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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
POSITIONJUMPER
TOPYES
YES
NO
NO
NO
YES
NO
BOTTOMYES
Set interrupt source to IRQ3 by installing jumper plugs on E4 as shown in
Table 2:
Table 2. E4 Settings
POSITIONJUMPER
IRQ2NO
YES
NO
NO
IRQ7NO
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
MSBLSB
UPUPDNDNUPDNDNDN
4/12/94
RD 3056-10
2
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
SWITCHPOSITION
1OFF
2ON
3OFF
4ON
5OFF
6OFF
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.
4/12/94
RD 3056-10
3
SOFTWARE
5
SOFTWARE
4/12/94
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).
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 NodeLAN ChannelLAN Sub Channel
NumberNumberNUMBER
200 - XXX- XX
TITITI
Slot No.Base No.Bit No.
Range = Range = Range = 01 to 16 for
01 to 1601 to 09Logic I/O
Range = 01 to 08 for
Numeric I/O
4/12/94
RD 3056-10
4
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.
4/12/94
RD 3056-10
4
OPERATION
9
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
MESSAGEDESCRIPTIONTROUBLESHOOTING
BROMThis 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,
EARCThis message is displayed during PLC Gateway
initialization if the MicroTrac Network Interface card
is not found. Initialization is not completed.
ECddThis 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 messagetable. Is the base you are trying to
is displayed and the PLC Gateway hangs.configure remote?
ECOMThis 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.
EIVAWhen 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.
ELIAWhen 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.
4/12/94
RD 3056-10
4
OPERATION
11
PLC Gateway Display Messages
4/12/94
ELOAWhen 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.
EMMAThis 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
ENIAWhen 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)
MESSAGEDESCRIPTIONTROUBLESHOOTING
RD 3056-10
OPERATION
PLC Gateway Display Messages
MESSAGEDESCRIPTIONTROUBLESHOOTING
ENOAWhen 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
ERDUWhen 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.
INITDisplayed during gateway initialization.
Initialization includes:
1. Internal array initialization
2. 5136-TI interface card initialization
3. Network card initialization
PUPnDisplayed 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.
4/12/94
RD 3056-10
4
OPERATION
13
PLC Gateway Display Messages
4/12/94
PUPnn=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.
RUNWhen 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.
THNPThis 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.
TIFLThis message is displayed during PLC Gateway
orinitialization if the 5136-TI card software never com-
TNRpletes its own initialization and remains not ready.
TQFLTransmission 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)
MESSAGEDESCRIPTIONTROUBLESHOOTING
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.
4/12/94
RD 3056-10
4
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 GREENCONDITION
ONONCard is in a reset state. The
TI RDC software module has
not yet been loaded onto the
card.
OFFDIMCard is executing software
and communications are
taking place. No configuration information exists.
OFFBRIGHTCard is executing software
and communications are
taking place. Data for a
created RBC is being
updated.
OFFOFFCard is executing software,
but no communications to
the card are taking place.
Table 9. Checking for No Communications
TROUBLE
INDICATORPOSSIBLE CAUSE
Green LED OFF1. 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