Rockwell Automation 57C435 User Manual
AutoMax
Processor Module
M/N 57C430A
M/N 57C431
M/N 57C435
Instruction Manual JĆ3650Ć6
E Copyright Reliance Electric Industrial Company 1996.
Motorolat 68010 and 68020 are trademarks of Motorola, Inc.
AĆBt is a trademark of AllenĆBradley Corporation.
IBMt is a trademark of International Business Machines, Inc.
Modbust is a trademark of Gould, Inc.
Multibust is a trademark of Intel Corporation.
Reliancer and AutoMaxr are registered trademarks of Reliance Electric Company
ąor its subsidiaries.
The information in this user's manual is subject to change without notice.
WARNING
ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND
OPERATION OF THE CONTROLLED EQUIPMENT SHOULD INSTALL, ADJUST,
OPERATE, OR SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS
MANUAL AND OTHER MANUALS APPLICABLE TO YOUR INSTALLATION.
FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY.
WARNING
INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY
RESULT IN UNEXPECTED MACHINE MOTION. POWER TO THE MACHINE
SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE
OR ITS CONNECTING CABLES. FAILURE TO OBSERVE THESE PRECAUTIONS
COULD RESULT IN BODILY INJURY.
CAUTION: This module contains staticĆsensitive components. Careless handling can
cause severe damage. Do not touch the connectors on the back of the module. When
not in use, the module should be stored in an antiĆstatic bag. The plastic cover should
not be removed. Failure to observe this precaution could result in damage to or
destruction of equipment.
Table of Contents
1.0 Introduction 1Ć1...............................................
1.1 Additional Information 1Ć2....................................
1.2 Related Hardware and Software 1Ć2...........................
1.3 Compatibility with Earlier Versions 1Ć3.........................
2.0 Mechanical/Electrical Description 2Ć1...........................
2.1 Mechanical Description 2Ć1...................................
2.2 Electrical Description 2Ć3.....................................
3.0 Installation 3Ć1................................................
3.1 Wiring 3Ć1..................................................
3.2 Initial Installation 3Ć1.........................................
3.3 Module Replacement 3Ć3.....................................
3.4 OnĆBoard Battery Replacement 3Ć4............................
3.5 Processor Module Diagnostics 3Ć5............................
3.5.1 PowerĆUp Diagnostics 3Ć5..............................
3.5.2 RunĆTime Diagnostics 3Ć5..............................
4.0 Programming 4Ć1..............................................
4.1 Loading the Operating System 4Ć1............................
4.2 Accessing Processor Ports 4Ć3................................
4.3 Programmable Tick Rate 4Ć4.................................
4.4 Restrictions 4Ć5.............................................
4.4.1 Number of Processors in a Rack 4Ć5.....................
4.4.2 Rack Slot Restrictions 4Ć5..............................
4.4.3 Use with the DCS5000 M/N 57C407 Processor Module
or the 57C430 Processor Module 4Ć5....................
4.4.4 Ethernet Commands 4Ć5...............................
5.0 Diagnostics and Troubleshooting 5Ć1............................
5.1 The OK" LED Is Off 5Ć1......................................
5.2 The BAT. OK" LED Is Off 5Ć2.................................
5.3 BUS ERROR 5Ć3............................................
5.4 Common Memory Module Diagnostic Failure 5Ć6................
5.5 Incorrect Data 5Ć7...........................................
I
Appendices
Appendix A
Technical Specifications AĆ1......................................
Appendix B
Module Block Diagram BĆ1......................................
Appendix C
Connecting the AutoMax Processor to the Personal Computer CĆ1....
Appendix D
Diagnostic LED Error Codes DĆ1..................................
Appendix E
Run Time LED Error Codes EĆ1...................................
Appendix F
Using Modems with AutoMax Systems FĆ1.........................
II
List of Figures
Figure 2.1 Ć Processor Module Faceplate 2Ć2...........................
Figure 2.2 Ć Typical RSĆ232C Circuit 2Ć3................................
Figure 3.1 Ć Rack Slot Numbers 3Ć2...................................
Figure 4.1 Ć Specifying the SETUP Parameter in an OPEN Statement 4Ć4...
III
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1.0 INTRODUCTION
The products described in this instruction manual are manufactured
by Reliance Electric Industrial Company. The Automax Processor
module plugs into the backplane of an AutoMax rack and executes
application programs which in turn control other AutoMax modules in
the system. The M/N 57C430A and 57C431 Processor modules are
based on the Motorola 68010 16Ćbit microprocessor. The M/N
57C435 Processor module is based on the Motorola 68020 32Ćbit
microprocessor. All three Processors are programmed using three
highĆlevel application languages: BASIC, Control Block and Ladder
Logic.
The Processor modules have the following memory/speed
configurations:
Model CPU Speed Memory
M/N 57C430A AutoMax
6010 Processor module
M/N 57C431 AutoMax
6011 Processor module
M/N 57C435 AutoMax
7010 Processor module
Up to four AutoMax Processor modules can be used in a rack
(M/N 57C331, M/N 57C332 or M/N 57C334) to increase the
processing capability and the total memory available for application
tasks. M/N 57C430A, 57C431, and 57C435 Processors can be used
in the same rack. M/N 57C430A Processors make 135KĆ150K
available for application programs depending on which operating
system is loaded onto the Processor. M/N 57C431 and 57C435
Processors make 300K available for application programs, regardless
of which operating system is loaded onto the Processor. Multiple
Processors in a rack require the use of the Common Memory module
(M/N 57C413 or M/N 57C423) for bus arbitration and sharing of
systemĆwide information. The Common Memory module can also be
used with a single Processor module to make available an additional
128K bytes of memory for common, i.e., systemĆwide, variables.
An onĆboard lithium battery and a superĆcapacitor protect the
Processor module from power failures. Should the system lose
power, the onĆboard battery of the M/N 57C430A or 57C431
Processor can maintain the contents of RAM for a minimum of 42
days. The onboard battery of the M/N 57C435 Processor can
maintain the contents of RAM for a minimum of 186 days.
The remainder of this manual describes the functions and
specifications of the module. It also includes a detailed overview of
installation and servicing procedures.
The thick black bar shown at the rightĆhand margin of this page
will be used throughout this instruction manual to signify new or
revised text or figures.
8 mHz 256K Parity RAM
8 mHz 512K Parity RAM
25 mHz 512K Parity RAM
1Ć1
1.1 Additional Information
You should be familiar with the following related publications to use
the AutoMax Processor correctly:
D JĆ3616Ć1 Kermit Communications Software Instruction Manual
D JĆ3618 Norton Editor Instruction Manual
D JĆ3636 Common Memory Module Instruction Manual
D JĆ3649 AutoMax Configuration Task Manual
D JĆ3675 AutoMax Enhanced Basic Language Instruction Manual
D JĆ3676 AutoMax Control Block Language Instruction Manual
D JĆ3677 AutoMax Ladder Logic Language Instruction Manual
D J2Ć3093 AutoMax Enhanced Ladder Editor
D J2Ć3094 AutoMax Enhanced Ladder Language Reference
D Your ReSource AutoMax Executive Software Loading Instructions
D Your ReSource AutoMax Programming Executive Instruction
Manual
D IEEE 518 Guide for The Installation of Electrical Equipment to
Minimize Electrical Noise Inputs to Controllers
D Your personal computer and DOS operating system manual(s).
D Other instruction manuals applicable to your hardware
configuration
1.2 Related Hardware and Software
1Ć2
M/N 57C430A contains one 256K AutoMax Processor module.
M/N 57C431 contains one 512K AutoMax Processor module.
M/N 57C435 contains one 512K AutoMax Processor module. The
Processor module is used with the following hardware and software,
which can be purchased separately:
1. IBMĆcompatible personal computer running DOS V3.1 or later.
2. ReSource AutoMax Programming Executive software (various
model numbers).
3. M/N 61C127 RSĆ232C ReSource Interface Cable. This cable is
used to connect the personal computer to the Processor module.
If you wish, you may also build your own cable using the pin
description found in Appendix C.
4. M/N 57C413B, 57C423 Common Memory module. This module
is used when there is more than one Processor in the rack.
5. RSĆ232C cable used for communicating with other devices
through the Processor ports in the rack not reserved for
connection to the personal computer. If you intend to use these
ports, you will need to build your own cable using the pin
description found in Appendix C.
6. M/N 57C331, 57C332 or 57C334 AutoMax PanelĆMount Rack.
7. M/N 57C491, M/N 57C493, or M/N 57C494 AutoMax Power
Supply Module.
8. M/N 57C385 AutoMax Replacement Battery. Note that the
Processor module comes equipped with one (1) battery.
9. M/N 57C404A Network Communications module. This module is
used to connect racks together as a network and supports
communication with all racks on the network that contain
57C404A modules through a single Processor module. M/N
57C404 can be used to connect racks on a network; however,
you cannot communicate over the network to the racks that
contain M/N 57C404 Network modules. You must instead
connect directly to the Processors in these racks.
1.3 Compatibility with Earlier Versions
AutoMax Processor module M/N 57C430A, M/N 57C431, and
M/N 57C435 are not compatible with Version 1.0 of the AutoMax
Programming Executive software (M/N 57C304Ć57C307).
Processor module M/N 57C430A and M/N 57C431 require Version
2.0 or later of the AutoMax Programming Executive software.
M/N 57C435 requires Version 3.1 or later of the AutoMax
Programming Executive software. M/N 57C430 cannot coĆexist in the
same rack with M/N 57C430A, 57C431, or 57C435.
AutoMax Programming
Executive Software
Version 1.0
M/N 57C304, 57C305
M/N 57C306, 57C307 (updates)
Version 2.0
M/N 57C390, 57C391
M/N 57C392, 57C393 (updates)
Version 2.1D
M/N 57C391
M/N 57C393 (update)
Version 3.0
M/N 57C395
M/N 57C397 (update)
Version 3.1
M/N 57C395
M/N 57C397 (update)
Version 3.3 and later*
M/N 57C395
M/N 57C397 (update)
*Note that if you are using the AutoMax Programming Executive for
drive control applications, the Universal Drive Controller module
(B/M 57552) is supported only in Version 3.3 and later of the
Programming Executive software.
Compatible
Processor Module
M/N 57C430
M/N 57C430
M/N 57C430A
M/N 57C430A
M/N 57C430A
M/N 57C431
M/N 57C435
M/N 57C430A
M/N 57C431
M/N 57C435
M/N 57C430A
M/N 57C430A
M/N 57C430A
M/N 57C431
M/N 57C435
M/N 57C430A
M/N 57C431
M/N 57C435
M/N 57C430A
M/N 57C431
M/N 57C435
M/N 57C430A
M/N 57C431
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2.0 MECHANICAL/ELECTRICAL
DESCRIPTION
The following is a description of the faceplate LEDs, field termination
connectors, and electrical characteristics of the field connections.
2.1 Mechanical Description
The Processor module is a printed circuit board assembly that plugs
into the backplane of the DCS 5000/AutoMax rack. It consists of the
printed circuit board, a faceplate, and a protective enclosure. The
faceplate contains tabs at the top and bottom to simplify removing
the module from the rack. On the back of the module are two edge
connectors that connect to the system backplane. Module
dimensions are listed in Appendix A.
The faceplate of the Processor module contains two
independentlyĆisolated 25Ćpin D" shell connectors for RSĆ232C serial
I/O links. The upper port (labeled PROGRAMMER/PORT B") of the
leftmost Processor in the rack is reserved for connection to the
personal computer only. The personal computer can communicate
with all Processors in the rack through this connection.
All remaining Processor module ports (both those labeled
PROGRAMMER/PORT B" and PORT A") are available for use by
application tasks running on the respective Processors. Refer to
figure 2.1 for the Processor module faceplate and Appendix C for a
pin description.
2Ć1
AutoMax
6010 Processor
57C430A
AutoMax
6011 Processor
57C431
AutoMax
7010 Processor
57C435
BAT.OK
1ST
OK
2ND
PROGRAMMER / PORT B
PORT A
BAT.OK
1ST
OK
2ND
PROGRAMMER / PORT B
PORT A
BAT.OK
1ST
OK
2ND
PROGRAMMER / PORT B
PORT A
2Ć2
M/N 57C430A
6010 Processor
256K
Figure 2.1 Ć Processor Module Faceplate
M/N 57C431
6011 Processor
512K
M/N 57C435
7010 Processor
512K
The faceplate contains two green status lights and two
sevenĆsegment LEDs used for diagnostic purposes. The upper status
light, labeled BAT. OK", indicates whether the onĆboard battery is
providing sufficient voltage to retain the contents of RAM (ON) or
should be replaced (OFF). See 3.4 for directions on replacing the
battery and Appendix A for battery specifications. The lower status
light, labeled OK", indicates whether the board is operational (ON)
or should be replaced (OFF).
Five preĆassigned variables are available for use in all application
tasks to test the status of the onĆboard battery. These common
boolean variables will have the value 1 if the battery is functional and
0 if the battery is not functional. The variables are named according
to the Processor whose battery is being tested. BATTERYSTATUS0@
is used for the Processor in slot 0. BATTERYSTATUS1@ is used for
the Processor in slot 1, etc. up to slot 4.
See 3.5.1 and 3.5.2 for more information about the two
sevenĆsegment LEDs on the Processor.
2.2 Electrical Description
The Processor module contains a local watchdog timer which must
be reset within a specified interval or the Processor will shut down
and all I/O modules will be reset (initialized to 0, FALSE, or OFF).
Byte parity is supported for all backplane address and data lines.
The superĆcapacitor on the Processor module can be charged to
more than 90% of its rated capacity in approximately 15 minutes and
is typically capable of retaining the contents of RAM memory for
approximately 10 hours should the BAT. OK" light go out and power
is removed from the Processor.
The Processor serial ports support full modem control. RSĆ232C
signals have 450V isolation to logic common. Refer to figure 2.1 for a
typical circuit diagram.
+5V
12
OPTO ISOLATOR
GND
12
OPTO ISOLATOR
GND
+5V
Figure 2.2 Ć Typical RSĆ232C Circuit
Refer to 4.2 for more information on the characteristics of the
Processor ports available to the user through application tasks.
XMIT
RECV
2Ć3
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3.0 INSTALLATION
This section describes how to install and replace the Processor
module and the onĆboard battery. M/N 57C430A and M/N 57C431
can be installed in the same rack.
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH THE NATIONAL
ELECTRICAL CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING
PRACTICES, GROUNDING, DISCONNECTS, AND OVERĆCURRENT
PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE
THIS PRECAUTION CAN RESULT IN SERIOUS BODILY INJURY OR LOSS OF
LIFE.
3.1 Wiring
To reduce the possibility of electrical noise interfering with the proper
operation of the control system, exercise care when installing the
wiring from the system to the external devices. For detailed
recommendations refer to IEEE 518.
3.2 Initial Installation
Use the following procedure to install the module:
Step 1. Turn off power to the system.
Step 2. If one or both of the RSĆ232C ports on the Processor are
Step 3. Take the module out of its shipping container. Take it out of
Step 4. Activate the onĆboard battery. When viewing the Processor
to be used by application tasks for serial communication
with devices other than the personal computer, use
shielded RSĆ232 cables. Cable connectors must be
equipped with EMI/RFIĆshielded cable clamps attached to
the cable shield. The cable shield must be grounded at
one end. The cable length must be in accordance with the
RSĆ232 specification. Be sure to label the connector so
that it can be easily reconnected later should it ever need
to be removed. A pin description can be found in
Appendix C.
the antiĆstatic bag, being careful not to touch the
connectors on the back of the module.
module from the front, you can access the battery through
the opening in the right wall portion of the Processor's
protective enclosure. Activate the battery by taking it out of
its holder and removing the tape that covers it. Replace
the battery in its holder. Make certain that the battery is
facing in the proper direction, i.e., the end marked +" on
the battery is facing the end marked +" on the battery
holder.
Note that the battery will begin to charge the
superĆcapacitor as soon as the battery is replaced in its
holder. For maximum battery life, you should not remove
3Ć1
the tape from the battery unless you intend to turn power
on to the module immediately.
If you are in a programming checkĆout" mode during
which power may be left off for extended periods of time,
you may wish to leave the tape on the battery and use the
superĆcapacitor for backup instead. The superĆcapacitor
will typically provide 10 hours of backup. Using the
superĆcapacitor for this purpose will extend the life of the
battery.
Step 5. Insert the module into the desired slot in the rack. In a
single Processor configuration, you can insert the
Processor in any slot 0-4. If the rack will contain multiple
Processors, they can only be placed in slots 1-4. In this
configuration, slot 0 is reserved for the Common Memory
module. Refer to figure 3.1.
Typical 16 Slot Rack
Typical 10 Slot Rack
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
P/S
Figure 3.1 Ć Rack Slot Numbers
Step 6. Using a screwdriver, attach cable M/N 61C127 (or your
Step 7. Turn on power to the system. The module will
Step 8. Load the operating system using the directions in 4.1.
own cable, built according to directions in Appendix C), to
the port labeled PROGRAMMER/PORT B" on the leftmost
Processor. Attach the cable from step #2 above to ports
being used to communicate with other devices.
automatically execute its powerĆup diagnostics. See 3.5.1
for more information. When diagnostics are complete, the
sevenĆsegment LEDs on the faceplate of the leftmost
Processor module will display LO", reading top to
bottom. Code LO" means that the operating system
needs to be loaded onto the Processors in the rack. See
4.1 for instructions on loading the operating system. The
LEDs on all other Processor modules in the rack should
be blank. The green OK" light on all Processors should
be lit. The BAT. OK" light on all Processors should also be
lit if the tape was removed from the batteries.
10
16
3Ć2
3.3 Module Replacement
When you replace the Processor module in a singleĆProcessor rack,
you will need to reĆload the operating system and all application
tasks unless the new Processor already has the operating system
loaded on it and the contents of RAM are valid. In this case, you will
need to load the application tasks only.
In a multipleĆProcessor rack, if your replacement Processor does not
already have an operating system and valid RAM, you will have to
reĆload the operating system and all application tasks to all
Processors in the rack. If the new Processor has an operating
system, you need only load the application tasks that you want to run
on that particular Processor.
Use the following procedure to replace a Processor module:
Step 1. Turn off power to the system. All power to the rack, as well
Step 2. Use a screwdriver to loosen the screws holding the
Step 3. Loosen the screws that hold the module in the rack.
Step 4. Place the module in the antiĆstatic bag it came in, being
Step 5. Take the new module out of the antiĆstatic bag, being
Step 6. Activate the battery by taking it out of its holder and
Step 7. Insert the module into the correct slot in the rack. Use a
Step 8. Attach the RSĆ232C cable connector(s) to the mating half
Step 9. Turn on power to the system. The module will
Step 10. Load the operating system using the directions in 4.1.
as all power to the wiring leading to the module, should be
off.
RSĆ232C connectors to the Processor. Detach the
connectors from the module.
Remove the module from the slot in the rack.
careful not to touch the connectors on the back of the
module. Place the module and the antiĆstatic bag in the
cardboard shipping container.
careful not to touch the connectors on the back of the
module.
removing the tape that covers it. Replace the battery in its
holder. Make certain that the battery is facing in the proper
direction, i.e., the end marked +" on the battery is facing
the end marked +" on the battery holder.
screwdriver to secure the module into the slot.
on the module. Make certain that the connector is the
proper one for this module. Use a screwdriver to secure
the connector to the module.
automatically execute its powerĆup diagnostics. At the
completion of its diagnostics, the seven segment LEDs on
the faceplate should display LO" if this is the only
Processor module in the rack or the leftmost Processor in
a multiĆProcessor configuration and there is no operating
system on the Processor. The LEDs on all other Processor
modules should be blank. The green OK" light should be
lit, and the BAT. OK" should be lit if the tape was removed
from the battery.
3Ć3
3.4 OnĆBoard Battery Replacement
WARNING
THE BATTERY USED WITH THIS DEVICE MAY PRESENT A HAZARD IF
MISTREATED. DO NOT RECHARGE, DISASSEMBLE, HEAT ABOVE 100_C
(212_F), INCINERATE, OR SWALLOW. REPLACE BATTERY WITH RELIANCE
ELECTRIC M/N 57C385 ONLY. DISPOSE OF USED BATTERY PROMPTLY. FAILURE
TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY
INJURY.
See section 5.2 for a list of the possible reasons that the BAT. OK"
light on the Processor faceplate can shut off. If you need to replace
the battery, the superĆcapacitor will provide a typical 10 hours of
backĆup power between the time the BAT. OK" light goes off and
power is removed from the rack, and the time you insert and activate
the new battery. If you replace the battery within this time limit, you
will not need to reĆload the operating system and application tasks.
Complete battery specifications can be found in Appendix A.
Use the following procedure to replace the battery on the Processor
module.
Step 1. Turn off power to the system. All power to the rack, as well
Step 2. Use a screwdriver to loosen the screws holding the
Step 3. Loosen the screws that hold the module in the rack.
Step 4. Take the old battery out of the holder. Remove the tape
Step 5. ReĆinsert the module into the correct slot in the rack. Use a
Step 6. ReĆattach the connector(s) to the mating half on the
Step 7. Turn on power to the rack. The module will automatically
as all power to the wiring leading to the module, should be
off.
connectors to the module. Remove the connectors from
the module.
Remove the module from the slot in the rack, being careful
not to touch the connectors on the back of the module.
from the new battery and insert it in the holder. Make
certain that the battery is facing the proper direction.
screwdriver to secure the module into the slot.
module. Make certain that the connector is the proper one
for this module. Use a screwdriver to secure the connector
to the module.
execute its powerĆup diagnostics. The green OK" light
should be lit, and the BAT. OK" should be lit. If this
Processor or any Processor in the rack displays code
LO", you will need to reĆload the operating system. See
4.1 for more information.
3Ć4
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