Yaskawa 545 PLC User Manual

RD 3056-10
1
Drive Description
4/12/94
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MicroTrac Gateway to Texas Instruments
545 PLC Part No. 46S03056-0010
For use on MicroTrac Local Area Network
1
INTRODUCTION
1
INTRODUCTION
4/12/94
I N T R O D U C T I O N
H A R D WA R E
The Texas Instruments 545 Programmable Logic Controller Gateway (PLC Gateway) allows any drive on the MicroTr a c®LAN to transfer data to or from a Texas Instruments 545 PLC. Both logic and numeric information can be t r a n s f e r r e d .
The Texas Instruments Gateway is a self-contained 6 slot PC back plane enclosure consisting of 2 half-size AT style slots, 1 half-size XT style slot, 2 full length AT style slots and 1 full length AT style slot all covered with a sheet metal c o v e r. The gateway also contains the power supply and has a sheet metal cover. Installed in the gateway are three XT style (8 bit) PC compatible cards. They a r e :
1. A MicroTrac interface card with an ARCNET high impedance (bus configuration) BNC connector for coaxial cable. MagneTek part number 0 5 P 0 0 0 9 0 - 0 2 6 9 .
2. A 5136-TI (Texas Instruments) interface card to connect to the Texas Instruments Remote I/O Network for 545 Series I/O Modules. M a g n e Tek part number 05P00090-0314.
3. An 80188 based CPU card with 64K RAM and 128K EPROM. M a g n e Tek part number 46S03162-0010 .
RD 3056-10
HARDWARE
Setup
S e t u p
Each of the three cards installed in the back plane has jumpers and switches that must be set before insertion into the back plane. After insertion, certain external cable connections must be made in order for the system to function properly.
M i c r o Tr a c
N e t w o r k
Interface Card
Set memory segment base to 0E000H and I/O memory base to 002E0H by installing jumper plugs on E1 as shown in Table 1:
Table 1. E1 Settings
POSITION JUMPER
TOP YES
YES
NO NO NO
YES
NO
BOTTOM YES
Set interrupt source to IRQ3 by installing jumper plugs on E4 as shown in Table 2:
Table 2. E4 Settings
POSITION JUMPER
IRQ2 NO
YES
NO NO
IRQ7 NO
If a MagneTek TI ROM configuration is used, enable ROM memory by installing a jumper plug at the /ENROM position of E3.
The node ID is set using the 8-position DIP switch, SW1. Enter the binary node ID by choosing either a "0" or "1" for each bit. The least significant bit (LSB) and the most significant bit (MSB) positions are labeled on the board. The LSB is toward the top of the board. Leaving the switch in the down position sets the switch at "0". For example, node ID 200, represented in binary form as 11 0 0 1000, is set as shown in Table 3:
Table 3. DIP Switch SW1 Settings
MSB LSB
UP UP DN DN UP DN DN DN
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HARDWARE
3
Setup
4/12/94
The node number for the PLC gateway will normally be 200; however, check your system schematic to confirm that this is correct. Occasionally a diff e r e n t node number might be used.
This card may be installed into any half-size slot of the back plane. A BNC type “T” connector is to be used to interconnect this board to the
M i c r o Trac DSD LAN’s coaxial cable. The 5136-TI (Texas Instruments) Interface card is designed to handle
communications between the 545 PLC and the CPU card. The card is used in the factory default state, with DIP switches set as shown in Table 4:
The 5136-TI Interface card is connected to the RS-485 remote I/O bus structure in the same way as any other remote base, with a DB-9 male connector. Refer to the cabling and wiring section of the TI installation manual for details.
Set serial port select to RS-232. This is done by installing a jumper plug on E1 on the CPU Card to connect from the center pin to the 232 pin.
Set I/O Channel Check to disabled. This is done by installing a jumper plug on E3 on the CPU Card to connect from the center pin to the DIS pin.
There is a 32K static RAM chip installed in both the RAM0 and RAM1 sockets.
There must be a 64K EPROM, containing the PLC gateway software, installed into socket ROM1.
There must be a 64K EPROM, containing the 5136-TI software, installed into socket ROM0.
Table 4. 5136-TI Interface Card Switch Settings
SWITCH POSITION
1 OFF 2 ON 3 OFF 4 ON 5 OFF 6 OFF
5136-TI Interface
C a r d
80188 Based
CPU Card
RD 3056-10
HARDWARE
General
General
Normally the PLC gateway will be mounted and wired on a MagneTek drive panel. However, the gateway can be mounted remotely by the customer. In this case, special consideration must be given to the 120 VAC power source for the gateway power supply. DO NOT plug the gateway power cord directly into a wall outlet. Instead, use an isolation transformer and tie one side of the secondary to the nearest earth ground (the steel structure of the building is usually a good choice). The ground studs on the MicroTrac drive panels or cabinets must also be connected directly to a solid earth ground in order to assure that the gateway enclosure and the drive panels are at the same potential. Otherwise, erratic operation of the MicroTrac LAN system may occur.
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SOFTWARE
5
SOFTWARE
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SOFTWARE
The EPROMs on the CPU card contain a software program that is fixed (i.e. not changeable on a job-to-job basis), and is transparent to the user. The software allows bi-directional communication between MicroTrac DSD drives and the Texas Instruments series 545 PLCs as follows:
Logics
1. PAC block LOGI, inputs from the PLC discrete output modules.
2. PAC block LOGO, outputs to the PLC discrete input modules.
Numerics
1. PAC block NUMI, inputs from the PLC register output modules.
2. PAC block NUMO, outputs to the PLC register input modules.
The PLC gateway provides a means of moving data between the nodes on the MicroTrac LAN and the Texas Instruments PLC. It does this by being a node on the MicroTrac LAN and also pretending to be one or more remote drops on the Remote I/O network of the Texas Instruments PLC. These drops are referred to as simulated drops because they are not physical drops with racks containing real modules.
Several steps are required to begin the exchange of data; some deal with configuring the Texas Instruments PLC, and some with programming the PAC blocks in the MicroTrac LAN nodes.
As described above, the PLC gateway looks to the Texas Instruments PLC as one or more bases. Even though these are simulated bases, the PLC treats them as normal bases. Therefore, they must be defined as simulated bases in the Texas Instruments Traffic Cop.
IMPORTANT: All slots in the TI Traffic Sop must be used by the drive
nodes. This can be accomplished by judicious PAC programming or PLC configuration. An alternative method is to use a MagneTek TI Gateway ROM configuration EPROM in the gateway.
Use the following information when assigning modules in the rack:
1. A base cannot be both real and simulated, so choose a base number that is not already use by real drops.
2. Simulated base numbers can be in the range of 1 to 9.
OPERATION
Configuring the
Texas
Instruments
545 PLC
RD 3056-10
OPERATION
Programming the PAC Blocks
3. The PLC gateway can only access modules in slots 1 to 16. If you define modules in other bases and slots, you can not access them through the PLC gateway.
4. Modules can only be of types 16Y (Discrete Output), 16X (Discrete Input), 8WY (8 Channel Register Output), or 8WX (8 Channel Register Input).
Table 5. Module Types
PAC
BLOCK LOGO 16X 16 point Discrete Input Module NUMO 8WX 8 channel Register Input Module LOGI 16Y 16 point Discrete Output Module NUMI 8WY 8 channel Register Output Module
TYPE DESCRIPTION
TEXAS INSTRUMENTS PLC MODULE
Programming
the PAC Blocks
The PLC gateway receives messages from the MicroTrac LAN. Each of these messages contains a channel number. This channel number specifies which Modicon module the message is addressing. The channel number can range from 011 to 249. The least significant digit is used to specify the slot number, and the 2 most significant digits specify the drop number. The rack is always assumed to be 2. When dealing with analog data, there is always a sub channel field that specifies the word within th analog module the message is addressing. This can range from 1 to 8. The discrete messages have a mask field which specifies the bits the message is addressing.
Table 6. Channel Number Designations
LAN Node LAN Channel LAN Sub Channel
Number Number NUMBER
200 - XX X - XX
TI TI TI
Slot No. Base No. Bit No.
Range = Range = Range = 01 to 16 for 01 to 16 01 to 09 Logic I/O
Range = 01 to 08 for
Numeric I/O
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OPERATION
7
Programming the PAC Blocks
4/12/94
An example may help clarify the above. Let’s assume we want to input discrete data from the Texas Instruments PLC and output 1 word of analog data to the PLC. Base 2 is not used by a real base, so we can choose that as our simulated base. In the Texas Instruments Traffic Cop for base 2, slot 1, we enter a 16Y discrete output module. In slot 2 of the same rack we enter a 8WX register input module. There is no special reason for choosing base 2 or slots 1 & 2.
The PAC program is responsible for supplying the PLC with information about where the simulated modules are located. After power-up, the node(s) on the MicroTrac LAN that want to read/write data to the Texas Instruments PLC must send the following messages:
A Remote Logic Input Configuration (Message Type 12) with the CHANNEL NUMBER equal to 021. The LOGIC MASK value reflects the bits you want to access.
A Remote Numeric Allocation Request (Message Type 11) with CHANNEL NUMBER equal to 022, SUB CHANNEL NUMBER equal to 1 for the first word of the analog module.
When the PLC Gateway receives these messages, it requests a confirmation from the Texas Instruments PLC to confirm that base 2 has a 16Y module in base 2, slot 2. Once this is confirmed, data can be exchanged.
The node number used by the PAC block to address the PLC gateway is usually 200. As mentioned previously, check the system schematic for confirmation.
Each Channel of a Texas Instruments analog module uses one 16 bit word. The word is presented to the Texas Instruments PLC as a two’s complement binary number (also called a signed integer). These numbers can range from +32767 to –32768. Each integer value has an assumed fixed location for the decimal point (DP). Since the number transferred to or from the PLC is an integer, there must be some way of determining in the PAC block where the decimal point is located. In numeric PAC blocks (NUMI and NUMO) this in accomplished by the DP (decimal point) parameter. For example, if the integer transferred from the PLC to a PAC block has a range of +32.767 to –32.768, the DP parameter for that PAC NUMI block must be specified as three (3).
When entering a discrete module into the Traffic Cop program of the Texas Instruments PLC, a reference number must also be entered. For discrete output points, the reference numbers are in the range Y0001 to Y2048; discrete input points range from X0001 to X2048. So if a discrete input module (16X) were entered into the Traffic Cop, X0001 would be entered as the reference number. The PLC then reserves X0002 through X0016 for the other points in
Example
Node Number
Format of Numeric Data
Format of Logic Data
RD 3056-10
OPERATION
Sending Numerics from PLC to DSD
the module. If this word is displayed, and the points X0001, X0002 and X0016 are enabled and the rest are disabled, then the value shown is Hex C001. X0001 is the most significant bit in that word, X0016 the least. The MicroTrac LAN message for allocating and upgrading logic contains a 4 byte mask field. If the bits within these 4 bytes are labeled 63-0, with 63 being the most significant bit and 0 the least significant bit, then to address point X0001 requires bit 1 (not bit 0) to be on, bit 2 for X0002, and so on.
Sending
Numerics from
PLC to DSD
Function
Number
Method
Specifics
DSD PAC code (PAC – programmable application code – the custom part of the DSD software) can be written to allow the PLC to send numerics to the DSD through either of two means. One method simply uses a NUMI block (numeric input) in the PAC code set to the proper PLC address. The other allows the PLC to read and change an adjustable function number parameter. Either method can be applied to any given numeric, and both methods can be utilized in a single PAC diagram.
The NUMI block method allows the same numeric to be set only from the PLC. It requires only one PLC address per numeric. The function number method allows the same numeric to be set from multiple locations, but requires two PLC addresses and needs additional PLC programming. This method does not allow the PLC to set the parameter outside of the predefined range of that number.
Adjustable parameters in the DSD are assigned function numbers between F1 and F299. These settings can be changed by using the standard testmeter which can be located on the DSD main PCB (SCDU – standard control display unit), the handheld testmeter (PCDU – portable control display unit), the remote display (RDU – remote display unit), or one or more of the many video screen, computer, or PLC connections to the LAN. DSD function number parameters that are to be settable through the PLC are placed in the “PLC INITIALIZATION” table that is usually located near the end of the DSD PAC diagram (software schematic diagram). This table defines the PLC address and decimal location for each parameter.
When the DSD/PLC interface detects a change in data from the PLC, it sends this new value over the LAN to the appropriate DSD. If this new setting is out of range for the function number in question, then the DSD/PLC interface sends the nearest allowed value to the DSD. The DSD then sends the new value it received back to the PLC as confirmation of a successful update. When the parameter is changed from a location other than the PLC (for instance, by using the RDU remote display), the DSD sends the new value to the PLC and expects the PLC to return this new value as confirmation of this change.
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OPERATION
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Function Number Method Specifics
4/12/94
Power up presents a special situation. There are two locations of nonvolatile memory for the same parameter. The DSD memory is chosen on power up over the PLC memory value. Value changes from the PLC after a power up will not be accepted by the DSD/PLC interface until the PLC sends the value it is reading from the DSD.
A sample ladder diagram for a TI PLC that meets the above requirements is shown in Figure 1.
Figure 1. Sample Ladder Diagram for TI PLC
p = 1.0
A : V100 B : WY23 N = 2
A : WX41 B : WY33 N = 2
TIMR1
(C3)
C3
(C1)
C1
X1
C1
C1
(C2)
C2
MOVW1
MOVW2
X1 = (load PB) pick up to send new value set by PLC to DSD V100 = new value as set by PLC WY33 = PLC numeric output address (PLC to DSD) WY41 = PLC numeric input address (DSD to PLC)
RD 3056-10
OPERATION
PLC Gateway Status
PLC Gateway
Status
The PLC gateway status is displayed on the four (4) character alphanumeric display that is mounted on the CPU card. Messages which are displayed are shown in Table 7.
Table 7. PLC Gateway Display Messages
MESSAGE DESCRIPTION TROUBLESHOOTING
BROM This message will appear only when a MagneTek TI
Gateway ROM Configuration is used. If the firmware does not see the correct configuration string in the EPROM socket memory address, it ignores the con­tents of the socket. If a valid configuration string is found at the start of the EPROM, the remainder of the EPROM configuration information is checked. If the remaining configuration lines contain an invalid base. slot, or module type, the firmware displays the "BROM" on the 4 character display and halts,
EARC This message is displayed during PLC Gateway
initialization if the MicroTrac Network Interface card is not found. Initialization is not completed.
ECdd This indicates that the PLC Gateway is unable to Check the cabling between the
get a configuration from the Texas Instruments . 5136-TI card and the TI RBC PLC for base "dd" Processor. Is the Texas Instruments
PLC on and has it been programmed? When the PLC Gateway receives an allocation Check the configuration and solve message (0x10, 0x11, 0x12, 0x13, or 0x2D) from tables that are loaded into the PLC. the DSD LAN, it decodes the channel number into Does the configuration include the a base and slot number and attempts to get a base being allocated? Is the base configuration for that base from the Texas being scanned? Check the solve Instruments PLC. If it cannot, this error message table. Is the base you are trying to
is displayed and the PLC Gateway hangs. configure remote?
ECOM This message appears during operation if the Check the cabling between the
5136-TI card is not communicating with the 5136-TI card and the TI RBC Texas Instruments PLC. Processor. Check that the cable is
connected on 5136-TI card.
EIVA When the PLC Gateway receives an allocation
message, it decodes the channel number into base and slot numbers. If either of these numbers is invalid, then this message is displayed. An alloca­tion error message is returned to the sending node.
ELIA When the PLC Gateway receives a logical input
allocation message, this error message could appear because the internal allocation table is full and cannot handle another allocation. The allocation table has room for 1024 allocations. A logical allocation uses 1 element in the table.
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OPERATION
11
PLC Gateway Display Messages
4/12/94
ELOA When the PLC Gateway receives a logical output
allocation message from the DSD LAN, this error message could appear for any of the following reasons:
1. The internal allocation table is full and cannot handle another allocation. The allocation table has room for 1024 allocations. A logical allocation uses 1 element in the table.
2. The bits specified in the allocation message overlap with bits already allocated by another node.
3. The bits specified by the allocation message are not exactly the same as the bits already allocated by this node.
EMMA This indicates a mis-match during allocation. Check the configuration in the
Texas Instruments PLC. For the base When the PLC Gateway receives an allocation and slot specified in the allocation message (0x10, 0x11, 0x12, 0x13, or 0x2D) from the message, the following modules are network, it decodes the channel number into a base expected in the allocation message: and slot number and then requests through the 5136-TI card the configuration for that base from 0x10 -LOGO- 16X, 16 point the Texas Instruments PLC. Once the configuration Discrete Input Module has been received, the gateway checks to make sure 0x11 -NUMO- 8WX, 8 channel that the module in that slot is the correct one. If Register Input Module not, then this message appears and an error 0x12 -LOGI- 16Y, 16 point message is sent to the node that issued the Discrete Output Module allocation message. 0x13 -NUMI- 8WY, 8 channel
Register Output Module
ENIA When the PLC Gateway receives a numeric input
allocation message, this error message could appear for one of the following reasons:
1. The internal allocation table is full and cannot handle another allocation. The table has room for 1024 allocations. A numeric allocation uses 8 elements in the table.
2. The sub channel is out of range. It can range from 1 to 8.
Table 7. PLC Gateway Display Messages (Continued)
MESSAGE DESCRIPTION TROUBLESHOOTING
RD 3056-10
OPERATION
PLC Gateway Display Messages
MESSAGE DESCRIPTION TROUBLESHOOTING
ENOA When the PLC Gateway receives a numeric output
allocation message from the network, this error message could appear for any of the following reasons:
1. The internal allocation table is full and
2. The sub channel is out of range. It can
3. The sub channel has already been
ERDU When the PLC Gateway receives a PLC Configuration
message, this error message appears if the internal RDU table is full and cannot accommodate another entry. The table has a capacity of 255 entries. The PLC Configuration message is ignored.
INIT Displayed during gateway initialization.
Initialization includes:
1. Internal array initialization
2. 5136-TI interface card initialization
3. Network card initialization
PUPn Displayed after the gateway has successfully
completed initialization and is ready to receive messages from the network.
n=1 – The PLC Gateway broadcasts a power-up
n=2 – During this stage, the PLC Gateway is
Table 7. PLC Gateway Display Messages (Continued)
cannot handle another allocation. The
table has room for 1024 allocations. A numeric allocation uses 8 elements in the table.
range from 1 to 8.
allocated by another node.
message across the DSD LAN. Also, if the PLC Gateway has returned to the PUP sequence because of an "ECOM" error (Communication error between 5136-TI card and the Texas Instruments S908 Remote I/O Processor) and communication has been re-established, then internal tables are also cleared.
decoding allocation messages (types 10, 11, 12, 13 and 2D) and setting up simulated drops
on the 5136-TI card. A list of all the drops
requested via the allocation messages is also made. If after 4 seconds no allocation messages are received, then the PLC Gateway proceeds to the next step.
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OPERATION
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PLC Gateway Display Messages
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PUPn n=3 – During this stage, the PLC Gateway checks
(cont’d) each base on its list and makes sure the base
has received configuration information from the Texas Instruments PLC. If not, an "ECdd" message is displayed, where "dd" is the base number of the base that has not responded. If all drops on the list are configured, then the gateway issues another power-up message across the network and enters the RUN stage.
RUN When this message is displayed, the PLC Gateway
has completed its power-up (PUP) sequence and is ready to transfer data to and from the Texas Instruments PLC. If, while in this stage, an alloca­tion message is received for a drop that has not been configured, the PLC Gateway jumps back to the PUP sequence. A "ECOM" error also causes the PLC Interface to leave the RUN stage and return to the PUP stage when communication is re-established between the 5136-TI card and the Texas Instruments RBS Processor.
THNP This message is displayed during PLC Interface Check that the 5136-TI card
has
initialization if it is determined that the 5136-TI been properly installed. The 5136-TI card is not present. card could be defective; swap it with
another that you know works properly.
TIFL This message is displayed during PLC Gateway
or initialization if the 5136-TI card software never com-
TNR pletes its own initialization and remains not ready.
TQFL Transmission Queue Full. This generally occurs • Reduce number of data points.
when the amount of data requested exceeds the • Change update rates in the PAC gateway bandwidth. program.
• If multiple drives are requesting the same data, change the PAC programs so that one drive requests the data and then passes it to the other drives.
• Add additional gateways to share the load.
Table 7. PLC Gateway Display Messages (Continued)
MESSAGE DESCRIPTION TROUBLESHOOTING
RD 3056-10
OPERATION
MicroTrac Network Interface Card
MicroTrac
Network
Interface Card
The interface card has two LEDs which indicate the following:
Red – Indicates activity is present on this node. Should be blinking or steady.
Green – Indicates that a token ring has been formed. Should be on (blinking or steady).
Hub Card
On large systems, a multi-port expansion Hub card may be present in the gateway card rack as a fourth card. If it is present, its LEDs signify the following:
Red Light (at Each Port) – Indicates activity for each individual port. If an active cable is connected to a port, the red light should be on.
Yellow – Indicates network configuration. Should be on only when network configuration is changed (i.e. adding a node) or on power-up.
Red – Indicates total network activity.
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OPERATION
15
Texas Instruments PLC Troubleshooting
4/12/94
Texas
Instruments
PLC
Troubleshooting
This section contains a list of scenarios and possible causes pertaining to communications problems that may be encountered with the 5136-TI Direct Link Interface card and the TI 545 PLC.
As a first check, the red and green LEDs on the face of the card provide a quick visual indication as to the state of the card. Table 8 indicates what is to be expected after a successful installation of the 5136-TI firmware module.
If communications are not taking place between the 5136-TI card and the PLC, check per Table 9.
Table 8. 5136-TI LED Indications
RED GREEN CONDITION
ON ON Card is in a reset state. The
TI RDC software module has not yet been loaded onto the card.
OFF DIM Card is executing software
and communications are taking place. No configur­ation information exists.
OFF BRIGHT Card is executing software
and communications are taking place. Data for a created RBC is being updated.
OFF OFF Card is executing software,
but no communications to the card are taking place.
Table 9. Checking for No Communications
TROUBLE
INDICATOR POSSIBLE CAUSE
Green LED OFF 1. Cabling to card is all the time. incorrect or disconnected.
2. Cabling to PLC is incorrect or disconnected.
3. PLC is powered off.
4. No bases or modules have been allocated by any drives.
RD 3056-10
MicroTrac Gateway User Reference
Data subject to change without notice. DSD, MicroTrac, & PAC are trademarks of MagneTek, Inc.
MagneTek 16555 W. Ryerson Road New Berlin, Wisconsin 53151
RD 3056-10 © 1994 MagneTek, Inc. 94-04
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