuration Option: Description:

requested packet interval (RPI) The RPI specifies the period at which data updates over a connection. For example, an

change of state (COS)

When you add a module, you also define a specific configuration for the module. While the configuration options vary from module to module, there are some common options that you typically configure:

input module sends data to a controller at the RPI that you assign to the module.

• Typically, you configure an RPI in milliseconds (ms). The range is 0.2 ms (200 microseconds) to 750 ms.

• If a ControlNet network connects the devices, the RPI reserves a slot in the stream of data flowing across the ControlNet network. The timing of this slot may not coincide with the exact value of the RPI, but the control system guarantees that the data transfers at least as often as the RPI.

Digital I/O modules use change of state (COS) to determine when to send data to the controller. If a COS does not occur within the RPI timeframe, the module multicasts data at the rate specified by the RPI.

Because the RPI and COS functions are asynchronous to the logic scan, it is possible for an input to change state during program scan execution. If this is a concern, buffer input data so your logic has a stable copy of data during its scan. Use the Synchronous Copy (CPS) instruction to copy the input data from your input tags to another structure and use the data from that structure.

communication format Many I/O modules support different formats. The communication format that you choose

also determines:

• data structure of tags

• connections

• network usage

• ownership

• whether the module returns diagnostic information

electronic keying When you configure a module, you specify the slot number for the module. However, it is

possible to place a different module in that slot, either on purpose or accidently. Electronic keying lets you protect your system against the accidental placement of the wrong module in a slot. The keying option you choose determines how closely any module in a slot must match the configuration for that slot before the controller opens a connection to the module. There are different keying options depending on your application needs.

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Place, Configure, and Monitor I/O 57

I/O connections

A Logix5000 system uses connections to transmit I/O data. A connection can be:

Connection: Description:

direct A direct connection is a real-time, data transfer link between the controller and an I/O

module. The controller maintains and monitors the connection between the controller and the I/O module. Any break in the connection, such as a module fault or the removal of a module while under power, causes the controller to set fault status bits in the data area associated with the module.

Typically, analog I/O modules, diagnostic I/O modules, and specialty modules require direct connections.

rack-optimized For digital I/O modules, you can select rack-optimized communication. A rack-optimized

connection consolidates connection usage between the controller and all the digital I/O modules on a rack (or DIN rail). Rather than having individual, direct connections for each I/O module, there is one connection for the entire rack (or DIN rail).

Connections for local and extended-local I/O modules

The FlexLogix controller automatically assigns one rack-optimized connection for the local DIN rail and one rack-optimized connection for the extended-local DIN rail. You then configure each I/O module on a DIN rail to either use that rack-optimized connection or to use a direct connection. The rack-optimized connection for each DIN rail exists whether or not you configure the I/O modules to use that rack-optimized connection.

The rack-optimized connection lets you organize all the digital I/O modules on one DIN rail into one connection to the controller. Or you can choose to configure each I/O module to have a direct connection to the controller. Analog I/O modules must have a direct connection to the controller.

It is not as critical to manage the number of connections for local and extended-local I/O modules as it is for remote devices because the controller supports a direct connection for each possible local and extended-local I/O device.

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58 Place, Configure, and Monitor I/O

Connections for remote devices

To optimize the number of available connections, place remote, digital I/O in the same location and use a rack-optimized connection to the remote adapter that connects the remote I/O to the FlexLogix system.

If you have remote analog I/O modules, or want a direct connection to specific remote I/O modules, you do not have to create the rack-optimized connection to the remote adapter. To use direct connections to remote I/O, select “none” for the communication format of the remote communication device.

For more information...

IMPORTANT

It is vital that you manage your connections to remote devices because, while the FlexLogix controller allows up to 100 total connections, the communications cards that connect to remote devices are limited to far fewer connections (i.e., 32 connections for ControlNet or EtherNet/IP).

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• configure I/O

• address I/O data

• buffer I/O data

The Logix5000 Controllers Design Guidelines Reference Manual, 1756-RM094 provides guidelines on how to:

• buffer I/O

• specify an RPI rate

• select a communication format

• manage I/O connections

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Place, Configure, and Monitor I/O 59

Configure Distributed I/O on EtherNet/IP

For a typical distributed I/O network…

controller

…you build the I/O configuration in this order

EtherNet/IP card

To communicate with distributed I/O modules over EtherNet/IP, you:

• install a 1788-ENBT communication card in your FlexLogix controller and add the card to the I/O configuration folder

• add an EtherNet/IP adapter, and I/O modules to the I/O Configuration folder of the controller.

Within the I/O Configuration folder, you organize the modules into a hierarchy (tree/branch, parent/child).

remote

adapter

I/O

module

device

1. Add the local communication card

2. Add the remote adapter for the distributed

I/O chassis or DIN rail.

For more information...

See EtherNet/IP Communication Modules in Logix5000 Control Systems User Manual, ENET-UM001.

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60 Place, Configure, and Monitor I/O

Configure Distributed I/O on ControlNet

For a typical distributed I/O network…

controller

…you build the I/O configuration in this order

built-n

ControlNet port

To communicate with distributed I/O modules over ControlNet, you:

• install a 1788-CNx communication card in your FlexLogix controller and add the card to the I/O configuration folder

• add a ControlNet adapter, and I/O modules to the I/O Configuration folder of the controller.

Within the I/O Configuration folder, you organize the modules into a hierarchy (tree/branch, parent/child).

remote

adapter

I/O

module

device

1. Add the local communication card

2. Add the remote adapter for the distributed

I/O chassis or DIN rail.

For more information...

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See ControlNet Communication Modules in Logix5000 Control Systems User Manual, CNET-UM001.

Place, Configure, and Monitor I/O 61

Configure Distributed I/O on DeviceNet

For a typical distributed I/O network…

single network

cardcontroller

several smaller distributed networks (subnets)

cardcontroller

device

device device device device

linking device

device device device

To communicate with the I/O modules over Device, you add the DeviceNet bridge to the I/O Configuration folder of the controller. You define a scanlist within the DeviceNet adapter to communicate data between devices and the controller.

device

linking device

device device

…you build the I/O configuration in this order

Add the local scanner module.

For more information...

See DeviceNet Communication Modules in Logix5000 Control Systems User Manual, DNET-UM004.

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Address I/O Data

I/O information is presented as a set of tags.

• Each tag uses a structure of data. The structure depends on the specific features of the I/O module.

• The name of the tags is based on the location of the I/O module in the system.

An I/O address follows this format:

Location :Slot :Type .Member .SubMember .Bit

Where: Is:

Location Network location

LOCAL = same chassis or DIN rail as the controller

ADAPTER_NAME = identifies remote communication adapter or bridge module Slot Slot number of I/O module in its chassis or DIN rail Type Type of data

I = input

O = output

= Optional

C = configuration

S = status Member Specific data from the I/O module; depends on what type of data the module can store.

• For a digital module, a Data member usually stores the input or output bit values.

• For an analog module, a Channel member (CH#) usually stores the data for a channel.

SubMember Specific data related to a Member. Bit Specific point on a digital I/O module; depends on the size of the I/O module (0-31 for a 32-point module)

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Determine When Data Is Updated

input or output data?

input

analog or digital?

analog

RTS ≤ RPI?

Yes

Data is sent to the backplane at the RTS.

FlexLogix controllers update date asynchronous with the execution of logic. Use the following flowchart to determine when a producer (controller, input module, or bridge module) will send data.

output

digital

COS for any point on the module?

Data is sent to the backplane at the RTS and RPI.

Yes

analog or digital?

analog

remote or local?

remote

digital

local

Data is sent to the backplane at the RPI and at the change of a specified point.

• Over a ControlNet network, remote data is sent at the actual packet interval.

• Over an EtherNet/IP network, remote data is sent close to the RPI, on average.

TIP

If you need to ensure that the I/O values being used during logic execution are from one moment in time (such as at the beginning of a ladder program), use the Synchronous Copy instruction (CPS) to buffer I/O data.

For more information...

See Logix5000 Controllers Common Procedures Programming Manual, publication number 1756-PM001 for examples of I/O buffering or to the Logix5000 Controllers General Instruction Set Reference Manual, publication number 1756-RM003 for information

on the CPS instruction.

Data is sent to the backplane at the RPI

Data is sent to the backplane at the RPI and at the end of every task.

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64 Place, Configure, and Monitor I/O

Monitor I/O Modules

The FlexLogix controller offers different levels at which you can monitor I/O modules. You can:

• configure an I/O module so that the controller faults if that I/O module loses its connection with the controller

• use the programming software to display fault data (Refer to Displaying fault data on page 5-64)

• program logic to monitor fault data so you can take appropriate action (Refer to Logix5000 Controllers Common Procedures Programming Manual, publication number 1756-PM001, for examples.)

Displaying fault data

Fault data for certain types of module faults can be viewed through the programming software.

To view this data, select Controller Tags in the Controller Organizer. Right-click to select Monitor Tags.

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The display for the fault data defaults to decimal. Change it to Hex to read the fault code.

Place, Configure, and Monitor I/O 65

Monitor a rack-optimized connection

The controller views the DIN rail as another module in the system. Each DIN rail has its own data. To view this data through the programming software:

1. In the Controller Organizer, select Controller Tags. Right-click to

display the Data Monitor.

2. Expand the data display as necessary.

ATTENTION

If you have an extended-local DIN rail (LOCAL2) or a split rail, the modules after the 1794-CE1, -CE3 cable will fault if the cable is disconnected. In this case, all outputs are reset, regardless of the module configurations.

You can write logic to monitor the rack bits and take appropriate action if a fault occurs. For example, the following logic determines whether an error occurs on the Local rail. Then, the logic determines whether the error occurred at the module in slot 0. You can continue this logic to check each module on the rail.

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66 Place, Configure, and Monitor I/O

Reconfigure an I/O Module

If an I/O module support reconfiguration, you can reconfigure the module via:

• Module Properties dialog in RSLogix 5000 software

• MSG instruction in program logic

WARNING

Use care when changing the configuration of an I/O module. You could inadvertently cause the I/O module to operate incorrectly.

Reconfigure a module via RSLogix 5000 software

To change the configuration of an I/O module via RSLogix 5000 software, highlight the module in the I/O Configuration tree. Right-click and select Properties.

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Reconfigure a module via a MSG instruction

To change the configuration of an I/O module programmatically, use a MSG instruction of type Module Reconfigure to send new configuration information to an I/O module. During the reconfiguration:

• Input modules continue to send input data to the controller.

• Output modules continue to controller their output devices.

A Module Reconfigure message requires the following configuration properties:

In this property: Select:

Message Type Module Reconfigure

To reconfigure an I/O module:

EXAMPLE

1. Set the required member of the configuration tag of the module

to the new value.

2. Send a Module Reconfigure message to the module.

Reconfigure an I/O module

When reconfigure[5] is on, the MOV instruction sets the high alarm to 60 for the local module in slot 4. The Module Reconfigure message then sends the new alarm value to the module. The ONS instruction prevents the rung from sending multiple messages to the module while the reconfigure[5] is on.

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68 Place, Configure, and Monitor I/O

Notes:

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Use This Chapter

Chapter

Develop Applications

For this information: See:

Manage Tasks 69

Develop Programs 70

Organize Tags 75

Select a Programming Language 76

Monitor Controller Status 79

Monitor Connections 80

Select a System Overhead Percentage 82

Use the Event Task 85

Manage Tasks

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

A Logix5000 controller lets you use multiple tasks to schedule and prioritize the execution of your programs based on specific criteria. This balances the processing time of the controller among the different operations in your application.

• The controller executes only one task at one time.

• A different task can interrupt a task that is executing and take

control.

• In any given task, only one program executes at one time.

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70 Develop Applications

Develop Programs

control application

task 1

The controller operating system is a preemptive multitasking system that is IEC 1131-3 compliant. This environment provides:

• tasks to configure controller execution

• programs to group data and logic

• routines to encapsulate executable code written in a single

programming language

controller fault handler

task 8

configuration

status

program 32

watchdog

program 1

main routine

fault routine

controller (global) tags I/O data system-shared data

program (local)

Organize Tags

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

analog I/O device

integer value

storage bit

With a Logix5000 controller, you use a tag (alphanumeric name) to address data (variables). In Logix5000 controllers, there is no fixed, numeric format. The tag name itself identifies the data. This lets you:

• organize your data to mirror your machinery

• document (through tag names) your application as you

develop it

counter

timer

digital I/O device

For more information...

When you create a tag, you assign the following properties to the tag:

• tag type

• data type

• scope

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• define tags

• create tags, arrays, and user-defined structures

• address tags

• create aliases to tags

• assign indirect addresses

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76 Develop Applications

Select a Programming

The FlexLogix controller supports these programming languages, both online and offline:

Language

If you are programming: Use this language:

continuous or parallel execution of multiple operations (not sequenced) ladder diagram (LD)

boolean or bit-based operations

complex logical operations

message and communication processing

machine interlocking

operations that service or maintenance personnel may have to interpret in order to troubleshoot the machine or process

continuous process and drive control function block diagram (FBD)

loop control

calculations in circuit flow

high-level management of multiple operations sequential function chart (SFC)

repetitive sequence of operations

batch process

motion control using structured text

state machine operations

complex mathematical operations structured text (ST)

specialized array or table loop processing

ASCII string handling or protocol processing

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Add-On Instructions

With version 16 of RSLogix 5000 programming software, you can design and configure sets of commonly used instructions to increase project consistency. Similar to the built-in instructions contained in Logix5000 controllers, these instructions you create are called Add-On Instructions. Add-On Instructions reuse common control algorithms. With them, you can:

• ease maintenance by animating logic for a single instance.

• protect intellectual property with locking instructions.

• reduce documentation development time.

You can use Add-On Instructions across multiple projects. You can define your instructions, obtain them from somebody else, or copy them from another project.

Once defined in a project, Add-On Instructions behave similarly to the built-in instructions in Logix5000 controllers. They appear on the instruction tool bar for easy access, as do internal RSLogix 5000 software instructions.

Save Time

With Add-On Instructions, you can combine your most commonly used logic into sets of reusable instructions. You save time when you create instructions for your projects and then share them with others. Add-On Instructions increase project consistency since commonly used algorithms all work in the same manner, regardless of who implements the project.

Use Standard Editors

You create Add-On Instructions by using one of three RSLogix 5000 software programming editors.

• Standard Ladder

• Function Block Diagram

• Structured Text

Once you have created instructions, you can use them in any RSLogix 5000 editor.

Export Add-On Instructions

You can export Add-On-Instructions to other projects as well as copy and paste them from one project to another. Give each instruction a

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78 Develop Applications

unique name so that you don’t accidentally overwrite another instruction of the same name.

Use Context Views

Context views let you visualize an instruction’s logic for a specific instant, simplifying online troubleshooting of your Add-On Instructions. Each instruction contains a revision, a change history, and an auto-generated help page.

Create Custom Help

When you create an instruction, you enter information for the description fields in software dialogs, information that becomes what is known as Custom Help. Custom Help makes it easier for users to get the help they need when implementing the instructions.

Apply Source Protection

For more information...

As the creator of Add-On Instructions, you can limit users of your instruction(s) to read-only access, or you can bar access to the internal logic or local parameters used by the instruction(s). This source protection lets you prevent unwanted changes to your instruction(s) and protects your intellectual property.

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• design and program sequential function chart (SFC) logic

• program structured text (ST) logic

• program ladder diagram (LD) logic

• program function block diagram (FBD) logic

• force logic

The Logix5000 Controllers Execution Time and Memory Use Reference Manual, publication 1756-RM087 provides information on memory

use and execution times for instructions.

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Monitor Controller Status

The FlexLogix controller uses Get System Value (GSV) and Set System Value (SSV) instructions to get and set (change) controller data. The controller stores system data in objects. There is no status file, as in the PLC-5 processor.

The GSV instruction retrieves the specified information and places it in the destination. The SSV instruction sets the specified attribute with data from the source.

When you enter a GSV/SSV instruction, the programming software displays the valid object classes, object names, and attribute names for each instruction. For the GSV instruction, you can get values for all the available attributes. For the SSV instruction, the software displays only those attributes you are allowed to set.

In some cases, there will be more than one instance of the same type of object, so you might also have to specify the object name. For example, there can be several tasks in your application. Each task has its own TASK object that you access by the task name.

You can access these object classes:

• AXIS

• CONTROLLER

• CONTROLLERDEVICE

• CST

• DF1

• FAULTLOG

• MESSAGE

• MODULE

• MOTIONGROUP

• PROGRAM

• ROUTINE

• SERIALPORT

• TASK

• WALLCLOCKTIME

For more information...

The Logix5000 Controllers General Instructions Reference Manual, 1756-RM003 describes how to use the GSV and SSV instructions. These instructions support several different attributes of information.

The Logix5000 Controllers Common Procedures Manual, 1756-PM001 provides information on how to:

• handle major faults

• handle minor faults

• determine controller memory use

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80 Develop Applications

Monitor Connections

See:

• Logix5000 Controllers Common Procedures Manual, 1756-PM001

• Logix5000 Controllers Design Considerations Reference Manual,

If communication with a device in the I/O configuration of the controller does not occur for 100 ms or 4 times the RPI (whichever is less), the communication times out and the controller produces the following warnings:

• The I/O LED on the front of the controller flashes green.

• A

shows over the I/O configuration folder and over the

device (s) that has timed out.

• A module fault code is produced, which you can access through:

– Module Properties dialog box for the module – GSV instruction

Determine if communication has timed out with any device

If communication times out with at least one device (module) in the I/O configuration of the controller, the I/O LED on the front of the controller flashes green.

• The GSV instruction gets the status of the I/O LED and stores it in the I_O_LED tag.

• If I_O_LED equal 2, the controller has lost communication with at least one device.

Get System Value

GSV

CIP Object Class MODULE CIP Object Name Attribute Name LedStatus Dest I_O_LED

EQU Equal Source A I_O_LED

Source B 2

where:

I_O_LED is a DINT tag that stores the status of the I/O LED on the front of the controller.

Determine if communication has timed out with a specific I/O module

If communication times out with a device (module) in the I/O configuration of the controller, the controller produces a fault code for the module.

• The GSV instruction gets the fault code for Io_Module and stores it in the Module_Status tag.

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• If Module_Status is any value other than 4, the controller is not communicating with the module.

Interrupt the execution of logic and execute the fault handler

1. In the controller organizer, right-click the module and select

Properties.

2. Click the Connection tab.

3. Select (check) the Major Fault If Connection Fails While in Run

Mode check box.

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82 Develop Applications

4. Develop a routine for the Controller Fault Handler. See the

Logix5000 Controllers Common Procedures, publication 1756-PM001.

Select a System Overhead Percentage

1. View properties for the controller and select the Advanced tab.

The Controller Properties dialog lets you specify a percentage for system overhead. This percentage specifies the percentage of controller time (excluding the time for periodic tasks) that is devoted to communication and background functions.

System overhead functions include:

• communicating with programming and HMI devices (such as RSLogix 5000 software)

• responding to messages

• sending messages

• re-establishing and monitoring I/O connections (such as RIUP

conditions); this does not include normal I/O communications that occur during program execution

• bridging communications from the serial port of the controller to other communication devices

The controller performs system overhead functions for up to 1 ms at a time. If the controller completes the overhead functions in less than 1 ms, it resumes the continuous task.

As the system overhead percentage increases, time allocated to executing the continuous task decreases. If there are no communications for the controller to manage, the controller uses the communications time to execute the continuous task. While increasing

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Develop Applications 83

the system overhead percentage does increase communications performance, it also increases the amount of time it takes to execute a continuous task - increasing overall scan time

The table below shows the ratio between the continuous task and the system overhead functions:

periodic

system overhead

continuous task

At this time slice: The continuous tasks

runs for:

And then overhead occurs for up to:

10% 9 ms 1 ms

20% 4 ms 1 ms

33% 2 ms 1 ms

50% 1 ms 1 ms

At a time slice of 10%, system overhead interrupts the continuous task every 9 ms (of continuous task time), as illustrated below.

Legend:

Task executes.

Task is interrupted (suspended).

1 ms 1 ms

9 ms 9 ms

0 5 10 15 20 25

elapsed time (ms)

periodic task

system overhead

continuous task

The interruption of a periodic task increases the elapsed time (clock time) between the execution of system overhead, as shown below.

1 ms 1 ms 1 ms 1 ms 1ms

1 ms 1 ms

9 ms of continuous task time 9 ms of continuous task time

0 5 10 15 20 25

elapsed time (ms)

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84 Develop Applications

system overhead

continuous task

system overhead

continuous task

If you use the default time slice of 20%, the system overhead interrupts the continuous task every 4 ms (of continuous task time).

1 ms 1 ms 1 ms 1 ms 1 ms

4 ms 4 ms 4 ms 4 ms 4 ms

5 10152025

elapsed time (ms)

If you increase the time slice to 50%, the system overhead interrupts the continuous task every 1 ms (of continuous task time).

1 ms

5 10152025

elapsed time (ms)

periodic task

system overhead

continuous task

If the controller only contains a periodic task(s), the system overhead timeslice value has no effect. System overhead runs whenever a periodic task is not running.

5 10152025

elapsed time (ms)

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Use the Event Task

The event task is available with FlexLogix controllers using firmware version 12.x or greater. Previously, the only tasks available were the continuous task and periodic task. However, the event task offers FlexLogix controller users a task that executes a section of logic immediately when an event occurs.

An event task performs a function only when a specific event (trigger) occurs. Whenever the trigger for the event task occurs, the event task:

• interrupts any lower priority tasks

• executes one time

• returns control to where the previous task left off

For FlexLogix controller, the event task trigger can only be the EVENT instruction or a consume tag.

Prioritizing Periodic and Event Tasks

Although a FlexLogix project can contain up to 8 tasks, the controller executes only one task at a time. If a periodic or event task is triggered while another task is currently executing, the priority of each task tells the controller what to do.

The FlexLogix controller has 15 priority levels for its tasks. To assign a priority to a task, use the guidelines described in the table..

If you want: Then Notes:

this task to interrupt another task

another task to interrupt this task

this task to share controller time with another task

Assign a priority number that is less than (higher priority) the priority number of the other task.

Assign a priority number that is greater than (lower priority) the priority number of the other task.

Assign the same priority number to both tasks.

• A higher priority task interrupts all lower priority tasks.

• A higher priority task can interrupt a lower priority task multiple times.

The controller switches back and forth between each task and executes each one for 1ms.

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86 Develop Applications

Let an EVENT instruction trigger the task.

Triggering the Event Task

To trigger an event task based on conditions in your logic, use the EVENT Instruction trigger.

Let an event trigger this task.

No tag is required.

The EVENT Instruction Only trigger requires that you use a Trigger Event Task (EVENT) instruction to trigger the task. You can use an EVENT instruction from multiple points in your project. Each time the

instruction executes, it triggers the specified event task.

EVENT instruction in program A

EVENT instruction in program B

event task

1 2

Description:

Program A executes an EVENT instruction.

The event task that is specified by the EVENT instruction executes one time.

Program B executes an EVENT instruction.

The event task that is specified by the EVENT instruction executes one time.

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Programmatically Determine if an EVENT Instruction Triggered aTask

To determine if an EVENT instruction triggered an event task, use a Get System Value (GSV) instruction to monitor the Status attribute of the task.

Status Attribute of the TASK Object

Attribute: Data Type: Instruction: Description:

Status DINT GSV

SSV

Provides status information about the task. Once the controller sets a bit, you must manually clear the bit to determine if another fault of that type occurred.

To determine if: Examine this bit:

An EVENT instruction triggered the task (event task only).

A timeout triggered the task (event task only). 1

An overlap occurred for this task. 2

Develop Applications 87

The controller does not clear the bits of the Status attribute once they are set.

• To use a bit for new status information, you must manually clear the bit.

• Use a Set System Value (SSV) instruction to set the attribute to a different value.

Checklist for an EVENT Instruction Task

For this: Make sure you:

q 1. EVENT instruction Use a Trigger Event Task (EVNT) instruction at each point in your logic that you

want to trigger the event task.

q 2. Task priority Configure the event task as the highest priority task.

If a periodic task has a higher priority, the event task may have to wait until the periodic task is done.

q 3. Number of event tasks Limit the number of event tasks.

Each additional task reduces the processing time that is available for other tasks. This could cause an overlap.

q 4. Automatic Output Processing For an event task, you can typically disable automatic output processing (default).

This reduces the elapsed time of the task.

For more information on using the event task, see Logix5000 Controllers Common Procedures programming manual, publication 1756-PM001.

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88 Develop Applications

Notes:

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Configure PhaseManager

Chapter

Use This Chapter

See:

• PhaseManager User Manual, LOGIX-UM001

PhaseManager Overview

Term Description

equipment phase An equipment phase is similar to a program:

The PhaseManager option of RSLogix 5000 software gives you a state model for your equipment. This chapter summarizes:

For this information: See:

PhaseManager Overview 89

State Model Overview 91

Compare PhaseManager to Other State Models 94

Minimum System Requirements 94

Equipment Phase Instructions 95

PhaseManager lets you add equipment phases to your controller. An equipment phase helps you lay-out your code in sections that are easier to write, find, follow, and change.

• You run the equipment phase in a task.

• You give the equipment phase a set of routines and tags.

An equipment phase is different from a program in these ways:

• The equipment phase runs by a state model.

• You use an equipment phase to do 1 activity of your equipment.

state model A state model divides the operating cycle of your equipment into a series of states. Each

state is an instant in the operation of the equipment. It's the actions or conditions of the equipment at a given time.

The state model of an equipment phase is similar to the S88 and PackML state models.

state machine An equipment phase includes an embedded state machine that:

• calls the main routine (state routine) for an acting state

• manages the transitions between states with minimal coding

You code the transition conditions. When the conditions are true, the equipment phase transitions the equipment to the next required state.

• makes sure that the equipment goes from state to state along an allowable path

PHASE tag When you add an equipment phase, RSLogix 5000 software makes a tag for the equipment

phase. The tag uses the PHASE data type.

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90 Configure PhaseManager

Controller

Controller Tags

Tasks

MainTask

Add Water Phase

Here’s how the PhaseManager into RSLogix 5000 programming software:

A PHASE tag gives you the status of an equipment phase.

An equipment phase directs 1 activity of your equipment. A state model divides the activity into a series of states.

Mix Phase

Drain Phase

Space Parts Phase

MainProgram

My Equipment Program

Running State Routine

How to add water

Equipment phase instructions control the transitions between states, handle faults, etc.

PSC POVR PCLF PRNP PATT

PCMD PFL PXRQ PPD PDET

Other code does the specific actions of your equipment

Water Feed

Conveyor Enable Axes

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Configure PhaseManager 91

State Model Overview

Start

Idle

Running

A state model divides the operating cycle of your equipment into a series of states. Each state is an instant in the operation of the equipment. It's the actions or conditions of the equipment at a given time.

In a state model, you define what your equipment does under different conditions, such as run, hold, stop, etc. You don’t need to use all the states for your equipment. Use only the states that you want.

There are 2 types of states:

Type of state Description

Acting Does something or several things for a certain time or until

certain conditions are met. An acting state runs one time or repeatedly.

Waiting Shows that certain conditions are met and the equipment is

waiting for the signal to go to the next state.

PhaseManager uses the following states:

Hold

Holding

Held

Your equipment can go from any state in the box to the stopping or aborting state.

Resetting

Reset

Complete

Reset

Hold

Restart

Restarting

Stop

Abort

Stopping

Stopped Aborted

Aborting

Abort

Acting

Acting states represent the things your equipment does at a given time.

Waiting

Waiting states represent the condition of your equipment when it is in-between acting states.

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92 Configure PhaseManager

With a state model, you define the behavior of your equipment and put it into a brief functional specification. In this way you show what happens and when it happens.

For this State: Ask:

Stopped What happens when you turn on power?

Resetting How does the equipment get ready to run?

Idle How do you tell that the equipment is ready to run?

Running What does the equipment do to make product?

Holding How does the equipment temporarily stop making product without

making scrap?

Held How do you tell if the equipment is safely holding?

Restarting How does the equipment resume production after holding?

Complete How do you tell when the equipment is done with what it had to do?

Stopping What happens during an normal shutdown?

Aborting How does the equipment shutdown if a fault or failure happens?

Aborted How do you tell if the equipment is safely shutdown?

How equipment changes states

The arrows in the state model show to which states your equipment can go from the state it is in now.

• Each arrow is called a transition.

• A state model lets the equipment make only certain transitions.

This gives the equipment the same behavior as any other equipment that uses the same model.

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PhaseManager uses the following transitions:

= transition

Command Done — No command. Use PSC instruction instead.

Configure PhaseManager 93

Your equipment can go from any state in the box to the stopping or aborting state.

Idle

Start

Running

Hold

Holding

Held

Hold

Restart

Resetting

Reset

Complete

Reset

Restarting

Stop

Abort

Stopping

Aborting

Stopped Aborted

Abort

Fault (specific use of the abort command)

Type of transition Description

Command A command tells the equipment to start doing something or do something different. For example the

operator pushes the start button to start production and the stop button to shutdown.

PhaseManager uses these commands:

reset stop restart

start hold abort

Done Equipment goes to a waiting state when it's done with what it's doing. You don’t give the equipment a

command. Instead, you set up your code to signal when the equipment is done. The waiting state shows that the equipment is done.

Fault A fault tells you that something out of the ordinary has happened. You set up your code to look for

faults and take action if it finds any. Suppose you want your equipment to shut down as fast as possible if a certain fault happens. In that case, set up your code look for that fault and give the abort command if it finds it.

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94 Configure PhaseManager

State that the equipment phase is in right now

Manually change states

RSLogix 5000 software has a window that lets you monitor and command an equipment phase.

To manually change states:

1. Take ownership of the equipment phase.

2. Give a command.

Compare PhaseManager to Other State Models

S88 PackML PhaseManager

Idle Starting ⇒ Ready Resetting ⇒ Idle

Running ⇒ Complete Producing Running ⇒ Complete

Pausing ⇒ Paused Standby subroutines, breakpoints, or both.

Holding ⇒ Held Holding ⇒ Held Holding ⇒ Held

Restarting none Restarting

Stopping ⇒ Stopped Stopping ⇒ Stopped Stopping ⇒ Stopped

Aborting ⇒ Aborted Aborting ⇒ Aborted Aborting ⇒ Aborted

Minimum System Requirements

This table compares PhaseManager’s state model to other common state models:

To develop PhaseManager programs, you need:

• FlexLogix controller with firmware revision 15.0 or later

• communication path to the controller

• RSLogix 5000 software version 15.0 or later

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To enable PhaseManager support, you need the full or professional editions of RSLogix 5000 software or the optional PhaseManager add-on (9324-RLDPMENE) to your RSLogix 5000 software package.

Configure PhaseManager 95

Equipment Phase Instructions

The controller supports several instructions to support equipment phases. The instructions are available in ladder diagram (LD) and structured text (ST).

If you want to: Use this instruction:

signal a phase that the state routine is complete so go to the next state

change the state or substate of a phase PCMD

signal a failure for a phase PFL

clear the failure code of a phase PCLF

initiate communication with RSBizWare Batch software PXRQ

clear the NewInputParameters bit of a phase PRNP

set up breakpoints within the logic of a phase PPD

take ownership of a phase to either:

• prevent another program or RSBizWare Batch software from commanding a phase

• make sure another program or RSBizWare Batch software does not already own a phase

relinquish ownership of a phase PDET

override a command POVR

PSC

PATT

For more information…

The PhaseManager User Manual, LOGIX-UM001 provides information on how to design, configure, and program, and phase manager application.

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96 Configure PhaseManager

Notes:

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Using this Appendix

Chapter

Maintain the Battery

For information about: See page

Storing Replacement Batteries 97

Estimating Battery Life 98

Replacing a Battery 99

Storing Replacement Batteries

Because a battery may leak potentially dangerous chemicals if stored improperly, store batteries as follows:

ATTENTION

Store batteries in a cool, dry environment. We recommend 25° C with 40% to 60% relative humidity. You may store batteries for up to 30 days between -45° to 85° C, such as during transportation. To avoid possible leakage, do not store batteries above 60° C for more than 30 days.

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98 Maintain the Battery

Estimating Battery Life

When the battery is about 95 percent discharged, the controller provides the following warnings:

• On the front of the controller, the BATTERY LED turns on (solid red).

• A minor fault occurs (type 10, code 10).

To prevent the battery from leaking potentially dangerous chemicals, replace the battery at least as often as:

ATTENTION

To prevent possible battery leakage, even if the BATTERY LED is off, replace the battery according to this schedule:

If the temperature 1 in. below the controller is:

0° to 35° C No required replacement

36° to 40° C 3 years

41° to 45° C 2 years

46° to 50° C 16 months

51° to 55° C 11 months

Replace the battery within:

56° to 60° C 8 months

To estimate how long the battery will support the memory of the controller:

1. Determine the temperature (° C) 1 in. below the

FlexLogix controller.

2. Determine the percentage of time that the controller is

powered off per week.

EXAMPLE

If a controller is off:

• 8 hr/day during a 5-day work week

• all day Saturday and Sunday

Then the controller is off 52% of the time:

1. total hours per week = 7 x 24 = 168 hours

2. total off hours per week = (5 days x 8 hrs/day) + Saturday + Sunday = 88 hours

3. percentage off time = 88/168 = 52%

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Maintain the Battery 99

Use the off-time percentage you calculated with the following table to determine battery life:

Worst-case battery life estimate:

Catalog number: Temperature: Power off 100%: Power off 50%: Battery duration after

1794-L34

(1)

The battery indicators (BATTERY) warns you when the battery is low. These durations are the amounts of time the battery will retain controller memory from the time the controller is powered down after the LED first turns on.

Replacing a Battery

° C

(1)

1.8 years 3.6 years 3 days

6.7 months 1.1 year 3 days

IMPORTANT

the LED turns on:

If the BATTERY LED turns on when you apply power to the controller, the battery life may be less than the table above indicates. Some of the warning time may have been used while the controller was off and unable to turn on the BATTERY LED.

Because the controller uses a lithium battery, you must follow specific precautions when handling or disposing a battery.

ATTENTION

The controller uses a lithium battery, which contains potentially dangerous chemicals. Before handling or disposing a battery, review Guidelines for Handling Lithium Batteries, publication AG-5.4.

1. Turn off power to the FlexLogix controller.

2. Does the existing battery show signs of leakage or damage?

If: Then:

Yes Before handling the battery, review Guidelines for Handling Lithium

Batteries, publication AG-5.4.

No Go to the next step.

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100 Maintain the Battery

3. Remove the old battery.

4. Install a new 1756-BA1 battery.

ATTENTION

Only install a 1756-BA1 battery. If you install a different battery, you may damage the controller.

5. Attach the battery label:

a. Write on the battery label the date you install the battery. b. Attach the label to the inside of the battery compartment.

6. On the front of the controller, is the BATTERY LED off?

If: Then:

Yes Go to the next step.

No A. Check that the battery is correctly connected to the controller.

B. If the BATTERY LED remains on, install another 1756-BA1 battery.

C. If the BATTERY LED remains on after you complete Step B., contact your

Rockwell Automation representative or local distributor.

7. Dispose the old battery according to state and local regulations.

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ATTENTION

Do not incinerate or dispose lithium batteries in general trash collection. They may explode or rupture violently. Follow state and local regulations for disposal of these materials. You are legally responsible for hazards created while your battery is being disposed.

Rockwell Automation 1794-L34 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FlexLogix Controller System User Manual

Important User Information

Table of Contents

Summary of Changes

Introduction

Updated Information

Introduction

Related Documentation

Use This Chapter

Design

Install Hardware

Use This Chapter

Connect the Controller via the Serial Port

Configure the Serial Driver

Select the Controller Path

Use This Chapter

EtherNet/IP

ControlNet

DeviceNet

Serial

DH-485

Third Party

Use This Chapter

Produce and Consume (Interlock) Data

Send and Receive Messages

Connection Overview

Calculate Connection Use

Connections Example

Use This Chapter

Select I/O Modules

Place Local I/O Modules

Configure I/O

Configure Distributed I/O on EtherNet/IP

Configure Distributed I/O on ControlNet

Configure Distributed I/O on DeviceNet

Address I/O Data

Determine When Data Is Updated

Monitor I/O Modules

Reconfigure an I/O Module

Use This Chapter

Manage Tasks

Develop Programs

Organize Tags

Monitor Controller Status

Monitor Connections

Select a System Overhead Percentage

Use the Event Task

Use This Chapter

PhaseManager Overview

State Model Overview

Compare PhaseManager to Other State Models

Minimum System Requirements

Equipment Phase Instructions

Using this Appendix

Storing Replacement Batteries

Estimating Battery Life

Replacing a Battery