Rockwell Automation 57C442 User Manual

Data Highway Plus Interface Module

(M/N 57C442)

Instruction Manual J2-3067-5

The information in this user’s manual is subject to change without notice.

IBM is a registered trademark of International Business Machines Corporation. Allen-Bradley, A-B, AutoMax, Data Highway Plus, PLC, PLC-2, PLC-5, SLC, and Reliance are registered trademarks of Rockwell Automation. Multibus is a trademark of Intel Corporation. Phoenix and Combicon are registered trademarks of Phoenix Contact Ltd. ReSource is a trademark of Reliance Electric Company or its subsidiaries.

ATTENTION: Only qualified electrical personnel who are familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Wiring practices, grounding, disconnects, and over-current protection are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The user must provide an external, hardwired emergency stop circuit outside the controller circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

ATTENTION: Inserting or removing a module may result in unexpected machine motion. Power to the machine should be turned off before inserting or removing the module. Failure to observe these precautions could result in bodily injury.

ATTENTION: This module contains static-sensitive 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 anti-static bag. The plastic cover should not be removed. Failure to observe this precaution could result in damage to or destruction of the equipment.

1.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Related Hardware and Software . . . . . . . . . . . . . . . . . . . . . . 1-3

2.0 Mechanical/Electrical Description. . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Mechanical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Electrical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4.0 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Register Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 Status and Control Registers . . . . . . . . . . . . . . . . . . . 4-2

4.1.2 Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.1.3 Global Data Registers. . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2 AutoMax Application Programming . . . . . . . . . . . . . . . . . . . 4-6

4.2.1 Variable Configuration. . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.2.2 Application Programming . . . . . . . . . . . . . . . . . . . . . . 4-8

4.2.3 Enabling the Data Highway Plus Interface Module. . . 4-9

4.2.4 Commands Initiated by the Data Highway Plu s

Interface Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.2.5 Commands from Remote Stations . . . . . . . . . . . . . . 4-11

4.2.6 Off-link Routing Paths. . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.2.6.1 Example of Bridging Two Data Highway Plus

Networks using 1785-- KA modules . . . . . . . . . . 4-13

4.2.6.2 Example of Bridging the DataHighway Plus

Link to a ControlNet Network. . . . . . . . . . . . . . . . 4-15

4.2.7 Programming Examples . . . . . . . . . . . . . . . . . . . . . . 4-16

5.0 Diagnostics and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 The OK LED Is OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Invalid Station Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Transmission Link Failures . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1 Rack Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.2 Remote Station and Link Failure. . . . . . . . . . . . . . . . . 5-2

5.4 Bus Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Appendices

Appendix A

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B

Module Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C

Network Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . C-1

Appendix D

Data Highway Plus Interface Module

7-Segment LED Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix E

GATEWAY_CMD_OK@ Status Codes . . . . . . . . . . . . . . . . . . . E-1

Appendix F

Mapping of Active Station List. . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

Appendix G

Appendix H

Extended Status (EXT STS) Codes for Command 0F . . . . . . . . H-1

Appendix I

Converting A-B Register Numbers to AutoMax Register

and Bit Numbers for Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Appendix J

Recommendations For Reducing Noise

On The Cable System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1

List of Figures

Figure 1.1 Connecting the AutoMax System to the

Data Highway Plus Network. . . . . . . . . . . . . . . . . . . . . 1-1

Figure 2.1 Data Highway Plus Interface Module Faceplate. . . . . . 2-2

Figure 4.1 Dual Port Memory Map. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Figure 4.2 Status and Control Register Assignments . . . . . . . . . . 4-2

Figure 4.2 Status and Control Register Assignments

(Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4.3 PLC-5 Data Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4.3 PLC-5 Data Image (Continued) . . . . . . . . . . . . . . . . . . 4-4

Figure 4.4 Global Data Register Assignments. . . . . . . . . . . . . . . . 4-5

Figure 4.5 Commands Used with

GATEWAY_CMD_OK@ . . . . . . . . . . . . . . . . . . . . . . 4-10

Figure 4.6 PLC-5 Command Set . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Figure 4.7 Privileged Commands in the Basic

Command Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Figure 4.8 Diagnostic Status Command Data . . . . . . . . . . . . . . . 4-12

Figure 4.9 Non-Privileged Commands in the Basic

Command Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Figure 4.10 Off-link Message Routing Bytes . . . . . . . . . . . . . . . . . 4-13

III

1.0 INTRODUCTION

The products described in this manual are manufactured or distributed by RelianceElectric Industrial Company.

The Data Highway Plus Interface module (M/N 57C442) provides a direct connection for the AutoMax system to the Allen-Bradley Data Highway Plus network. The Data Highway Plus Interface module can be placed in any slot in an AutoMax rack that contains at least one AutoMax Processor, and can communicate with up to four AutoMax Processors in that rack. The AutoMax rack containing the Data Highway Plus Interface module appears as a single station on the Data Highway Plus network. Figure 1.1 illustrates an AutoMax system connected to a Data Highway Plus network.

Figure 1.1 – Connecting the AutoMax System to the Data Highway Plus Network

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Each AutoMax Processor has access to the look-alike PLC-5 or SLC registers through the AutoMax rack backplane. The Data Highway Plus Interface module transfers data between the PLC-5 look-alike image and remote Allen-Bradley equipment using the Word Range Read, Word Range Write, and Read-Modify-Write commands. The module is capable of responding directly to these commands as well as typed read and write commands from the PLC-5 command set and eight other commands from the basic command set. These commands are described in section 4.2. The individual command formats are described in the various Allen-Bradley instruction manuals.

The remainder of this manual describes the functions and specifications of the Data Highway Plus Interface module. It also includes a detailed description of module installation and troubleshooting procedures, as well as programming methods.

1.1 Additional lnformation

You must be familiar with all the instruction manuals that describe your system configuration. This may include, but is not limited to, the following:

• J-3636 COMMON MEMORY MODULE INSTRUCTION MANUAL

• J-3649 AutoMax CONFIGURATION TASK INSTRUCTION

• J-3650 AutoMax PROCESSOR MODULE INSTRUCTION

• J-3669 AutoMax POCKET REFERENCE

• J-3675 AutoMax ENHANCED BASIC LANGUAGE INSTRUCTION

• J-3676 AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION

• J2-3093 AutoMax LADDER EDITOR INSTRUCTION MANUAL

• J2-3094 AutoMax ENHANCED LADDER LANGUAGE

• J-3677 AutoMax LADDER LOGIC LANGUAGE INSTRUCTION

• IEEE 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL

• Your ReSource AutoMax PROGRAMMING EXECUTIVE

• 1770-6.5.16 Allen-Bradley Data Highway/Data Highway Plus/DH-

• Data Highway Cable Assembly and Instruction Manual

• Your personal computer and DOS operating system manuals

• Other instruction manuals applicable to your hardware

MANUAL

INSTRUCTION MANUAL

MANUAL

EQUIPMENT T O MINIMI ZE ELECTRI CAL NOI SE INPUTS TO CONTROLLERS

INSTRUCTION MANUAL

485 Communication Protocol and Command Set

configuration

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1.2 Related Hardware and Software

M/N 57C442 contains one Data Highway Plus Interface module. The module can be used with the following hardware and software:

1. M/N 57C430A, 57C431, 57C435 Automax Processor.

2. IBM -AT compatible computer running DOS version 3.1 or later.

3. M/N 61C127 RS-232C ReSource Interface cable. This cable is used to connect the personal computer to the AutoMax Processor module.

4. M/N 57C413 or 57C423 Common Memory module. This module is used when there is more than one AutoMax Processor in a rack.

5. (various model numbers) ReSource AutoMax Programming Executive software.

6. A-B Data Highway Plus cabling hardware.

The thick black bar shown on the right-hand margin of this page will be used throughout this instruction manual to signify new or revised text or figures.

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2.0 MECHANICAL/ELECTRICAL DESCRIPTION

This section describes the mechanical and electrical characteristics of the Data Highway Plus Interface module.

2.1 Mechanical Description

The Data Highway Plus Interface module is a printed circuit assembly that plugs into the backplane of an AutoMax rack. The module consists of a printed circuit board, faceplate, and protective enclosure. The faceplate contains ejector tabs at the top and bottom to simplify removing the module from the rack. See figure 2.1 for an illustration of the module faceplate.

The 6-pin Phoenix Combicon connector on the faceplate is used to make the connection to the Data Highway Plus network by means of a standard twin-axial cable. Refer to Appendix C or to Data Highway Plus documentation for the cable connections.

The two thumbwheel switches on the faceplate are used to set the

module’s stationnumber (in octal) on the Data Highway Plus network. The upper thumbwheel switch represents the most significant digit; the lower thumbwheel switch represents the least significant digit. If you set the switches to invalid octal digits (8 or 9), the station number will not be accepted and module error code ”6” will be displayed on the sevensegment LED.

For diagnostic purposes, the faceplate contains a seven-segment LED which displays error codes. The error codes are defined in Appendix D. A green status LED (labeled ”OK”) on the faceplate indicates when the module is operational (ON) or when it should be replaced (OFF).

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2-2

Figure 2.2 – Data Highway Plus Interface Module Faceplate

2.2 Electrical Description

The Data Highway Plus Interface module contains an 8 MHz microprocessor that shares 32K of dual port memory with the AutoMax rack backplane. This memory is accessible to both the on-board microprocessor and AutoMax Processors in the rack. A block diagram is shown in Appendix B. The module contains a watchdog timer which is enabled when power is turned on to the module. The microprocessor must reset the watchdog timer within a specified time or the

microprocessor will shut down and the status LED labeled ”OK” on the faceplate will turn off.

At power-up, the on-board microprocessor runs diagnostics on the microprocessor, EPROM, RAM and dual port memory, as well as performing system-level diagnostics. As each test is run, a number is written out to the seven-segment display. If there is a fault during these tests, the microprocessor halts, the watchdog times out, and the sevensegment LED displays the code of the failed diagnostic. See Appendix D for a list of error codes.

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3.0 INSTALLATION

This section provides instructions on how to install the Data Highway Plus Interface module.

3.1 Wiring

ATTENTION: The user is responsible for conforming with all

applicable local, national, and international codes. Wiring practices, grounding, disconnects, and over-current protection

3.2 Initial Installation

are of particular importance. Failure to observe this precaution could result in severe bodily injury or loss of life.

T o reduce the possibility of electri cal noise interfering with the operation of the control system, exercise care when installing the wiring from the control system to the external devices. For detailed recommendations refer to IEEE 518.

Use the following procedure to install the module: Step 1. Stop any application tasks that may be running.

ATTENTION: This equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could result in severe bodily injury or loss of life.

ATTENTION: Inserting or removing a module may result in unexpected machine motion. Power to the machine should be turned off before inserting or removing the module. Failure to

observe these precautions could result in bodily injury.

Step 2. Turn off power to the rack. All power to the rack as well as all

power leading to the rack should be off.

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Step 3. Take the module out of its shipping container. Take it out of

the anti-static bag, being careful not to touch the connectors on the back of the module.

Step 4. Insert the module in the desired slot in the rack, making sure

it is well-seated in the rack. The module may reside in any slot in the rack. Use a screwdriver to secure the module in the rack.

Step 5. Set the station number of the Data Highway Plus Interface

module (in octal) using the two thumbwheel switches on the module faceplate. The upper switch is the most significant digit and the lower switch is the least significant digit. The station number is read from the thumbwheel switches only at power-up. Therefore, make sure each device on the network has a unique station number (0--77 octal) before power is applied. If more than one device on the network is given the same station number, the module will not be able to communicate and an error will be displayed.

Step 6. Connect the module to the Data Highway Plus network. Refer

to Appendix C for information on cabling and termination.

Step 7. Turn on power to the rack. An internal diagnostic routine is

automatically executed by the module. If an error is detected, an error code is displayed on the seven-segment LED. If the green status LED is OFF and no seven-segment error code is displayed, a local watchdog failure has occurred. If a

diagnostic fault code other than “3”, “4”, “6”, “7”, or “C” is displayed for more than 5 seconds, the Data Highway Plus Interface module must be replaced.

If the thumbwheel switches are set to an invalid station number, fault code “6” will be displayed on the sevensegment LED on the module faceplate after power-up. To clear the invalid station number fault code, refer to section

5.2.

Step 8. After power-up diagnostics are complete, the green status

LED will go on. Verify the installation by monitoring registers on the module. Refer to Appendix I.

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3.3 Module Replacement

Use the following procedure to replace the Data Highway Plus Interface module:

Step 1. Stop any application tasks that may be running.

ATTENTION: his equipment is at line voltage when AC power is connected. Disconnect and lock out all ungrounded conductors of the AC power line. Failure to observe these precautions could

result in severe bodily injury or loss of life.

ATTENTION: Inserting or removing a module may result in unexpected machine motion. Power to the machine should be turned off before inserting or removing the module.Failure to observe these precautions could result in bodily injury.

Step 2. Turn off power to the rack. All power to the rack as well as all

Step 3. Disconnect the cable from the module faceplate. Step 4. Use a screwdriver to loosen the screws that hold the module

Step 5. T ake the new module out of it s shipping container. Take it out

Step 6. Insert the module in the rack, making sure that it is well-

Step 7. Set the station number of the new module to the same

Step 8. Attach the Data Highway Plus cable to the module faceplate. Step 9. Turn on power to the rack. Step 10. After power-up diagnostics are complete, the green status

power leading to the rack should be off.

in the rack. Take the module out of the slot in the rack.

of the anti-static bag, being careful not to touch the connectors on the back of the module.

seated in the rack.

number as the old module by using the two thumbwheel switches on the module faceplate. The upper switch is the most significant digit and the lower switch is the least significant digit.

LED will go on. Verify the installation by monitoring registers on the module. Refer to Appendix I.

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4.0 PROGRAMMING

The Data Highway Plus network is a token-passing network, which means that any device on the network can initiate communication with any other device. Each node can also pass one word of global data with the token. This global data is available to all other nodes on the network.

Up to 64 devices can be connected directly to the network, with station numbers ranging from 0 to 77 octal. Duplicate addresses are not allowed. The network communication rate can be 57.6, 115.2, or 230.4 Kbaud, depending upon the user configuration.

This section describes how the data is organized in the module and provides examples of how the module is accessed by the application software. For more detailed information on programming, refer to the AutoMax Programming Language manuals.

4.1 Register Organization

The Data Highway Plus Interface module contains dual-port memory that can be accessed through the AutoMax rack backplane by application tasks running on the AutoMax Processor as well as by the microprocessor on the module. The memory organization is as shown in the following diagram. The following sections describe the different register areas in more detail.

Registers Description

0-3 Reserved

4-63 Status and control registers

64 – 1063 Binary file B3 1064 - 1087 Reserved 1088 - 2087 Binary file B4 2088 - 3087 Binary file B5 3088 - 3583 Reserved 3584 - 4095 Reserved

4096 – 4352 Global data registers

4353 - 4383 Reserved

4384 - 16383 Integer files N7 – N18

Figure 4.1 – Dual Port Memory Map

ATTENTION: Registers and bits in the data highway plus interface module that are described as “read only” or for “system use” only must not be written to by the user.Writing to these

registers and bits may result in improper system operation. Failure to observe this precaution could result in bodily injury.

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