Rockwell Automation D64046.5.1 U MNL WIN DDMC User Manual
Allen-Bradley
Distributed
Diagnostics and
Machine Control
(Cat. No. 6404-DDMC)
User Manual
Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this control
equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and
safety requirements, including any applicable laws, regulations, codes
and standards.
The illustrations, charts, sample programs and layout examples shown in
this guide are intended solely for purposes of example. Since there are
many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability (to
include intellectual property liability) for actual use based upon the
examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application,
Installation, and Maintenance of Solid State Control (available from your
local Allen-Bradley office), describes some important differences
between solid-state equipment and electromechanical devices that should
be taken into consideration when applying products such as those
described in this publication.
Allen-Bradley publication ICCG-9.11, Software Licensing Agreement,
provides the licensing terms for the use of this software as both a
developer’s tool and a Runtime package. All software that is part of this
package is covered by the license including:
FIX, Factory Link, and RSView code/screens
PLC (ladder) functions
PanelView screens
Reproduction of the contents of this copyrighted publication and software,
in whole or in part, without written permission of Allen-Bradley Company,
Inc., is prohibited.
Throughout this manual we use these notes to make you aware of
safety considerations:
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
Attention statements help you to:
identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is critical for successful application
and understanding of the product.
Distributed Diagnostics and
Machine Control
T
able of Contents
Using
This Manual
Understanding How a
DDMC32 System Works
Installing DDMC32 Hardware
Components
Preface
Manual Objectives P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audience P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What this Manual Contains P-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATTENTION and Important Notes P-3. . . . . . . . . . . . . . . . . . . . . . .
Terms and Conventions P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications P-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1
What this Chapter Contains 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How the DDMC32 System Works 1-1. . . . . . . . . . . . . . . . . . . . . . .
Understanding the SDS Instruction 1-3. . . . . . . . . . . . . . . . . . . . . . .
Understanding the DFA Instruction 1-7. . . . . . . . . . . . . . . . . . . . . . .
Implementing DDMC32 Instruction in Levels 1-8. . . . . . . . . . . . . .
DDMC32 System Components 1-8. . . . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2
What this Chapter Contains 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Configurations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing DDMC32 Components 2-3. . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing DDMC32 Software
Configuring SDS
Instructions
Chapter 3
What this Chapter Contains 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Up Your Operator Interface Terminal 3-1. . . . . . . . . . . . . . .
Installing and Configuring the Software 3-1. . . . . . . . . . . . . . . . . . .
Installing DDMC32 Software 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Completing the DDMC32 Software Installation 3-8. . . . . . . . . . . . .
What to Do Next 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4
What this Chapter Contains 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smart Directed Sequencer Overview 4-2. . . . . . . . . . . . . . . . . . . . .
Programming the SDS Instruction 4-5. . . . . . . . . . . . . . . . . . . . . . . .
Documenting the SDS Instruction 4-18. . . . . . . . . . . . . . . . . . . . . . . .
Configuring the SDS Instruction 4-22. . . . . . . . . . . . . . . . . . . . . . . . .
Exiting the SDS Instruction 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Editing and Copying SDS Instructions 4-34. . . . . . . . . . . . . . . . . . . .
What to Do Next 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
Distributed Diagnostics and
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able of Contents
Configuring DFA
Instructions
Creating and Updating the
Message Database
Configuring Diagnostic
Message
Chapter 5
What this Chapter Contains 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Fault Annunciator Overview 5-2. . . . . . . . . . . . . . . . . . .
Programming the DFA Instruction 5-2. . . . . . . . . . . . . . . . . . . . . . .
Documenting the DFA Instruction 5-12. . . . . . . . . . . . . . . . . . . . . . .
Configuring Messages for the DFA Instruction 5-16. . . . . . . . . . . . .
Exiting the DFA Instruction 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 6
What this Chapter Contains 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Importing the SDS and DFA Documentation 6-1. . . . . . . . . . . . . . .
Message Database Options 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7
What this Chapter Contains 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding the Parts of a Diagnostic Message 7-1. . . . . . . . . . .
Diagnostic Message Types 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing the Message Template Editor Functions 7-5. . . . . . . . . .
Message Template Editor Function 7-6. . . . . . . . . . . . . . . . . . . . . . .
Configuring Diagnostic Messages 7-8. . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Debugging Your DDMC32
System
ii
Chapter 8
What this Chapter Contains 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting Step Configuration Errors 8-1. . . . . . . . . . . . . . . . . . . . .
Locating Sequencing and Timing Errors 8-5. . . . . . . . . . . . . . . . . . .
Troubleshooting Problems in Your Operator Interface 8-12. . . . . . . .
What to Do Next 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributed Diagnostics and
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able of Contents
Configuration and Operation
of the DDMC32 System
Using the Report Generator
Software
Chapter 9
What this Chapter Contains 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Output Devices 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring the Clock/Creep Option 9-2. . . . . . . . . . . . . . . . . . . . .
Selecting Instruction Type(s) to Use 9-5. . . . . . . . . . . . . . . . . . . . . .
Auto-Starting DDMC32 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto-Hiding the Banner 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto-Purging the Current Database 9-6. . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping DDMC32 Software 9-6. . . . . . . . . . . . . . . . .
Monitoring the Fault Log 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing the Fault Log 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 10
What this Chapter Contains 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Becoming Familiar with the Report Generation Options 10-1. . . . . .
Menu Selections 10-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Reports 10-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generating Reports 10-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scheduling Reports 10-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Operations 10-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What to Do Next 10-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Information
Appendix A
Appendix Overview A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Information for the SDS Instruction A-1. . . . . . . . . . . . .
Reference Information for the DFA Instruction A-7. . . . . . . . . . . . .
iii
Distributed Diagnostics and
Machine Control
T
able of Contents
iv
Using this Manual
Preface
Manual Objectives
Audience
This manual shows you how to implement and use a Distributed Diagnostics
and Machine Control (DDMC32) system. This system provides diagnostic
machine fault detection and automatic messaging capabilities. Diagnostic
messages provided by DDMC32 help reduce the downtime associated with
troubleshooting your equipment.
In this manual we provide procedures for:
installing DDMC32 system components
configuring DDMC32 software
monitoring a system, using DDMC32
We assume that if you are using this manual, you know or are familiar with:
PLC-5 hardware
6200 Series software
1771 I/O
Allen-Bradley operator interface and programming terminals
the line or machine for which you are developing the program
P-1
Preface
Using this Manual
What this Manual Contains
Overview of DDMC32 components and how they fit into the
system
Procedures for installing DDMC32 hardware components 2 — Installing DDMC32 Hardware
Procedures for setting up your operator interface terminal;
procedures for installing 6200 Series and DDMC32 software
Overview of the Smart Directed Sequencer instruction in the
PLC-5 and the PLC-5/250 and procedures for entering data into
the instruction screens; naming steps; editing step descriptions
Overview of the Diagnostic Fault Annunciator instruction in the
PLC-5 and the PLC-5/250 and procedures for entering data into
the instruction screens; configuring instruction messages;
documenting the instruction
Procedures for importing the SDS instruction’s documentation into
the operator interface data base; message database options
Table P.A lists the chapters of this manual and the contents of each chapter.
T
able P
.A
Sections
If you want to read about: Refer to chapter:
of this Manual
1 — Understanding How a DDMC32
System Works
Components
3 — Installing DDMC32 Software
4 — Configuring SDS Instructions
5 — Configuring DFA Instructions
6 — Creating and Updating the
Message Database
Overview of the parts of the diagnostic message and procedures
for configuring the format of diagnostic messages for display
Software tools and techniques for debugging your system; error
list, I/O monitor, step history, input history, extended status, and I/O
history screen displays
Procedures for configuring output devices, Clock/Creep Option,
Start/Stop and other related options
Overview of the Report Generator; configuring and scheduling
fault logs
Smart Directed Sequencer execution times, control file
requirements, step description file requirements, maximum steps,
and step description file layout; Diagnostic Fault Annunciator
execution times, control file requirements; Data Highway Plus
message block layout and communication delay
7 — Configuring Diagnostic
Messages
8 — Debugging Your DDMC32
System
9 — Configuration and Operation of
the DDMC32 System
10 — Using the Report Generator
Software
Appendix A — Reference Information
P-2
Preface
Using this Manual
ATTENTION and Important
Notes
Terms and Conventions
Information that is especially important is identified with an ATTENTION or
Important note:
ATTENTION: identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
Important: provides you with information that is critical for the successful
application and understanding of this product.
In this manual, we use the following terms:
DDMC32 (Distributed Diagnostics and Machine Control 32–bit) —
Industrial automation system containing hardware and software components
that help you configure a control and diagnostics system for your equipment
SDS (Smart Directed Sequencer) — An instruction that resides in ladder
logic, providing state machine control and up-to-date diagnostics for your
machine
DFA (Diagnostic Fault Annunciator) — A monitoring-only instruction
which resides in ladder logic, used to generate messages when a fault occurs
programmable controller — A solid-state control device that is
programmed to control process or machine operation
I/O — Input/Output
State — The current value of an input or output at a particular point in time
P-3
Preface
Using this Manual
In this manual, we use the following conventions to describe how you enter
information.
The Enter key and Function keys look like this:
[ENTER]
[ESC] [F2]
Words or commands that you enter appear in bold. For example:
SDS
Variables that you must enter appear in italics. For example:
N
xx:00
Messages on the screen look like this:
While
DRILL STATION 32R was AT FULL DEPTH the RETURNED LIMIT
SWITCH turned ON
“Type” means type in the information using your keyboard
“Enter” means type in the information and then press your keyboard’s
[ENTER]
key
P-4
Preface
Using this Manual
Related Publications
For more information about DDMC32 components, see the following
publications:
Publication Title Publication Number
DDMC32 User Manual 6401–6.5.1
PLC-5 Processors
1785 PLC-5 Family Programmable Controllers Installation Manual 1785-6.6.1
1785 PLC-5 Programmable Controller Design Manual 1785-6.2.1
Pyramid Integrator Design Manual
PLC-5 Programming Software Documentation Set 9399-PLC5MAN
PLC-5/250 Programming Software Documentation Set
Communications
Data Highway/Data Highway Plus Protocol and Command Set
User’s Manual
Peer Communication Link Interface Module (cat. no. 1784-KT)
Product Data
5000-6.2.1
9313–5250
1770-6.5.16
1784-2.3
P-5
Preface
Using this Manual
Notes:
P-6
Chapter
1
Understanding How a DDMC32
System Works
What this Chapter Contains
How the DDMC32 System
Works
This chapter provides an overview of Distributed Diagnostics and Machine
Control (DDMC32). It contains the following sections:
Section: Page:
How the DDMC32 System Works 1-1
Understanding the SDS Instruction 1-3
Understanding the DFA Instruction 1-7
Implementing DDMC32 Instructions in Levels 1-8
DDMC32 System Components 1-8
What to do Next 1-12
Distributed Diagnostics and Machine Control (DDMC32) for
WindowsNTt is an industrial automation system built around
programmable controllers, operator interfaces, communications, and
software. The system architecture lets you configure DDMC32 to your
manufacturing needs. Ideal in transfer line and other machine applications,
DDMC32 can be configured for other industrial applications such as
material handling, packaging, and assembling.
DDMC32 is a flexible system based on the PLC-5 family of programmable
controllers. You can use single or multiple PLC-5 processors to create
either a centralized or distributed configuration. Processors communicate
with each other over the Data Highway Plus.
Special instructions in the PLC-5 processor — a Smart Directed Sequencer
(SDS) and a Diagnostic Fault Annunciator (DFA) provide diagnostic
machine-fault detection and automatic messaging capabilities in the
DDMC32 Monitoring system. You enter SDS and DFA instructions into
ladder logic in 6200 Series software.
When a fault is detected, the SDS instruction sends a message over the
Data Highway Plus to the operator interface terminal where the Monitoring
software automatically assembles the appropriate diagnostic message.
This diagnostic message helps reduce downtime associated with
troubleshooting your equipment, because it specifies the device that caused
the fault condition and the step in the sequence when the fault occurred.
1-1
Chapter 1
Understanding How a DDMC32 System W
orks
The DDMC32 System illustration (seen below) shows how DDMC32 uses
the SDS instruction to detect a fault condition and send the diagnostic
message to the operator interface.
1. SDS instruction detects a
fault condition.
SDS
PLC-5/20
Input to PLC-5
PLC-5/20
DDMC32
2. PLC sends encoded
message to operator
interface on Data
Highway Plus.
System
IMC 123
EMSG
Symbol
Data
Base
While SLIDE was
ADVANCING, the
returned LS
turned ON.
3. Background task
extracts information from
data base and constructs
message.
Operator Interface
1-2
IMC 120
4. Concatenated message
is displayed on CRT and
passed out COM 1 port.
Chapter 1
Understanding How a DDMC32 System W
orks
Understanding the SDS
Instruction
An integral part of the DDMC32 system is the Smart Directed Sequencer
(SDS) instruction (see the figure below). The SDS instruction provides
state-based control and resides in ladder logic. The SDS instruction lets
you develop control and diagnostic programs using state logic. The SDS
instruction is provided as a custom application routine (CAR) which is
downloadable into the PLC-5 processor through 6200 Series software prior
to instruction entry. The CAR occupies one program file and is declared
when entering an SDS instruction; it is referenced by the SDS instruction
at runtime.
Smart
Directed Sequencer Instruction Terminal Display (PLC-5
processor)
DRILL
MACHINE
HEAD 1
SDS
SMART DIRECTED SEQUENCER
Control File
Step Desc. File
Length
No. of Steps
Position/Step:
No. of I/O
Prog file number
N10:0
N11:0
144
12
(EN)
(ST)
(ER)
0
(ES)
8
3
Each SDS instruction contains a sequence of user-defined steps which
guide the logical flow of the instruction, for example, Ready, Advancing,
Advanced, etc. Each step represents a unique collection of I/O
(input/output) and subsequent step conditions (or destination steps you
define according to your application). Information for each step is easily
configured through a fill-in-the-blanks configuration template (see next
page). This template contains fields for the following:
inputs and outputs (you enter actual names for control items rather than
obscure addresses)
transitions of the inputs or equations for combined inputs
destination steps
output states
step timer (how long until a timeout occurs)
message on or off
1-3
Chapter 1
Understanding How a DDMC32 System W
orks
Sample
Step Configuration T
STEP 1 READY TIMER=0.0s – DISABLED MSG:OFF
No Input ID Equation Destination No Output ID State
0 RET’D LS OFF––>ON STEP 0 0 FORWARD MOTOR 1 OFF
1 ADV’D LS OFF––>ON STEP 10 1 REVERSE MOTOR 1 OFF
2 FULL DEPTH LS OFF––>ON STEP 0 2 DRILL MOTOR OFF
3 ADVANCE COMMAND OFF––>ON **STEP 2
4 RETURN COMMAND
Press a function key.
Program edit mode PLC–5/25 Addr 1
Display Step Step Edit Step Msg Input Output Marked
Symbol Name Type Step Timer On Transit State Exit
F2 F3 F4 F5 F6 F7 F8 F9 F10
emplate With SDS Instruction
How the Transitional SDS Instruction Handles Inputs
Transitional equations provide state-based control. Each transitional
equation defines the destination step based on the transition of a particular
input (ON ––> OFF or OFF ––> ON). When input state transition
conditions are used, the expected input states appear on the left side of the
equation column and the transition states on the right. The destination
column is on the right of the equation column (see the figure above).
At power up, the SDS instruction starts out in an “initialized” step. The
instruction searches through each defined step to find a match based on the
expected states of inputs. If it cannot find a match, the SDS instruction
looks for a set of conditions defined by a combinatorial equation (see the
figure on page 1-5). If a transition is specified, you must validate the
entry state or you will not see a transition and will be locked into a step.
Because all input states in each step may be important, you must consider
the logical progression of I/O sequencing when developing a step
configuration. These considerations differ from those you make with
traditional ladder logic, as the sequence of I/O changes are not relevant.
1-4
For example, in the figure below, the expected input conditions for step 1
are (in order): off, off, off, off, don’t care. The instruction will enter this
step only when inputs 0, 1, 2, and 3 are off. This figure shows another
example of the SDS instruction looking for a step to enter.
SDS
Instruction Looking for a Step to Enter
When transition conditions are
used the instruction looks for a
match of actual and expected
inputs. If inputs do not match,
the instruction continues its
search.
Chapter 1
Understanding How a DDMC32 System W
ACTUAL INPUTS
OFF
ON
OFF
ON
orks
When the instruction
finds a match, it enters
the step.
STEP 1 EXPECTED INPUTS STEP 2 EXPECTED INPUTS
OFF
OFF
OFF
ON
––> ON
––> ON
––> ON
––> OFF
OFF
ON
OFF
ON
––> ON
––> OFF
––> ON
––> OFF
During runtime, an input change or a step timer timeout directs the SDS to
another step. If the instruction detects a mismatch (the actual inputs do not
match the expected inputs), it generates a mismatch fault. To aid you with
programming, the software looks for obvious programmed mismatches
before you accept an instruction.
How the Combinatorial SDS Instruction Handles Inputs
Combinatorial equations define destination steps based on input state
values and the relationship between a collection of inputs. The
combinatorial equation lets you accommodate complex combinations in
the instruction while keeping the number of steps within a configuration to
a minimum. (You can define up to 4 logical AND combinations in an
8-input SDS instruction; You can define up to 8 ANDed conditions in a
16- or 32-input instruction.)
1-5
Chapter 1
Understanding How a DDMC32 System W
orks
The instruction scans the inputs from the top of the input list to the bottom,
looking for a transition. When the actual inputs do not match the expected
inputs, the instruction begins scanning the combinatorial equations for a
match and remains in the step until all conditions for the equation(s) are
met. The combinatorial SDS instruction ignores the “expected” entry
states so that, even if possible, no mismatch error is generated.
When a valid transition, a set of conditions as specified by an equation, or
a timeout occurs, the instruction moves to the destination step to verify the
inputs before entering the step (this occurs for transition equations only,
not ANDed conditions). See the following section for information on how
the SDS handles outputs.
How the SDS Instruction Handles Outputs
The SDS instruction sets or resets outputs as it enters each step (based on
how you define outputs in the configuration template). The table below
shows what happens to outputs when the SDS enters an error step, step 0,
or the initialization step.
States
of Outputs Based on Destination Steps
If the SDS instruction enters: Then outputs:
an error step are set as defined in that step
step 0 reset to off
initialization step stay in the last state
Message Generation
The SDS instruction generates an error message or status message when it
enters a new step which has its message bit enabled. This message is
displayed on the operator interface terminal and/or an annunciator panel if
you so specify. (The figure on page 1–4 shows where you can turn
messages on and off using the [F7] key.) Error messages are cleared from
the display device (operator interface terminal or annunciator panel) only
when the instruction goes to step 0. All other types of messages are
cleared when the instruction moves to the next step.
1-6
Chapter 1
Understanding How a DDMC32 System W
orks
Understanding the DFA
Instruction
The Diagnostic Fault Annunciator (DFA) instruction is a monitoring–only
instruction; that is, it monitors inputs you define, but it cannot control
outputs. Valid inputs can be:
storage points, such as binary bits
counter/timer done bits
outputs (real or logical)
lube level sensors
alarms
fault bits set by another device or by ladder logic
any valid bit address
The following figure shows a DFA instruction in a ladder program.
A
DF
A Instruction (PLC 5/250)
ASSEMBLY
MACHINE
DFA
DIAGNOSTIC FAULT ANNUNCIATOR
Control File
No. of I/O
Program file number
Msg Control Block
N27:0
0MSG0:0
16
(EN)
(ER)
3
If you currently have diagnostics programmed in ladder logic, you can use
the DFA instruction to generate messages when a fault occurs. In addition,
you can create other types of operational and diagnostic messages with the
DFA instruction, such as tool change messages and operating instructions.
1-7
Chapter 1
Understanding How a DDMC32 System W
orks
Implementing DDMC32
Instruction in Levels
You can implement DDMC32 instructions at three different operational
levels, depending on the amount of diagnostics and control that you need
for your application. Each level provides incremental increases in terms of
diagnostic coupling with the control. The figure and table below show the
levels of implementation.
Levels
The DFA instruction can be used on all levels since it is
used for global type errors. Unlike the SDS instruction, which
is constructed around a given mechanism and its associated
I/O, the DFA instruction is constructed around constantly
monitored conditions that do not fit into a state structure.
• Ladder Logic for Control
• SDS Instruction for
Level 1
• Ladder Logic for Control
and Diagnostics
• DFA Instructions for
Messages
Messages and Diagnostics
• DFA Instruction for Messages
of DDMC32 Implementation
Level 2
Important:
SDS instruction for control and diagnostics. You may also include Level
and Level 2 Implementations for diagnostics outside of the Level 3 SDS
1
instruction, for example, lube faults or overloads.
Level 3
• SDS Instruction for Control
and Diagnostics
• DFA Instruction for Messages
A Level 3 Implementation does not limit you to only using the
This level Uses this
1 DFA ladder logic ladder logic DFA
2 SDS and DFA ladder logic SDS SDS and DFA
3 SDS and DFA SDS and ladder logic SDS SDS and DFA
DDMC32 System Components
1-8
Description
of DDMC32 Levels
DDMC32
instruction
Control is handled by: Diagnostics are
handled by:
Message
Generation is
handled by:
A typical DDMC32 system applies the following system components:
6400 Series Software
Monitoring software (6404-DDMC)
6200 Series Software
PLC-5 family of programmable controllers
Chapter 1
Understanding How a DDMC32 System W
orks
1771 I/O
6180 Industrial Computer with the following minimum configuration:
Cat.
# 6180 – AB C B D B A C A C Z A
100 MHZ Pentium Processor
10.4” TFT
PCI 2Mg DRAM Video Board
16Mg RAM
1.3G Hard Drive
3.5” Floppy Drive
Series
No Software
Windows NTt 4.0
120V Power Card
1784-KTX
Data Highway Plus
Dataliner message displays
DDMC32 Software
DDMC32 software contains several tools to help you monitor, generate,
annunciate, and store information about faults.
When a fault is detected by a PLC diagnostic instruction, a message packet
with the appropriate coded data is sent to the operator interface terminal.
The DDMC32 software assembles the data used during programming to
form the text of the fault message. If configured by the user, the terminal
automatically displays the message in a window reserved for alarm
messages. Because the software automatically assembles the message, you
do not have to create and store separate and unique diagnostic messages.
You have to configure the message templates using the Template Editor in
the DDMC32 software. The Template Editor permits you to design
templates to reflect individual types of DFA and SDS faults (per each
Processor/Control File combination for these instructions. When a DFA or
SDS instruction generates a fault, the corresponding template is used by
the DDMC32 software to build the appropriate message that will be
displayed.
For more information on the DDMC32 Message Template Editor see the
section on Accessing the Message Template Editor in Chapter 7 –
Configuring Diagnostic Messages.
1-9
Chapter 1
Understanding How a DDMC32 System W
orks
The DDMC32 software also provides:
a fault log that shows all fault messages generated by the software
an interface for marquees to optionally display diagnostic messages
a fault report which lets you see where and when each fault occurs by
frequency and duration
These selections are configured by the user who may direct the faults to
some or all of the above devices.
6200 Series Software
This software provides the capability to program and monitor your PLC-5
family programmable controller using your operator interface terminal.
6200 Series Software uses menu-driven screens and configuration utilities
that simplify entry. You can use 6200 Series Software to develop ladder
programs and configure DDMC32 instructions.
To learn more about 6200 Series Software, refer to the PLC-5
Programming Software Documentation Set (publication 9399-PLC5MAN)
or the PLC-5/250 Programming Software Documentation Set (publication
9313–5250).
PLC-5 Family of Programmable Controllers
The PLC-5 family of programmable controllers is the heart of the
DDMC32 system, providing a flexible framework for processing. You can
create:
a centralized configuration to control a large number of I/O from one
location
a distributed configuration to control I/O from several remote locations.
(All PLC-5 processors can be linked using the Data Highway Plus to a
common operator interface terminal where programming, monitoring,
and troubleshooting are performed.)
1-10
Chapter 1
Understanding How a DDMC32 System W
orks
All PLC-5 processors can still be programmed with familiar ladder logic in
addition to using the diagnostic instructions. In DDMC32, PLC-5
processors utilize the instructions that can automatically detect machine
faults and abnormal conditions. Using 6200 Series software, you can
program PLC-5 processors with industrial computers, the plant floor
terminals, or any IBM AT–compatible computer.
If you want to know more about the PLC-5 processor, refer to PLC-5
Family Programmable Controllers Installation Manual (publication
1785-10.4) or the Pyramid Integrator Design Manual (publication
5000-6.2.1).
1771
I/O
With DDMC32 you can select from more than 80 types of I/O modules to
create a configuration perfect for your manufacturing needs. I/O modules
can be discrete, analog, or intelligent. Refer to the Automation Systems
Product Catalog.
6180 Industrial Computer
The 6180 Industrial Computer provides an industrially hardened,
expandable hardware platform. This computer is versatile and modular,
and lets you design a configuration suitable for your individual application.
The 6180 computer is the common operator interface for your DDMC32
system.
You can use the 6180 computer to:
develop ladder logic rungs and SDS instructions using 6200 Series
Software and the SDS Configuration Utility
display diagnostic messages using Monitoring Software
define graphic displays of your equipment that can be used to monitor
the operation
For more information about the 6180 Industrial Computer, refer to the
6180 Industrial computer brochure (publication 6180-1.0).
1-11
Chapter 1
Understanding How a DDMC32 System W
orks
Data Highway Plus
Data Highway Plus (DH+) is the network that links the PLC-5
programmable controllers and the operator interface terminal so that they
can communicate with one another.
The Data Highway Plus lets you:
download ladder logic with SDS instructions into multiple PLC-5s
receive diagnostic messages from multiple PLC-5s
implement a centralized common operator interface for all control
elements of the DDMC32 system
If you want to know more about Data Highway Plus, refer to Data
Highway/Data Highway Plus Protocol and Command Set Manual
(publication 1770-6.5.16).
What to Do Next
Dataliner Message Displays
Dataliner message displays (bul. no. 2706, series DL10) are highly visible
message display devices used for diagnostics, operator prompts, and status
messages. These displays can be used with your system as annunciator
panels for the messages sent by the DDMC32 software.
This chapter gave you an overview of how the DDMC32 system works to
diagnose faults and generate messages, and how the SDS and DFA
instructions work within the DDMC32 system. In addition, this chapter
described the components that make up a DDMC32 system.
Chapter 2 contains information for installing the DDMC32 hardware
components described in this chapter.
1-12
Chapter
Installing DDMC32 Hardware
Components
2
What this Chapter Contains
Hardware Configurations
Read this chapter to learn how to install your DDMC32 hardware
components when using a 6180 Industrial Computer.
In this chapter we overview DDMC32 hardware configurations and
provide procedures for installing the hardware components. In addition,
we reference specific hardware publications so that you can find more
information, if needed.
This chapter contains the following sections:
Section: Page:
Hardware Configurations 2-1
Installing DDMC32 Components 2-3
What to do Next 2–4
You can have one or several PLC-5 processors in your DDMC32 hardware
configuration, in addition to a 6180 Series Industrial Computer. The
different DDMC32 hardware configurations are referenced in the
following table and on the subsequent pages.
DDMC32
One PLC-5 and the 6180 Industrial Computer DDMC32 Component Configuration with one
Multiple PLC-5 (multi-drop peer communications
link) and the 6180 Industrial Computer
Hardware Configurations
If your configuration uses: Refer to figure:
PLC-5 Processor and a 6180 Industrial
Computer
DDMC32 Component Configuration with
multiple PLC-5 Processors and a 6180
Industrial Computer
2-1
Chapter 2
Installing DDMC32 Hardware Components
DDMC32
Computer
Component Configuration with one PLC-5 Processor and a 6180 Industrial
DDMC32 Software
DDMC32
Component Configuration with Multiple PLC-5 Processors and 6180
Industrial Computer
DDMC32 Software
2-2
Chapter 2
Installing DDMC Hardware Components
ATTENTION: If you are using your DDMC32 software
(cat. no. 6404-DDMC) with a PLC-5/250 processor, you must
make certain that the Remote Scanner Module (cat. no.
5150-RS) has a daughterboard (cat. no. 5150-MRS) with a part
number of 960456-05 or later (For example, -05, - 06, -07, etc.).
You can locate this part number along the bottom edge of the
removable 5150-MRS daughterboard. Failure to observe this
caution could result in erroneous data appearing in the input
image table or internal storage table.
Contact your local Allen-Bradley support office or call Technical Support
at (216) 646-6800 to arrange for shipment of updated modules.
Installing DDMC32
Components
The procedure for installing DDMC32 components varies depending on
the operator interface terminal you use. We describe procedures for 6180
Industrial Computer on the following pages.
Using a 6180 Industrial Computer
The table below lists the general procedure for installing your DDMC32
hardware components when using a 6180 Industrial Computer. Refer to
the manuals listed for more detail.
2-3
Chapter 2
C
X X X
Installing DDMC32 Hardware Components
Installing
DDMC32 Hardware Components when using a 6180 Industrial
Computer
To perform this task: Refer to this manual: Publication or Cat.
1. Install PLC-5 or PLC-5/250 and 1771 I/O PLC-5 Family Processor Installation
Instructions
Pyramid Integrator
Design/Installation/Startup and
Integration Manual
2. Install communications link:
a. Set the 6-switch assembly switches as follows:
1 2 3 4 5 6
OPEN
LOSED
(Based on the factory’s setting, only switches 2 and 3
must be modified.)
Important: When installing and configuring your 6200
series software, the switch setting for “on” will
correspond to a 1 and the switch setting for “off” will
correspond to a 0.
b. Install Data Highway Plus Interface Module (cat. no.
1784-KT) into an ISA slot .
X X X
Communication Interface Module
Installation Data
6180 Industrial Computer User’s Manual 6160-6.5.1
Number:
1785-10.4
5110-ISET
1784-2.31
What to Do Next
c. Connect the 1784-CP cable from the 6180 to the
PLC-5 or 5/250.
If using a multiple PLC-5 configuration:
Connect PLC-5 processors with cables and 3-pin
connectors
Now that you have installed your hardware components, you can install
your software. Chapter 3 describes procedures for installing software for a
DDMC32 system.
PLC-5 Family Programmable Controllers
Hardware User Manual
Pyramid Integrator Design/Installation/
Startup and Integration Manual
1786-6.5.12
5110-ISET
2-4
Chapter
Installing DDMC32 Software
3
What this Chapter Contains
Setting Up Your Operator
Interface Terminal
Read this chapter to learn how to install your DDMC32 software. To
install your software, you perform the following tasks:
set up your operator interface terminal
install 6200 Series software
install DDMC32 Monitoring Software
This chapter contains the following sections:
Section: Page:
Setting Up Your Operator Interface Terminal 3-1
Installing and Configuring the Software 3-1
Installing DDMC32 Software 3-2
Completing the DDMC32 Software Installation 3-8
What to do Next 3-8
Before you install your DDMC32 software, you must power up the 6180
Industrial Computer or your PC with 6200 Series software (v. 4.5 or later),
Microsoft Windows NTt 4.0, and RS Linx (v. 1.70.62 or later).
Installing and Configuring the
Software
Using a 6180 Industrial Computer
To power up the 6180 computer, turn the system power switch on the rear
of the computer to the ON position. The system performs a series of
self-tests to determine if its components are properly installed and
operating. You do not have to change the 6180 setup information to run
the DDMC32 software.
Install and configure Windows NTt on your PC according to your product
information.
Next, install and configure RSLinx on your operator interface terminal
(refer to the Rockwell Software Installation Guide for Windows-based
products for further information).
3-1
Chapter 3
Installing DDMC3Installing DDMC32 Software
Finally, install your 6200 Series software on your PC (reference the PLC-5
Programming Software documentation, publication 6200-N8.001).
Once you have the software installed, you must configure the 1784-KT
address to correspond with the switch assembly setting.
For the 6180 Industrial Computer, set the 1784-KT address to 001011.
This address is a recommended station address only. If you have
conflicting hardware installed, you must find your own settings.
Installing DDMC32 Software
There are several DDMC32 disks in the installation disk set. To install
your DDMC32 software, follow the procedure below. At this point, we
assume that you have formatted your hard disk and installed Windows
NTt.
1. Insert the first DDMC32 disk into the appropriate drive.
2. From the Start menu on the Windows NT Taskbar, choose R
un... to
begin the DDMC32 setup program.
3. In the Run dialog box, enter the drive letter and name of the
DDMC32 setup program (e.g., A:\setup.exe).
4. Ensure the drive letter is correct and click on OK.
Setup will begin. Follow the instructions as they appear on the
screen.
3-2
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