GE Fanuc Series Six Plus Manual

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Programmable Control Products

Archive

Document

This electronic manual was created by scanning a printed document, then processing the file using character-recognition software.

Please be aware that this process may have introduced minor errors. For critical applications, use of a printed manual is recommended.

Series Six Plus

Programmable Logic Controller

User’s Manual

GEK-96602A November 1987

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

G F L - 0 0 2

Warnings, Cautions, and Notes as Used in this Publication

Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used.

Caution notices are used where equipment might be damaged if care is not taken.

Note

Notes merely call attention to information that is especially significant to understanding and operating the equipment.

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance.

Features may be described herein which are not present in all hardware and software systems. GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply,

The following are trademarks of GE Fanuc Automation North America,

Inc.

Alarm Master

CIMPLICITY

CIMPLICITY PowerTRAC

CIMPLICITY 90-ADS

CIMSTAR

Field Control

GEnet

Genius

Genius PowerTRAC

Helpmate

Logicmaster

Modelmaster

ProLoop

PROMACRO

Series Five

Series 90

*Copyright 1995 GE Fanuc Automation North America, Inc.

AI1 Rights Reserved

Series One

Series Six

Series Three

VuMaster

Workmaster


Preface

GEK-96602

. . .

iii

PREFACE

This is the second edition of the Series Six’” Plus Programmable Logic Controller User’s

Manual. This manual provides the user with the information required to configure, install, implement and maintain the Series Six’” Plus Programmable Logic Controller.

Chapter 1. Introduction to

the

Series Six Plus PLC.

This chapter describes the features, functions and specifications of the Series Six Plus PLC, along with information on programming, communications options and optional peripheral equipment that can be included as part of your Series Six Plus PLC system. A cross reference guide is included listing the compatibility of the Series Six Plus PLC vs the previously available Series Six family of PLCs.

Chapter 2. Physicaf Equipment Configuration.

This chapter describes the hardware components included in a Series Six Plus PLC system.

The CPU rack configuration is such that it contains all of the necessary modules for a complete PLC system, including communications options, with up to 6 slots for I/O modules in the rack. All of the system interface modules required when adding I/O racks to contain up to the maximum of 32 K of I/O (16K Inputs and l6K Outputs) are described. A description of the various available communications options is included.

Chapter 3. Installation Instructions.

This chapter contains installation specifications and instructions required in order to configure, and rack, panel or walI mount and wire your Series Six Plus Programmable Logic Controller system.

Chapter 4.

Expanded

CPU

Operation. This chapter describes the Expanded functions and

Expanded mode

of

operation for the Series Six Plus Programmable Logic Controller.

Included is a description of how to configure the Expanded functions on the W o r k m a s t e r computer using Logicmaster 6 software. Also included in this chapter is information on how to use the Genius I/O diagnostics with the Expanded functions in a Series Six Plus

Programmable Logic Controller.

Chapter 5. Troubleshooting and Repair.

This chapter provides the basic information required to maintain your Series Six Plus Programmable Logic Controller system, including the CPU and I/O system. The troubleshooting method described emphasizes a logical approach to analyzing any faults and subsequent replacement of any failed modules.

Appendix A. Glossary of Terms.

This is a glossary of commonly used programmable logic controller terminology to aid the user in understanding those unique terms.

A comprehensive index is provided as an aid to quickly finding a particular subject in this manual.

Shoufd additional information be required, contact your GE Fanuc-NA Distributor, GE

Fanuc-NA salesperson or GE Fanuc Automation North America, Inc., P.O. Box 8106,

Charlottesville, Virginia, 22906.

Henry A. Konat

Senior Technical Writer


i v Preface

GEK-96602

RELATED PUBLICATIONS

For more information on subjects discussed in this manual, refer to these publications:

GEK-25361

Series Six Installation and Maintenance Manual,

which describes the earlier models of Series Six programmable logic Controllers.

GEK-25365

GEK-25364

GEK-25367

GEK-25368

Application Guide for the Series Six Programmable Controller,

which provides information on how to developement typical applications using a

PLC.

Series Six Data Communications Manual,

which describes the function and operation of the Communications Control Modules (CCM).

Series Six Data Sheet Manual,

which contains technical descriptions, specifications, and wiring information on available modules.

Series Six Axis Positioning Module Type 1 Manual,

which describes installation, programming and application of the APM, Type 1.

GEK-25398

GEK-25373

GEK-25379

GEK-90486

GEK-90800

GEK-90802

GEK-90817

GEK-90820

GEK-90825

Series Six ASCII/BASIC Module Manual,

which describes installation programming and troubleshooting procedures for the ABM.

WORKMASTER G u i d e t o O p e r a t i o n ,

which provides information for configuration and installation of the Workmaster computer.

Logicmaster 6 User’s Manual,

which provides the information required to program and document a Series Six Plus PLC.

G enius l/O System User’s Manual,

which provides configuration, programming, operation, and troubleshooting information to aid in implementing the Genius I/O system into a Series Six Plus PLC system.

Series Six Axis Positioning Module Type II User’s Manual,

which describes installation, programming and application of the APM, Type 2.

ProLoop Process Controllers,

which contains the information required to use the family of ProLoop Process Controllers. Includes data on stand-alone operation and the Loop Management Module, which interfaces the process controllers to a Series Six Plus PLC system.

Series Six Operator interface Terminal User’s Manual,

which describes the configuration, installation, programming, and operation of the OIT for use with a Series Six Plus PLC.

V u M a s t e r Co/or G r a p h i c s T e r m i n a l ,

which describes the installation, configuration, and operation of a color graphics system as an operator interface for data collection and analysis.

Series Six PC l/O link Local Module User’s Manual,

which describes the link between a Series Six Plus PLC and the I/O structure for the Series

One family and Series Three PLCs.


FCC Note

GEK-96602

V

The Series Six Plus Programmable Logic Controller and its associated modules have been tested and found to meet or exceed the requirements of FCC Rule, Part 15, Subpart J.

The FCC requires that the following note be published.

NOTE

This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio communications.

It has been tested and found to comply with the limits of a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user at his or her own expense will be required to take whatever measures may be required to correct the interference.



Contents

GEK-96602 vii

CONTENTS

TITLE

PAGE

CHAPTER f .

INTRODUCTION TO THE SERIES SIX PLUS

PROGRAMMABLE LOGIC CONTROLLER

What are Programmable Logic Controllers?

Advantages of Programmable Logic Controllers

Series Six Plus Programmable Logic Controller features of the Series Six Plus PLC

General Specifications

Genius I/O System

Programming the Series Six Plus PLC

Workmaster Industrial Computer

Other Software Packages

Programming Language for the Series Six Plus PLC

Programmable Logic Controller Concepts

Function of the Central Processor Unit

Memory Types Used in the Series Six Plus PLC

Function of the Input/Output Circuitry

Optional Devices Supporting the Series Six Plus PLC

Redundant Processor Unit

Operator Interface Unit

Operator Interface Terminal

ProLoop Process Controllers

ASCII/BASIC Module

Axis Positioning Module

Communications Control Modules

GEnet Factory LAN

Series Six PLC Network Interface

Datagram Communications Service

Global Data Service

RS-232 to RS-422 Adaptor Unit

System Planning

Typical Applications Using PLCs

PLC Terminology

PLC Compatibility Guide

CHAPTER 2. PHYSICAL EQUIPMENT CONFIGURATION

Product Structure for the Series Six Plus PLC

19 Inch CPU Rack Configuration


Basic Unit Configuration

2 - 1

2 - 1

2 - 2

2 - 2

2 - 2

1 - 1

1-15

1-15

1-16

1-17

1 - 1 7

1-18

1-18

1 - 2 0

1-20

1-21

1-21

1-22

1 - 2 2

1 - 2 3

1 - 2 4

1 - 1

1 - 2

1 - 2

1 - 4

1 - 5

1 - 6

1-7

1 - 8

1 - 8

1 - 9

1-11

1-11

1 - 1 1

1 - 1 2

1-14

1-14


. . .

VIII

Contents

GEK-96602

CONTENTS

TITLE

PAGE

CHAPTER 2.

PHYSICAL EQUIPMENT CONFIGURATION (Continued)

Power Supply for the Series Six Plus PLC

Terminal Block Connections

Power Supply Specifications

Outputs and System Control Signals

Power Supply Auxiliary Circuit Board l/O Control Module

User Connections

Status Indicators

User Configurable Jumpers

Logic Control Module

Arithmetic Control Module


Combined Memory Module

Logic Memory Function

Register Memory Function

Internal Memory Function

Detection of Active Override in System

Scratch Pad Items

Type of Memory Used

Battery Status Indicator

Location in Rack

Precautions When Handling Memory Modules

Memory Protection

Bus Controller Module

Versions of Bus Controller


Communications Control Module, Type 2 (CCM2)

System Configuration

User Items


CCM2 Mode

CCM3 Remote Terminal Unit (RTU) Mode

Dual Mode Usage

I/O Communications Control Module (l/O CCM)

I/O Link Local Module l/O Structure for the Series Six Plus PLC l/O Racks

2-23

2-23

2-25

2-25

2-25

2-25

2-26

2-27

2-29

2-29

2-14

2-14

2-16

2-16

2-16

2-16

2-17

2-17

2-4

2-6

2-7

2-8

2-9

2-10

2-10

2-10

2-11

2-12

2-18

2-18

2-19

2-19

2-19

2-21

2-21

2-22

2-22


Contents

GEK-96602

CONTENTS

TITLE PAGE

CHAPTER 2.


I/O Addressing

Normal Mode I/O Addressing

Expanded Mode l/O Addressing

Channel Reference Numbering

Real I/O Memory Allocation

Internal Discrete Reference Memory Allocation

Expanded Mode I/O References

I/O System Configuration

I/O Rack Interconnections

CPU I/O Station

Local I/O Station

Remote l/O Station l/O Interface Modules

I/O Receiver

I/O Chain Signal Continuation or Termination

Module Connections


Advanced l/O Receiver

2 - 4 5

2 - 4 6

Module Connections 2-46

I/O Signal Continuation or Termination

2-47

Status and Diagnostic Indicators

2-48

I/O Transmitter

2-49

Isolation Circuitry

Location in Rack and I/O Channel Addressing

2-50

2-51


2-51

Configuration Jumpers 2-51

Connector

Remote l/O System

2-51

2-52

System Connections

Remote System Response Time

2 - 5 2

Remote l/O Addressing

Printed Circuit Board Jumpers

2-53

2-53

2 - 5 4

Remote I/O Driver

Remote I/O Driver Addressing

2-55

2 - 5 6

Status Indicators 2 - 5 7

Option Jumpers 2-57

Remote I/O Receiver

Connectors

2 - 5 8

2-59

Status Indicators 2 - 5 9

Option Jumpers 2 - 5 9

2-31

2-33

2 - 3 3

2-33

2 - 3 4

2 - 3 4

2 - 3 4

2 - 3 6

2 - 3 6

2-37

2 - 3 9

2-40

2 - 4 2

2-43

2 - 4 4

2-44 iX


X

Contents

GEK-96602

CONTENTS

TITLE PAGE

CHAPTER 2.


AuxiIiary I/O System

Workmaster Computer to

Series Six Plus PLC Connections

Workmaster to Series Six Interface Adaptor Boards

Connection to I/O Control or

I/O Receiver Modules

Connection to an I/O Transmitter Module

Connecting Cable

Connections Using the Serial Version of

Logicmaster 6

Using the Cimstar I Computer With a

Series Six Plus PLC

Parallel Version of Logicmaster 6 Software

Serial Version of Logicmaster 6 Software

Programming a Series Six Plus PLC With an IBM PC

CHAPTER 3.

INSTALLATION INSTRUCTIONS FOR THE SERIES

SIX PLUS PROGRAMMABLE LOGIC CONTROLLER

Introduction

Quality Control

Packaging

Visual Inspection

Preinstallation Check

Rack Installation

Extraction/Insertion Tool

Inserting a Printed Circuit Board

Removing a Printed Circuit Board

Module Installation


Battery Installation

External AuxiIiary Battery Select ion


Logic Control Module - Advanced, Expanded or Expanded II l/O Control Module

Auxiliary I/O Module

Communication Control Modules

CPU Power Supply

2-60

2 - 6 2

2 - 6 2

2 - 6 2

2 - 6 2

2 - 6 3

2 - 6 4

2 - 6 4

2 - 6 4

2 - 6 5

2 - 6 5

3-11

3 - 1 2

3 - 7 3

3-13

3-14

3-1

3 - 1

3 - 1

3 - 1

3 - 2

3 - 2

3 - 2

3 - 4

3 - 5

3 - 6

3 - 6

3 - 8

3 - 8

3 - 9


Contents

GEK-96602

CONTENTS

TITLE

CHAPTER 3.

INSTALLATION INSTRUCTIONS FOR THE SERIES

SlX PLUS PROGRAMMABLE LOGIC CONTROLLER

(Continued)

System Grounding Procedures

Recommended Grounding P ractices

Ground

Conductors

Series Six Plus PLC Equ

I/O System Configuration ipment Ground ing

I/O Power Supply

AC Power Source Connections

DC Power Source Connections

I/O System Interface Modules

I/O Receiver or Advanced I/O Receiver

I/O Transmitter


Remote l/O Receiver

Parallel I/O Chain Cables

Parallel I/O Cable Configuration

Serial Link Cable to Remote I/O System

I/O Point Selection

Power Supply Load Capacity

Load

Capacity for a Series Six Plus CPU Rack

Load Capacity for an I/O Rack

Initial Start-up Instructions for a

New

Series Six

CPU

Running Expanded l/O on the Series Six Plus PLC

As Internal Coils Only

To Be Solved to Real World I/O Points

How It Works

System Design Considerations

CHAPTER 4. EXPANDED CPU OPERATION

Introduction

Normal Mode of Operation

Expanded Functions

Series Six PLC I/O Diagnostics for

Series Six Plus PLCs l/O Transmitter Diagnostic Feature

Interrupt Module Location

Normal Mode l/O Addressing

PAGE

3 - 1 5

3 - 1 5

3-16

3-16

3-19

3 - 2 0

3 - 2 0

3-21

3-21

3 - 2 2

3 - 2 2

3 - 2 3

3 - 2 4

3 - 2 4

3 - 2 5

3 - 2 6

3 - 2 7

3 - 2 8

3 - 2 8

3 - 3 0

3-31

3 - 3 4

3 - 3 4

3 - 3 4

3 - 3 4

3 - 3 9

4 - 1

4-1

4-7

4 - l

4 - 2

4 - 2

4 - 2

4 - 3

x i


xii

GEK-96602

Contents

.-

CONTENTS

TITLE

CHAPTER 4.

EXPANDED CPU OPERATION (Continued)


I/O Channels


Real I/O Mapping

Internal Mapping of Discrete References

Register Memory Size

Expanded Mode I/O References

Summary of Required I/O References

Summary of Required Register References

Dynamic User Memory Checksum

Memory Checksum Calculation

Logicmaster 6 Display of Checksum Error

Restarting a CPU Stopped by a Checksum Error

Configuration of Expanded Functions Through

Logicmaster 6 Software

Expanded Functions Menu

CPU Configuration Set Up Menu

Making Entries on the CPU

Configuration Set Up Page

Cancelling Entries to the CPU

Configuration Set Up Menu

CPU Configuration Menu: Definitions

Displaying and Editing the Genius Bus

Controller Locations Page

Editing the Bus Controller Map

Cancelling Changes to the Bus Controller Map

Displaying and Clearing Genius I/O Faults

Displaying the Genius I/O Fault Table

Genius I/O Fault Table Definitions

Viewing Additional Fault Listings

Clearing Faults

Floating Point Functions

Floating Point Display Format

Valid Number Format

Programming Floating Point Arithmetic Functions

Floating Point Addition

Floating Point Subtraction

Floating Point Multiplication

Floating Point Division

Floating Point Greater Than

Convert Integer to Floating Point

Convert Floating Point to Integer

PAGE

4 - 1 2

4 - 1 2

4 - 1 3

4 - 1 4

4 - 1 4

4-14

4-21

4-21

4-21

4 - 2 2

4 - 2 2

4 - 2 2

4 - 2 3

4 - 2 3

4-17

4-17

4-17

4-18

4-18

4-19

4 - 2 0

4 - 2 0

4 - 2 4

4 - 2 4

4 - 2 4

4 - 3

4 - 3

4 - 4

4 - 5

4 - 5

4 - 5

4 - a

4 - 9

4 - 9

4-11

4-11

4-11

4-11


Contents

GEK-96602

. . .

XIII

CONTENTS

TITLE

PAGE

CHAPTER 4.


Window (DPREQ) Function

Entering a Window Function

Using the Do l/O Function to Address

16K Inputs and Outputs

Entering a Do I/O Function

Expanded Time Reference (Real-Time Clock)

Format of the Real-Time Clock

Genius I/O Diagnostics

Diagnostic Fault Table

Register Memory Size VS Genius I/O Diagnostics

Fault Table Pointer

Input Data From Bus Controller

Selecting Addresses for Diagnostic

Data Storage

Bus Controller Status Byte 2 (Address 0),- Input 1

Bus Controller Status Byte 1 (Address 0) - Input 2

Bus Controller Status Byte 1 (Address 0) -

Inputs 3, 4, 5, 6)





Bus Controller Status Byte 1 (Address 0) -

Input 7 & 8

Fault Table Registers

Register 1 - Genius l/O Bus Controller

Address Decoding

Register 2

Register 3

Register 4 and 5

Register 5 (Upper Byte) and Register 6

Register 7

Registers 8, 9, 10

Bus Controller Output Data

Output 1 (Bit 0) Definition, Disabled Outputs

Output 2 (Bit 1) Definition, Clear All Faults

Output 3 (Bit 2) Definition, Clear Circuit Fault

Output 4 (Bit 3) Definition, Pulse Test

Output 9 (Bit 0 of Byte 2) Definition,

Circuit Type

4-24

4-25

4-30

4-31

4-32

4-32

4-32

4-32

4-33

4-33

4-33

4-34

4-34

4-35

4-35

4-36

4-36

4-36

4-37

4-37

4-37

4-38

4-26

4-26

4-27

4-27

4-28

4-28

4-28

4-28

4-28

4-29

4-29

4-30


xiv

GEK-96602

Contents

CONTENTS

TITLE

PAGE

CHAPTER 4.


Point Status Bit Map

Bus Status/Control Byte Location

Input Status Definitions

Output Control Definitions

Computer Mail Box

Using the Computer Mail Box to Communicate

With Genius I/O Bus Controllers

Operation of the Computer Mail Box

Communication Window Opens

Register R - Bus Controller Address

Command Data Registers

Register R+1 - Operation (Read or Write)

Register R+2 - Communications Status

Register R+3 - Target Block Start Address

Register R+4 - Mailbox Address for Data

Register R+5 - Data Buffer Length

Data Registers

Command Verification

Terminating Computer Mail Box Communication

Using the DPREQ Function to Communicate

With Genius I/O

Typical DPREQ Operation

Contents of First Register

Contents of Second Register

Contents of Third Register

Contents of Fourth Register

Contents of Fifth Register

4-38

4-39

4-39

4-40

4-40

CHAPTER 5. TROUBLESHOOTING AND REPAIR 5-1

Introduction 5-1

Minimum Downtime 5-1

Logical Troubleshooting 5-1

Troubleshooting

5 - 2

Replacement Module Concept

5 - 2

Isolate the Problem

5 - 2

4-44

4-44

4-4s

4-45

4-45

4-46

4-46

4-40

4-41

4-41

4-41

4-42

4-42

4-42

4-43

4-43

4-43

4-43

4-43

4-44


Contents

GEK-96602

CONTENTS

TITLE

PAGE

CHAPTER 5.

TROUBLESHOOTING AND REPAIR (Continued)

Section 1 Central Processing Unit Troubleshooting

Fault Isolation and Repair

Check Condition of Status Indicator Lights

Check Position of Key Switches

Battery Light Out

Alarm Relay

Section 2.

I/O System Troubleshooting

Troubleshooting the I/O Rack Power Supply

I/O Indicator Chart

I/O Rack Connections

Suggested Troubleshooting Sequences

Examples of Intermittent Fault Conditions & Causes

Troubleshooting with the Advanced I/O Receiver Module

Example of Determining the Output Byte Address

5-3

5-3

5-3

5-3

5-16

5-18

5-20

5-20

5-22

5-27

5-31

5-36

5-38

5-41

APPENDIX

APPENDIX A. GLOSSARY OF TERMS A - 1


xvi

GEK-96602

FIGURES

Figure 1.1

1.2

1.3

1.4

Programmable Logic Controller Block Diagram

Typical Series Six Plus PLC Rack

Genius l/O Typical Communications Link

Workmaster Industrial Computer

Redundant Processor Unit Configuration

1.5

1.6

1.7



1.8 Typical Proloop System Equipment

1.9

GEnet Factory LAN

1 .10 LAN Interface Module Connects a Series Six Plus PLC to a Carrierband Network

1 .11

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10


Product Structure for Series Six Plus PLC

Basic CPU Rack Configuration for the Series Six Plus

Brackets in Position for Rack Mounting

Brackets in Posit ion for WalI or Panel Mounting

Illustration of Power Supplies

CPU Terminal Block Connections

CPU Power Supply Block Diagram

Power Supply Auxiliary Circuit Board l/O Control Module

Example of Logic Control Module


2.11

2.12

2.13

2.14

2.15

2.16

Basic Word Structure

Typical Combined (Logic) Memory Module

Illustration of CCM2 Module

Illustration of I/O CCM Module

I/O Link Local Module to Series One or

2.17

2.18

2.19

2.20

2.21

2.22

2.23

2.24

2.25

2.26

2.27

2.28

2.29

2.30

Series Three Remote I/O Racks

I/O Link Local Module

Typical I/O Rack l/O Point Address Switches

Dip Switch Settings for 8-Circuit Modules

CPU l/O Station

Local l/O Station

Remote I/O Station Configuration

I/O Receiver User Items

I/O Receiver Dip Shunt/Jumper Rack Configuration

Location of User Items l/O Transmitter Module

Typical Remote I/O System Connections

Remote I/O Driver Module

Remote I/O Receiver Module

Contents

1 - 2 0

1-21

2 - 1

2 - 3

2 - 3

2 - 3

2 - 4

2 - 6

2 - 8

2 - 9

2-11

2-13

2-15

2-16

2 - 2 0

2-24

2-26

2-43

2-44

2-47

2-50

2-52

2-55

2-58

2-27

2-28

2-29

2-31

2-32

2-38

2-39

2-41

PAGE

1 - 1

1 - 3

1 - 6

1 - 7

1-14

1-15

1-15

1-16

1-19


Contents xvii

G E K - 9 6 6 0 2

Figure 2.31

2.32

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

3.20

3.21

3.22

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

5.1

5.2

5.3

3.23

3.24

3.25

3.26

4.1

Auxiliary I/O Module Board Layout

Workmaster Computer Connections to the Series Six Plus PLC

Rack Mounting (19” Rack)

Wall or Panel Mounting (19” Rack)

Extraction/Insertion Tool

Position of Extraction/insertion Tool for Board Insertion

Positioning the Extraction/Insertion Tool for Board Removal

CPU Module Location Guide

Memory Board Battery Connect ion

Printed-Circuit Board Orientation in a Rack

Logic Control to Arithmetic Control Ribbon Cable

I/O Control Module Jumper Location

CPU Power Supply Connections

PLC System Grounding

Rack Safety Ground Wiring

Series Six Plus PLC Rack Signal Ground Connections

I/O Station Grounding

Programming Device Ground Connection

Typical I/O Rack

I/O Power Supply Connect ions

Parallel I/O Chain Cable

Remote I/O Twisted Pair Cable

Remote I/O Cable for RS-232 Modems

Dip Switch Settings for I/O Point Selection for 8 Circuit Modules

Example 1 - Correct Configuration

Example 2 - Correct Configuration

Example 3 - Incorrect Configuration

Example 4 - Incorrect Configuration

I/O Transmitter Dip Switch Settings for

Expanded I/O Channel Selection

Expanded l/O Reference Format

Memory Map for 8K and 16K Registers

Memory Map for 1K Registers

Floating Point Arithmetic Display Format

Bus Controller Input Status Reference Definition

Fault Table Registers

Bus Controller Output Status Reference Definition

Register Format for Computer Mail Box

Series Six Plus CPU Indicators and Switches

Power Supply Output Voltage Terminals (TB1)

CPU Power Supply Block Diagram

PAGE

2-61

2-63

3 - 3

3 - 3

3 - 4

3 - 5

3 - 6

3 - 7

3 - 9

3 - 1 0

3-11

3 - 1 2

3-14

3 - 1 6

3 - 1 6

3-17

3 - 1 8

3 - 1 8

3 - 1 9

3 - 2 0

3 - 2 5

3 - 2 6

3 - 2 6

3 - 2 7

3 - 3 5

3 - 3 6

3 - 3 7

3 - 3 8

4 - 4

4 - 4

4 - 6

4 - 7

4-21

4-31

4 - 2 9

4 - 3 6

4 - 4 0

5 - 5

5 - 7

5 - 8


Contents

GEK-96602

FIGURES

Figure 5.4

Battery Mounting Clips and Connectors

5.5

5.6

CPU Power Supply Terminal Board

Input Voltage Terminal Board

5.7

Output Voltage Terminal Board for Standard Power Supply

5.8

Output Voltage Terminal Board for High Capacity

Power Supply

5.9

CPU to I/O Rack Configuration

5.10

I/O Rack to I/O Rack Configuration

5.11

Typical I/O Rack Wiring Scheme

5.12

Advanced I/O Receiver Status Indicators

Table 1

.1

1.2

1.3

1.4

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

1.5

1.6

1.7

1.8

1.9

2.1

2.2

2.3

2.12

2.13

2.14

2.15

2.16

2.17

2.18

2.19

TABLES

Series Six Plus PLC Features


Programming Functiona Groups

Standard I/O Modules

Genius l/O Blocks

Other Modules

Typical PLC Applications

Common PLC Terminology

Compatibility Guide Series Six Plus PLC vs Series Six PLCs

Power Supply User Items

Conditions Causing Alarms

Power Supply Specifications

I/O Control Module Indicators

Arithmetic Control Module Status Indicators

Combined Memory Modules

Scratch Pad Storage Items

Combined Memory Module Status Indicators

CCM2 Status Indicator Definitions l/O Rack and Power Supply Specifications l/O Point References and Register Mapping for

Expanded Mode Operation

I/O lnterf ace Modules

I/O Receiver Status Indicators

Status and Diagnostic Indicator Definitions l/O Transmitter Status Indicator Definitions

Typical System Response Times to Remote I/O

I/O Point Ranges in Remote I/O Stations

Remote I/O Driver Status Byte

Remote I/O Driver Status Indicators

1 - 2 4

2 - 5

2 - 7

2 - 7

2-10

2-14

2 - 1 6

2-17

1 - 4

1 - 5

1 - 9

1 - 1 2

1 - 1 3

1 - 1 3

1 - 2 2

1 - 2 3

2-18

2 - 2 3

2 - 3 0

2 - 3 5

2 - 4 2

2 - 4 5

2 - 4 8

2-51

2 - 5 3

2 - 5 4

2 - 5 6

2 - 5 7

PAGE

5-17

5-18

5-21

5-21

5-21

5 - 2 8

5 - 2 9

5 - 3 0

5 - 3 8


Contents

TABLES

Table 2.20

4.2

4.3

4.4

4.5

4.6

4.7

2.21

2.22

3.1

3.2

3.3

3.4

3.5

3.6

3.7

4.1

4.0

4.9

5.1

5.2

5.3

5.4

Remote l/O Driver Option Settings

Remote l/O Receiver Status indicator Definitions

Remote I/O Receiver Options

Combined Memory Modules

I/O Control Option Jumpers

Expanded I/O Channel Selection

Parallel I/O Chain

Cable

Catalog Numbers

CPU Rack Power Supply Capacities

Summary of Units of Load for CPU Rack Modules

Summary of Units of Load for I/O Modules

Memory Map for Expanded Mode I/O References

Reserved l/O References

Reserved Register References

Bus Controller Addresses for Diagnostic Storage

Decoding of Byte 6 for Circuit Fault Types

FauIt Types in Register 6

Analog I/O Block Reference Example

Bit Status Meaning for Analog Blocks

Bus Controller Status/Control Byte Definition

CPU Indicator Chart

Conditions Causing Alarm Relays to Switch

I/O Power Supplies

I/O Module Status indicator Definitions

xix

GEK-96602

PAGE

4 - 9

4-10

4-29

4-31

4-35

4-37

4-38

4 - 3 9

5 - 4

5-19

5-20

5-22

2-57

2-59

2-60

3 - 8

3-12

3-22

3-24

3-28

3-29

3-30

4 - 8



Introduction To The Series Six Plus PLC 1 - 1

GEK-96602

CHAPTER 1

INTRODUCTION TO THE SERIES SIX* PLUS


The Series Six Plus Programmable Logic Controller is an enhanced version of the Series

Six* family of programmable logic controllers.

The Series Six family of programmable logic controllers was first introduced in 1980

and

is used extensively in factory automation. Series Six Plus Programmable Logic Controllers are used worldwide in an ever growing variety of applications.

Programmable Logic Controllers (PLCs) are also referred to as Programmable Controllers

(PCs). In this manual, in order to avoid any confusion, we will refer to these electronic control devices as programmable logic controllers or PLCs, since the use of the acronym

PC is universally used when referring to Personal Computers.

WHAT ARE PROGRAMMABLE LOGIC CONTROLLERS?

Programmable logic controllers are general purpose microprocessor controls, that have been designed specifically for operation in the harsh environment usually encountered in the factory.

A programmable logic controller accepts data from input devices, such as limit switches, proximity switches, and sensors.

It then performs logical decisions in an orderly and repetitive sequence as determined by a program entered in memory by the user, and provides output control for machines or processes.

Input modules convert electrical signals provided by the input devices to logic levels for processing by the Central Processing Unit (CPU) and Output modules convert signals from the CPU to the proper electrical signals for control of machines or processes. The Input and Output (I/O) modules also provide electrical isolation, for signals in the CPU, from electrical noise typically found in the factory environment. Figure 1.1 is a basic block diagram of a programmable logic controller.

a42063

CPU

r ---v-- -I

1 mF@Mt,,/JER 1 * PREsOR

I

L

- - - - - -

-l

LOGIC STORAGE 4

MEMCRY’,

SUPPLY

I/O

+ O U T P U T S

POWER

SUPPLY

c-w

1

,’ FIELD ‘

DEVICES 1 i-i

Figure 1 .I PROGRAMMABLE LOGIC CONTROLLER BLOCK DIAGRAM


l-2

Introduction To The Series Six Plus PLC

GEK-96602

ADVANTAGES OF PROGRAMMABLE LOGIC CONTROLLERS

Programmable Logic Controllers offer many advantages over other control devices, such as electrical timers and counters, relays, and drum type mechanical controllers. Some of the many advantages to be considered when planning a system include:

-

-

-

-

Improved reliability, you do not need to be concerned with frequent breakdown of electro-mechanical devices.

-

Less space required, since a proliferation of relays, electrical timers, etc., are not needed

Easier to maintain.

Built-in diagnostics and reliable solid-state devices equate to few breakdowns.

When failures do occur, they are quickly detected and repaired. In fact, the revolutionary Genius* I/O system with its enhanced diagnostics, when used in the I/O structure, reduces failure detection and repair time to an absolute minimum.

Easily reprogrammed if control requirements change.

Flexibility - one device is able to perform many functions.

SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER

The Series Six Plus PLC is an extension of the Series Six family of Programmable Logic

Controllers; previously available models 60, 600 and 6000. The Series Six Plus PLC is available as a single 19” or 13” rack, (referred to as the CPU rack) that can be configured to meet the application requirements. Memory is available on a combined memory board that contains the internal memory, up to 64K of logic memory and up to 16K of register memory.

Up to 16K of I/O points (16K Inputs/l6K Outputs) are available to the user in a system.

All of the existing Series Six I/O modules are compatible with and can be used in a Series

Six Plus PLC system. The 6 left slots in the 19” CPU rack are available for I/O modules

(3 slots available for I/O in a 13” rack). If the PLC system is to include an Auxiliary I/O module, which must be placed in slot 6 or 7 (numbered from the right), 5 slots are available for l/O modules in the 19” CPU rack, or 2 slots in the 13” CPU rack.

When more than the 3 (13” rack) or 6 (19” rack) I/O modules that can be contained in the

CPU rack are required, standard Series Six I/O racks are available to add to the l/O system. I/O racks connected directly to the CPU through the I/O Control module can be located up to 50 feet (15 meters) from the CPU in a daisy chain in a CPU station. I/O racks in a Local I/O station can be located up to 500 feet (150 meters) from the CPU, connected by I/O Transmitters to I/O Receivers or Advanced I/O Receivers, through cables on the parallel I/O bus. Up to 4 I/O Transmitters can be used in series to allow up to 2400 feet (600 meters) from the CPU station to the most distant I/O Receiver.

In addition, the I/O racks in a Remote I/O station can be located up to 10,000 feet (3 km) from a CPU or Local I/O station, when connected by a serial link through a 2-pair twisted cable. For virtually unlimited distances between I/O racks or the CPU and I/O racks, connection can be made through a serial communications link using RS-232 compatible modems.



GEK-96602

Figure 1.2 is an illustration of a Series Six Plus Programmable Logic Controller showing the location of modules in the CPU rack. l/O and CPU racks are available as either

13” or 19” racks.

a4i !069

Figure 1.2 TYPICAL SERIES SIX PLUS PLC RACK



GEK-96602 l - 5


General specifications for the Series Six Plus PLC are listed below.

Table 1.2 GENERAL SPECIFICATIONS

Operating Temperature

Storage Temperature

Humidity (Non-Condensing)

AC Power Source

Frequency

Maximum Load

0 to 60°C (32 to 140°F)

(at outside of rack)

-20 to 70°C (-4 to 158°F)

5% to 95%

95 to 260 V ac

47 to 63 Hz

250 VA

DC Power Source

Maximum Load

20 to 32 V dc (24 V dc Supply)

Or

100 to 150 V dc (125 DC Supply)

180 VA

37 lbs. (17 kg>

Rack Weight, 19" (Filled)

Rack

Dimensions (19", 11 slots)

Rack Mount

19.0(W) x 14.0(H) x 10.3(D) inches

483 x 356 x 261 millimeters

Panel Mount 20.0(W) x 14.0(H) x 10.3(D) inches


Rack Dimensions (13", 8 slots)

Rack Mount

Rack Mount with Brackets for standard 19" Rack

Panel Mount (Brackets on sides)

Panel Mount (Brackets on Top and Bottom, Side by Side Mount)

Typical Battery Life, Loaded 1

Battery Shelf life, No Load 1

Typical Scan Rate (Relay Functions)

16.0(W) x 13.25(H) x 9.3(D) i n c h e s


19.0(W) x 13.25(H) x 9.3(D) inches


16.0(W) x 13.25(H) x 9.3(D) inches

13.25(W) x 16.15(H) x 9.3(D) inches

337 x 410 x 236 millimeters about 1 year

8 to 10 years

.8 mSec per K of user memory

Maximum Number of I/O Points

Normal Mode 2 2K Inputs

2K Outputs

Expanded Mode * 16K Inputs

16K Outputs

1.

Depending Upon Temperature

2.

Mode selected by enabling desired mode on the CPU Configuration Set Up Menu on a

Workmaster computer, using Logicmaster 6 software, Version 3.01 or greater.


1 - 6 Introduction To The Series Six Plus PLC

GEK-96602

GENIUS I/O SYSTEM

In addition to the standard rack-based I/O modules, the Series Six Plus PLC fully supports the Genius I/O system.

This revolutionary l/O system is a major improvement over existing l/O systems.

It can be mixed with the rack-based I/O or can comprise the total

I/O system. The Genius I/O is available in units called blocks, and includes both discrete and analog blocks.

Genius l/O blocks are connected to the Series Six Plus CPU through a Bus Controller by a single twisted-pair communications link. The total number of Bus Controllers in a system is limited only by the l/O capacity of the Series Six Plus PLC. Each Bus Controller can have up to 30 blocks connected to it in a daisy chain, thereby providing up to 480 addressable l/O points on each bus.

.

For detailed information on the Genius I/O system, refer to GEK-90486, the Genius l/O

System User’s Manual. Some of the many benefits of the Genius l/O system are as follows:

Each block is a stand-alone unit, no separate rack or power supply required.

Each discrete block can be configured to be inputs, outputs, or any combination of inputs and outputs.

Extensive diagnostics monitor not only the blocks, but also field devices.

There are no fuses to be concerned with, since the discrete outputs have built-in electronic fusing for circuit protection.

A convenient, easy to use Hand Held monitor is used for system configuration, calibration and troubleshooting.

Easier installation and troubleshooting, and fewer spare parts required in inventory provide a signif icant cost savings over traditional I/O systems.

a41057

SERIES~X PLUS figure 1.3 GENIUS l/O TYPICAL COMMUNICATIONS LINK



GEK-96602

1-7

PROGRAMMING THE SERIES SIX PLUS PLC

Programs are entered, edited, and monitored using the Workmaster* industrial computer or the CIMSTAR I industrial computer.

Programming the Series Six Plus with

Expanded II functions requires version 4.01 or later of the Logicmaster* 6 software.

Prior versions of Logicmaster 6 may be used to program the Expanded II instruction set provided that no Auxiliary I/O references are used (no Auxiliary I/O chain) and no

Expanded II features are required.

An lBM* PC, PC-XT or PC-AT personal computer can also be used with unbundled software.

For detailed information on programming the

Series Six Plus PLC, refer to the Logicmaster 6 Programming and Documentation

Software User’s Manual, GEK-25379.

a40532

Figure 1.4 WORKMASTER INDUSTRIAL COMPUTER

*IBM

is a registered trademark of International Business Machines Incorporated


1 - 8 tntroduction To The Series Six Plus PLC

GEK-96602

Workmaster

Industrial

Computer

The Workmaster industrial computer, with Logicmaster 6 software, is the main device used for developing and entering new user’s programs, editing existing programs, or real-time system monitoring of the PLC.

The Workmaster computer is built around a portable, industrial hardened, IBM* compatible personal computer. It can be configured to have either one or two diskette drives or one or two diskette drives

and

a 20 megabyte fixed hard disk.

The diskette drives are 3.5” drives.

The capacity of each diskette is 720 K bytes (double sided, double density) after formatting.

The small physical size of the diskettes makes them convenient to handle and store.

Once your program has been developed on the

Workmaster computer and stored on a diskette, it is retained for future use even through power fail conditions.

Other Software Packages

In addition to program development and entry for the Series Six Plus PLC, many other software packages can be run on the Workmaster computer by adding the required configure and monitor ProLoop Process Controllers; Modelmaster Factory Modeling

System, which is a graphically enhanced flexible modeling system used to simulate factory manufacturing facilities; Vumaster, an intelligent color graphics operator interface; Motionmaster, which provides a powerful tool for the development and maintenance of motion control software in conjunction with the Axis Positioning (APM1 and APM2) Modules; Alarm Master, which is used to create fault and alarm monitoring programs, and Logicmaster 1 and 3 software, which is used for developing and entering programs on the Series One family or Series Three PLCs.

In addition, there are a number of Vendor Logo software packages available for use with a Series Six Plus PLC system.

For information on other programs that can be run on the Workmaster computer, contact your local GE Fanuc - NA sales off ice or GE Fanuc Automation North America, Inc.,

Charlottesville, Va.



GEK-96602

Programming Lanquage for the Series Six Plus PLC

The basic programming language used by the Series Six Plus PLC is relay ladder logic.

This has been expanded to include instructions for applications more complex than those requiring only the basic relay ladder logic functions.

Three versions of programming instruction sets are available, Advanced, Expanded, and Expanded II. The instruction sets are contained in PROMS on the appropriate Logic Control module. The version of the module must be selected, depending on the programming (instruction set) requirements (Advanced Functions, Expanded Functions, or Expanded II Functions.

The Expanded functions include a group of 7 instructions that provide the capability for floating point math calculations to be performed. Several other functions are enhanced to expand their capabilities to allow their use with the full 32K of l/O and 16K of user accessible 16-bit data registers and permit the use of the powerful Genius I/O diagnostics. The Expanded II functions include all of the functions available with the

Expanded functions. Additionally, instructions are included for accessing a new I/O system to be available in the future, and changes in the microcode have been made to allow operation which provides faster execution of ladder logic programs. Available programming functions are listed below.

Table 1.3 PROGRAMMING FUNCTIONAL GROUPS

RELAY

ARITHMETIC

CONTROL

MOVE/CONVERT

ADVANCED FUNCTIONS

Normally Open and Normally Closed Contacts

"Real World" Output Coils

Internal Coils

Latches

One-shots

Timing

(0.01, 0.1, and 1.0 Second Increments)

Counting (up and down)

Auxiliary I/O References

Addition

Subtraction

Compare

Shift

1

Unsigned Binary

Double Precision

Addition, Subtraction Signed 2's

Multiply, Divide

Greater Than

I Complement

Master Control Relay and Skip

Do Subroutine, Do I/O

Suspend I/O, Return, Status

Data Moves

I/O Table to Register

Register to I/O Table

Table To Destination

Source To Table, Move Table, Move Table Extended

Move Right 8 Bits, Move Left 8 Bits

Block Move, Move A To B

Convert

Binary to BCD, BCD to Binary


l-10

Introduction To The Series Six Pius PLC

G E K - 9 6 6 0 2

Table 1.3 PROGRAMMING FUNCTIONAL GROUPS(Continued)

- ADVANCED FUNCTIONS (Cont.1

COMM. REQUESTS

DPREQ and SCREQ

MATRIX

AND

Inclusive & Exclusive OR

Invert

Masked Compare

Set/Sense

Clear/Sense Bit

Shift Right

Shift Left

LIST

MISCELLANEOUS

Add to Top

Remove from Bottom

Remove from Top

Sort

End of Sweep, NO OP

RELAY

ARITHMETIC

CONTROL

EXPANDED FUNCTIONS

All Advanced Functions plus:

Valid Reference Range Expanded for

Full 32K I/O Points; an additional 68K of discrete references and 16K Registers


Floating Point Functions

Add, Subtract, Multiply, Divide

Greater Than

Integer to Floating Point

Floating Point to Integer


Do I/O enhanced and Status enhanced

COMM. REQUESTS

MOVE/CONVERT

MATRIX,

LIST

Miscellaneous

SCREQ - Same as Advanced

DPREQ Enhanced

All Advanced Functions



EXPANDED

II

FUNCTIONS

All Advanced

and Expanded

-Support of 64K User

-Auxiliary I/O overrides.

Functions plus:

-Changes in system microcode which provides faster execution of ladder logic.

-Dynamic user program memory checksum calculation.

-Detection of active overrides in system.

- Instructions added to allow accessing a future I/O system.

Logic

memory.


introduction To The Series Six Plus PLC 1 - 1 1

GEK-96602

PROGRAMMABLE LOGIC CONTROLLER CONCEPTS

When using a new product for the first time, there are always new concepts and terms to become familiar with. Although PLCs are easy to install, program, and apply, there are some simple principles to follow. The following paragraphs describe the components of a

Programmable Logic Controller.

Function of the Central Processor Unit

The Central Processor Unit (CPU) is basically a microprocessor containing the circuitry that performs logical decision making functions.

It reads in the status of the control system, makes decisions based upon the logic that has been programmed, and then provides decisions to the actuating portion of the control system.

The CPU also performs self checking of its internal operation to ensure reliable operation. This is done by a circuit called the watchdog timer. The watchdog timer is a hardware timer set at 300 ms +/-50 ms to ensure that memory or internal circuit faults do not cause the CPU to enter an endless loop because of hardware failure. If a scan is not completed at least once every 300 ms +/-50 ms, the hardware will shut the CPU down and turn the outputs OFF. If an error is detected, it will shut itself down. The logic entered by the programmer is actually stored in the CPU along with data storage and storage for the operation of timers and counters.

Memory Types Used in the Series Six Plus PLC

All memory for the Series Six Plus PLC is located on one module, which is the Combined

Memory Module.

This module contains all internal, register, and logic (user) memory.

The memory provided for these storage functions is normally measured in K words, where

K is an abbreviation for kilo or 1024. Typically, one word is required for storage of each function such as a relay contact, timer preset or timer storage. These words can be of various lengths such as 16 bits, 8 bits, or even 4 bits, with a bit being the lowest level of measurement and can have only two states (on or off). The Series Six Plus uses the most common measurement, 16 bits per word. The number of words required per function wilI vary, however, with the more complex functions requiring up to 6 words each.

The most common type of memory used in PLCs to store both logic and data is CMOS.

CMOS is an acronym commonly used for CMOS RAM (Complimentary Metal-Oxide

Semiconductor, Random Access Memory). CMOS is a fast, low power memory that can be easily examined (read) and changed (written).

However, it is volatile, in that it can lose its content if power is removed.

To avoid reloading memory (and losing counts and system status) every time power is turned off, the CMOS memory is provided with a Lithium-Manganese Dioxide battery to maintain its content (not system operation) when power fails. Due to the low power drain of CMOS technology, a single new lithium battery can maintain memory without application of power for up to 1 year. The battery is not used when power is applied and the system is operating normally. Its storage or shelf life is typically 8 to 10 years.

A dynamic user program memory checksum is available when the Expanded II Logic

Control module option is selected.

The user program checksum feature provides more data integrity within the user program.

It traps certain types of errors not caught by memory parity checking.


1-12 Introduction To The Series Six

Plus

PLC

G E K - 9 6 6 0 2

Function of the Input/Output Circuitry

The final element of a PLC is the Input/Output section. Electrical noise such as spikes on the power lines, inductive kickback from loads, or interference picked up from field wiring is very prevalent in industrial applications.

Since the CPU operates at relatively low voltage levels (typically 5 volts), this noise would have serious impact on its operation if allowed to reach the internal circuits of the CPU.

The I/O section, both inputs and outputs, protects the CPU from electrical noise entering through the I/O modules or wiring.

The I/O section is where status signals are filtered to remove noise, voltage levels are validated, and where decisions made by the CPU are put into operation.

Inputs

provide their status to a storage area within the CPU and outputs are driven from similar stored status in the CPU.

For detailed information on the I/O module types and capacities available for use with a

Series Six Plus PLC, refer to the Series Six Data Sheet Manual, GEK-25367 and the

Genius l/O User’s Manual, GEK-90486. The exact type of l/O module to be specified, for example, 115 V

ac

or 24 V dc, is usually determined by the field device selected by the user. Tables 1.4 and 1.5 list the available I/O modules.

Table 1.4 STANDARD I/O MODULES

MODULE TYPE

NUMBER OF CIRCUITS AND I/O CAPACITY

INPUT OUTPUT

115 V ac/dc

115 V ac Isolated

115 V ac Protected

120 V dc

220 V ac/dc

220 V ac Isolated

12 V dc

24 V dc

48 V dc

5V TTL

10 to 50 V dc

6

8

8

6 (ac/dc)

8 (ac/dc)

8 (ac/dc)

8 (ac/dc)

32

32

8 (2 Amp

6 (3 Amp)

4 (4 Amp)

ac,

1.5 Amp dc)

8 (2 Amp)

8 (2 Amp)

6 (3 Amp)

8 (2 Amp

Sink/Source)

8 (2 Amp Sink/Source)

8 (2 Amp Sink/Source)

32 (25 mA)

32 (250 mA Sink)

(500 mA Source>

Reed Relay

Analog (12 bit)

0 to +l0 V dc 8

4 to 20 mA/+l to +5 V dc

-10 to +lO V dc

4

to 20

mA

6 (100 Va Max) NO or NC

4 (5 mA Max.)

a

4 (+/-5 mA Max.>

4 (20 mA Max.)

Thermocouples (12 Bit)

(Types 3, K+, S, T, B, f, R)

Interrupts 8

8


Introduction To

The

Series

Six Plus PLC

GEK-96602

Table 1.5

GENIUS I/O BLOCKS

BLOCK TYPE

115 V ac Grouped

115 V ac/dc Isolated

24 to 48

Analog,

V dc Source

24 to 48 V dc Sink

12-bit

Analog, 12-bit

Relay Output, NC

Relay Output, NO

RTD Input

RTD Input

CURRENT/VOLTAGE

2 A, Total 15 A

2 A, Total 16 A

2 A, Total 16 A

2 A, Total 16 A

115 V

ac

Power Source 4 In/2 Out

24 to 48 V dc Power Source

115/230 V ac, 2A

115/220 V

NUMBER OF CIRCUITS

8

8

16

16

ac, 2A

4 In/2 Out

16

16

115 V ac/125 V

dc 6

24 to 48 V dc

6

In addition to l/O modules, other available modules include system interface modules, communications modules, and intelligent modules.

Table

1.6 OTHER MODULES

SYSTEM INTERFACE MODULES

Local

>

I/O

Receiver

Remote



COMMUNICATIONS MODULES

Control Module, Type 2

Multi-Mode Protocol, Master/Slave/Peer

CCM3

Communications Control Module, Type 3

Has Functionality of CCM2 and Also Interfaces To

Process Controllers

I/O Link Local Interfaces To Series

One

and Series Three PLCs.

Allows I/O Communications with

Those PLCs.

I/O

CCM

Functionality of CCM3 in an I/O slot

LAN Interface Local Area Network Interface Module provides a direct LAN attachment to IEEE 802.4 carrierband network, has two communication services for

control

data transfer, and provides extensive station configuration, management and diagnostic tools

INTELLIGENT MODULES

Axis Positioning, Type 1 (Resolver)

Axis Positioning, Type 2 (Encoder)

High Speed Counter

ASCII/BASIC

Loop Management


1-14 Introduction To The Series Six Plus PLC

GEK-96602

OPTIONAL DEVICES SUPPORTING THE SERIES SIX PLUS PLC

Several devices

are

available as options for the Series Six Plus PLC system. These devices enhance a PLC system by providing capabilities not provided by the PLC itself.

Redundant

Processor Unit

The Redundant

Processor

Unit (RPU) allows two CPUs to operate in parallel, connected to one I/O structure within one system.

A fault in either system can be detected and alarmed, and the alternate CPU will continue system operation. The RPU also allows a second I/O structure to be added to the system, which allows switching between CPUs or

I/O systems. For

a

detailed description and operation of the RPU, refer to the Series Six

Redundant Processor Unit Manual, GEK-25366.

CPU#2

94tmp8

TO

AUXlLlhRY l/o UODULE

CPU1 Ak CPU2

I I

ON/OFFPOWER SWlTCH

I

PU1/AUTO/CPUZ

1

TO AUXlLlARY l/o

C;AlN NO. I AND HO.2

1

I I T%il’6eL

ALARM

TERMINALS

I/O CHAlN NO. I

I/O CHAIN NO.2

Introduction To The Series Six Plus PLC 1 - 1 5

GEK-96602


The Operator Interface Unit (OIU) is an ASCll device that can be driven by the CCM2 or

CCM3 module. This unit allows an operator to access, for the purpose of displaying or altering, register data, l/O states, I/O override status, and timer or counter operation.

Up

to

8 OlUs can be connected to one CPU. A detailed description of the OlU can be found in the Series Six Data Sheet Manual, GEK-25367.

6830103

Figure 1.6 OPERATOR INTERFACE UNIT


The Operator Interface Terminal (OIT) is an industrial hardened CRT terminal, designed for use in the factory environment.

The OIT connects to the CPU through an

ASCII/BASiC module, providing a powerful tool for monitoring and interfacing to a control system.

The OIT provides CRT background screens for the display of status from the CPU. The user can configure the screens to allow the displays to fit a particular application.

Detailed information on operation and configuration of the OIT can be found in the Operator Interface Terminal Manual, GEK-90817.

a41087

Figure 1.7 OPERATOR INTERFACE TERMINAL


1 - 1 6 Introduction To The Series

Six Plus PLC

GEK-96602

P r o L o o p Process

Controllers

The Protoop Process Controllers are a group of analog control devices that can be integrated into any Series Six Pius PLC system.

Each ProLoop Controller can operate independent of, or under the supervision of a Series Six Plus PLC. The ProLoop

Controller system is suitable for applications requiring precise control of temperatures, fluid levels, fluid flows, or pressures.

The ProLoop Controllers are available in a variety of configurations, including Single

Loop, Auto Tune, and Multi Loop.

The Loop Management Module (LMM) is the interface from the ProLoop Controllers to a PLC. Command and setup information is passed from the PLC to the ProLoop Controllers and status information is returned from the ProLoop

Controllers to the PLC.

The ProLoop Controllers can be programmed using a low-cost Hand Held Configurator, which plugs into the front panel of a ProLoop Controller, and allows access to digital information in the ProLoop Controller.

For more convenient programming of the

ProLoop Controllers, the Processmaste r software package is available. This software package configures

a

series of screens on the CRT of a Workmaster computer or on the

Operator Interface Terminal.

This allows the ProLoop Controller system to be easily configured by moving the cursor and entering the proper data.

For complete information on the ProLoop Process Controllers, refer to the ProLoop

Process Controllers System Manual, GEK-90802.

a40315 f’R 0 LO 0 p SINGLE LOOP CONTROLLER

PROCESS

VARIABLE

II

VERTICAL

BARGRAPHS

POWER-ON

1NDlCATlON

Figure 1.8 TYPICAL PROLOOP SYSTEM EQUIPMENT


Introduction To The Series Six Plus PLC 1-17

GEK-96602

ASCII/BASIC Module

The ASCII/BASIC Module is an intelligent module, which under control of a built-in

BASIC programming language, GE/BASIC, can manipulate and transfer data to and from a

Series Six Plus CPU. This module can be programmed to read the contents of the scratch pad, any register or status tables (status tables in the Main I/O chain or channels 0 and 81 in a CPU.

In addition, this module, under program control can write data into the

registers and status tables.

An ASCII/BASIC Module has two configurable serial ports, which give it the ability to interface to external devices using either RS-232, RS-422 or 20 mA current loop, with data rates up to 19.2 K bps. Through these ports, the module can communicate with devices using an ASCII code. These devices typically can be printer terminals, bar code readers, CRT terminals, other computers and other ASCII/BASIC Modules.

The ASCII/BASIC Module can also be used as a stand-alone microcomputer with

GE/BASIC developed programs entered, edited, and run independent of the CPU.

The ASCII/BASIC module is available in two versions. Catalog Number IC600BF944 which provides l2K bytes of user memory and Catalog Number IC600BF949 which provides 28K bytes of user memory.

Each module requires a single I/O slot and must be installed in a CPU rack or High Capacity l/O rack.

For detailed information on the installation, theory and use of the ASCII/BASIC Module, refer to the ASCII/BASIC Module Manual, GEK-25398.

Axis Positioninq Modules

The Axis Positioning Modules (APMs) are intelIigent programmable, single axis positioning controllers that require only a single slot of a High Capacity I/O rack or a CPU rack.

They provide a real time interface between a Series Six Plus PLC and a servo or stepper controlled axis and thereby fully integrate closed-loop position or velocity control with overalI machine control.

The APMs are programmed and monitored using the Workmaster computer. Commands and return data are passed to and from an APM through 32 consecutive inputs and outputs. The various parameters exchanged between an APM and CPU user logic include discrete commands, set up commands, move commands and special commands in the output group and in the input group; discrete return data and return data.

The APM is available in two versions. Catalog Number IC600BF915 is APM Type 1

(Resolver Feedback) and Catalog Number IC600BF917 is APM Type 2 (Encoder Feedback).

For detailed information on Axis Positioning Modules refer to the applicable user’s manual. These manuals are:

Axis Positioning Module, Type 1, GEK-25368.

Axis Positioning Module, Type 2, GEK-90800.



In addition to controlling peripheral devices, the Communications Control Modules (CCM) provide for communications among all of the GE Fanuc - NA PLCs, which include the

Series Six Plus, Series Six, Series Three, Series One Plus, Series One, and Series One

Junior.

In addition, the Workmaster and Cimstar I computers, Operator Interface

Terminals and host computers can be included in a communications system.

These devices all use the C C M protocol which supports point-to-point and multidrop configurations with data rates from 300 to 38.4K baud. A master CCM device such as the

Series Six Plus PLC can poll up to eight slave devices controlled by the Communications

Request function (SCREQ).

GENET Factory LAN

For applications requiring much broader communications capabilities than the CCM can provide or a Local Area Network (LAN) for communications with other factory automation equipment, the GEnet Factory LAN is available. The GEnet Factory LAN is a

10M bps broadband token passing bus which provides high speed communications between

GE Fanuc

- NA equipment, including Programmable Controllers, Numerical Control equipment and higher level factory level management control systems.

The GEnet Factory LAN is based on accepted industry standards. It uses the

International Standards Organization’s Open System Interconnection (OSI) model as the basis for its communications architecture.

GEnet complies with the General Motors

Manufacturing Automation Protocol (MAP) specification and with the ANSI/IEEE

Standard 802.4-1985 for token bus networks.

The Programmable Controllers and Numerical Control equipment interface to the broadband token bus through a Bus Interface Unit (BIU). The BIU is tailored by loading device specific software to provide the required interface to the various automation products. As an example, any device supporting the CCM protocol can access the GEnet

Factory LAN with translation to MAP through the BIU.

Other basic components of the GEnet Factory LAN are the Network Management Console

(NMC) and the Head End Remodulator. The NMC provides overall system configuration management and control.

It operates on a Workmaster or Cimstar I industrial computer equipped with PLC-BIU hardware and network management software. The head end contains the equipment required to provide for RF operation on the broadband cable.

For further information on the GEnet Factory LAN, refer to the System User’s Manual,

GEK-96608 and the Network Management Console User’s Manual, GEK-96607.



GEK-96602

Figure 1.9 is an illustration of a typical configuration for a GEnet Factory LAN.

1 - 1 9

a 4 1 0 5 1

2000 CNC

With MAP Option

Series Six Family

With CCM

Series Six Family

With CCM

Series Three Family

Series One Family

With DCU

Head End

Remodulator w

Other MAP

Compliant

D e v l c e s

I I c

P

CCM MAP z:

-0

E

Interface

T - -

Software

BIU

RS-422 Multidrop

CCM Communications Bus l0Mb/s Broadband Token Bus

R

CCM

DEC, HP, or

IBM Host

Workmaster

Third Party

Graphics Station

With CCM support figure 1.9 GEnet FACTORY LAN


1-20 Introduction To The Series Six Plus PLC

GEK-96602

Series Six PLC Network

Interface

The

Series Six PLC Network (or LAN) interface modute is

a

member of the family of

GEnet Factory LAN communications products. The Series Six LAN Interface module provides a direct connection for a Series Six Plus PLC to a carrierband network. The

LAN consists of two boards (controller board and modem board) which plug directly into slots 5 and 6 of the Series Six Plus CPU rack. The LAN Interface module connects directly into the carrierband cable plant through the 5 Mbps carrierband modem board.

Intermediate devices such

as

bridges or gateways are not required. The direct connection provides the high performance required for real-time applications. Carrierband networks are designed to handle small to medium size applications with 6 to 20 stations as a typical number which might be attached, although more stations can be connected. Carrierband networks can extend over cable distances as far as 2000 feet.

a4

1993

CARRIERBAND NETWORK

LAN INTERFACE

MODULE

SERIES SIX

PLUS CPU

.

IAN INTERFACE

MODULE

I

SERIES SIX

PLUS CPU

IAN INTERfACE

MODULE

SERIES SIX

PLUS CPU

I NETWORK 1

1 MANAGEMENT 1

] CONSOLE 1 f ‘OFfEU ;

FIGURE 1.10 - LAN Interface Module Connects a Series Six Plus

PLC to a Carrierband Network

Datagram Communications Service

There are two types of communication services which transfer control data on the net work.

They are the Datagram Communication Service and the Global Data

Communication Service.

The Datagram service is a real-time service which provides peer-to-peer message transfers (read and write messages) from one station on the network to another. Each request must be explicitly initiated in the ladder logic program using the Series Six Serial Request [SCREQ] instruction, and the initiating station receives immediate acknowledgement that the data was or was not transferred successfully. The

Datagram service anticipates MAP/EPA specifications and will evolve to comply with them when they are approved as standards.

Datagram services should be used to send messages which are destined to

a

single station or whose delivery must be guaranteed.


Introduction To The Series Six Plus PtC 1 - 2 1

GEK-96602

Global Data Service

Global Data service is a proprietary, real-time protocol which provides a means of sharing data (such as blocks of registers or l/O points) among a group of stations. Once a request is initiated using a single

[SCREQ]

instruction, data continues to be transferred at a rate specified in the request.

This service is not part of the MAP specification, but co-exists on the network with MAP messages without interference. Global Data services should be used when the application requires that data must be updated on a periodic basis and shared by multiple stations on the network.

In distributed control applications it allows I/O points wired to one PLC to be made available to other PLCs quickly and with minimum intervention by the ladder logic.


The RS-232 to RS-422 Adaptor Unit converts RS-232 signal levels to RS-422 signal levels and can be used to isolate and repeat communications signals. If a device uses RS-422 signal levels for communications, the Adaptor, when connected between those devices and devices requiring RS-232 signal levels can be used with no loss in baud rate. The

Adaptor unit also has a multidrop capability that can expand a normal eight device

RS-422 link into a 64 device link by using eight Adaptor units. If an RS-422 link should be required to extend beyond its normal 4000 feet (1.2 Km), the Adaptor can be used as a repeater to boost the signal levels and obtain another 4000 feet of driving distance for the signals.

a42088 figure 1.11 RS-232 to RS-422 ADAPTOR UNiT


1 - 2 2 Introduction To The Series Six Plus PLC

GEK-96602

SYSTEM PLANNING

Decisions such as the number of 115 V ac solenoids, 24 V dc solenoids, motor starters, limit switches (operating voltages), control panel lamps (voltage required), pushbuttons, and external relays have a major impact on the configuration of any PLC. These parameters should be established as early as possible in the overall design of the control system. Being a flexibte device, the PLC configuration, either on paper or in hardware, can easily be changed if requirements change.

Typically, the user provides the field devices, wires them to the I/O section, and provides the power source to operate them.

TYPICAL APPLICATIONS USING PLCs

Programmable Logic Controllers are used in a wide variety of machine and process control applications. These applications range from replacing a few relays to controlling complete factory automation projects.

Table 1.7 is a list of typical applications for the

Series Six Plus PLC. This list is only a very small sampling of possible PLC applications, many others are possible and more are being identified all the time For further information on any of the applications listed here or any other application you may have, contact your local GE Fanuc - NA Programmable Logic Controller Distributor, GE Fanuc

- NA sales office or GE Fanuc Automation North America, Inc. in Charlottesville,

Virginia.

Table 1.7 TYPICAL PLC APPLICATIONS

I i

Auto Insertion

Bagging

Baking

Bonding

Boxing

Capping

Casting

Cement Batching

Combustion Control

CompressIon Mol

ding

Conveyors

Cranes

Cutting

Data Collection

Dipping

Drawing

Drilling

Energy Management

Engines

Engine Test Stands

Extrusion

Forging

Gas Fields

Gauging

Generators

Grinding

Heat Treatlng

Injection Molding

Joining

Milling

Mining Operations

Navigation

Nuclear Plants

Oil Fields

Pipelines

Railroad Switching

Robots

Rolling

Routing

Security Systems

Sewage Treatment

Solar Energy

Sorting

Spool winding

Stackers

Tire Body Building

Traffic Control

Treating

Turbines

Water Treatment

Weaving

Welding

Well Flooding


introduction To The Series Six Plus PLC

GEK-96602

1-23

PLC TERMINOLOGY

In the preceding discussion of Programmable Logic Controller concepts, many terms were discussed that you should be familiar with relating to PLCs. Table 1.8 provides a list of the most common PLC terms.

A more complete list of terms is provided in the glossary

in

the

back

of this manual.

Table1.8 COMMON PLC TERMINOLOGY

TERM

PLC

DEFINITION

Programmable Logic Controller or Programmable

Controller.

An industrial control device using microprocessor technology to perform logic decision making with relay 1adder diagram based programming.

Programmer A device for entry, examination and alteration of the

PLC's memory including logic and storage areas.

Logic

CPU

A fixed set of responses (outputs) to various external conditions (inputs). All possible situations for both synchronous and non-synchronous activity must be specified by the user. Also referred to as the program.

Central Processor Unit - the physical here.

unit

in which the

PLC's intelligence resides.

Decision making is performed

Memory

K

A physical place to store information such as programs and/or data.

An abbreviatlon for kilo or exactly 1024 in the world of computers.

Usually related to 1024 words of memory.

Word

CMOS

A measurement of memory length, usually 4, 8, or 16 bits long.

In the Series Six Plus PLC, 16 bits.

A read/write memory that requires a battery to retain its content upon loss of power.

PROM A read only memory that requires a special method of loading, but is inherently retentive upon power loss.

I/O Input/Output - that portion of the PLC to which field devices are connected.

Isolates the CPU from electrical noise.

Noise Undesirable electrical disturbances to normal signals generally of high frequency content.


1 - 2 4 Introduction To The Series Six Plus PLC

GEK-96602

Table 1.8 COMMON PLC TERMINOLOGY (Continued)

Input A signal, typically ON or OFF, that provides information to the plc.

output A signal typically ON or OFF, originating from the PLC with user supplied power to control external devices based upon commands from the CPU.

field Devices User supplied devices typically providing information to the PLC (Inputs: pushbutton, limit switches, relay contacts, etc.) or performing PLC tasks (Outputs: motor starters, solenoids, indicator lights, etc.).

PLC COMPATIBiLITY GUIDE

Most of the hardware and software items can be used by both the Series Six Plus and the earlier models of the Series Six CPU’s As an aid to the compatibility of these items, a basic compatibility guide is provided in table 1.9. For comprehensive information on compatibility of equipment, contact your GE Fanuc - NA sales office or PLC Distributor

Table1.9 COMPATIBILITY GUIDE

SERIESSIX PLUS PLC VS SERIES SIX PLCs

Catalog Number

Description

60

Model of PLC

600

6000 6+

Power Supplies

IC6OOPM5OO

IC600PM541

IC6OOPM546

CPU Racks, 8-Slot

IC6OOCP610

115/230 V ac Power Supply

24 V dc Power Supply

125 V dc power Supply

CPU Racks, 11-Slot

IC600CR201

IC6OOCR301

IC600CR401

IC600CP600

Memory

IC600CM552

IC6OOCM554

IC6OOCM544

IC600CM548

2K Logic/256 Registers

4K Logic/1K Registers

4K Logic

8K Logic

1.

Required for Expanded

II

functions.

2.

Parity checking is not available with this combination.




Physical Equipment Configuration 2 - 1

GEK-96602 --

CHAPTER 2

PHYSICAL EQUIPMENT CONFIGURATION

This chapter describes the components of a Series Six* Plus Programmable Logic

Controller.

Included are descriptions of the Central Processing Unit, power supplies, combined memory modules, racks, optional modules, system configuration, standard rack-based l/O system, Genius* I/O subsystem

and

peripheral devices. For a complete

list of available hardware and software, refer to GEP-761, Products and Publications

Master Price List. For further information on any of the individual components described in this chapter

that

are not part of the CPU, refer to the applicable manual.

PRODUCT STRUCTURE FOR THE SERIES SIX PLUS PLC

The product structure for the Series Six Plus PLC is such that many different configurations, including combinations of l/O modules, may be contained in a single CPU rack. The design is flexible to meet the user’s requirements. Figure 2.1 illustrates this product structure, showing the location of modules in the rack.

a422

13

SLOT NUMBER +

f-

ill IO 9 8 7 6 5 4 3 2 II

-

I

A 1 I r

!?I

L

‘:oco’

T 1

H C C

M

E C : :

: ; ii

C

T 0

R L oc OL

+I3"RACK HAS 8 SLOTS

WITHUP TO 4SLOTS

AVAILABLE FOR

I/O MODULES

IT---~ 1 1

I/O MODULES 14OR 6 SLOTSIA

- P R O G R A M M I N G F U N C T I O N

1 1 1 ) 1 ) lRE&JiRED OPTIONI

ADVANCED,EXPANDED,OR EXPANDED It

DISCRETE,ANALOG,APMlR,

ASCII/BASIC,I/O CCM, l/O TRANSMITTER,HIGH SPEED

COUNTER,REHOTE l/o DRIVER,

GENIUSBUS CONTROLLER,

I/O LINK LOCAL

I/O OR AUXILIARY I/O -

I I

LAC (95-260 VACI

DC (20-32 VDC OR 100-150 VDCI

INCLUDED WITHBASIC RACK

~LOGICiREGISTER MEMORY

REQUlRED OPTION) l/O,AUXlLMRY l/O OR -

LOCAL AREANETWORK

(LAN ISA2SLOTOPTIONl

- AUXILIARY I/O,COMMUNlCATlONS

CONTROLOR LOCALAREANETWORK

[LAN ISA2SLOTOPTION1

Figure 2.1 PRODUCT STRUCTURE FOR SERIES SIX PLUS PLC

Each of the modules shown in figure 2.1 is described on the following pages. The descriptions include information relative to module location in the rack, and the function of each module in the system. For installation instructions, refer to Chapter 3.


2-2

Physical Equipment Conf igutation

GEK-96602


The 19 inch (483 millimeters) rack used to contain the Series Six Plus PLC modules is designed for either 19 inch rack or panel mounting. Figure 2.2 is an iIlustration of the rack. Each rack is supplied with reversible mounting brackets for mounting as required by the user. With the brackets attached to the front of the rack as shown in figure 2.3, mounting them on the rear of the rack,

as

shown in figure 2.4, the rack can then be either wall or panel mounted.

Each rack has 11 slots to accommodate modules. For reference purposes these slots are numbered from 1 through 11, beginning at the right slot (next to the power supply). The slot number is printed on the rack backplane adjacent to the bottom board slot. Slots 6 through 11 can contain l/O modules.

Any module in the I/O system can be placed in any of these slots as long as their total power requirements, in addition to the power requirements of the CPU modules, do not exceed the power output of the power supply, which is 16.5 amps (275 units of load) for +5 V dc, 1.5 amps (60 units of load) for +12 V dc and 1 .O amps for -12 V dc (40 units of load). A list of the power requirements, expressed in units of load, for each I/O module is included in Chapter 3, Installation.

If an Auxiliary I/O module is added to a system, it can be placed in slot 5, 6 or 7. If the

GEnet Series Six Network Interface LAN (Local Area Network), which is a two-board module, is required for a system those modules must be placed in slots 5 and 6, which would then require the Auxiliary I/O module to be placed in slot 7. Slots 1 through 4 are for the I/O Control, Logic Control, Arithmetic Control, and Combined Memory, in that order. If a Communications Control module is selected, it is placed in slot 5.


The 13 inch (330 millimeters) rack is designed to be mounted several different ways, including rack mount in a I0” deep rack (brackets on front), rack mount in a standard 19" rack (wide brackets on front), panel mount (brackets on rear sides), and panel mount in a

NEMA 12 wide (30”) enclosure (brackets on rear top and bottom). When mounted in a

NEMA 12 enclosure,

two

CPUs can be mounted side-by-side. Each 13” rack has 8 slots available to accommodate modules. The slots are numbered from 1 through 8, beginning

at

the right slot, next to the power supply. All of the modules are located in the same position in the slots as in the 19” rack with either 1 or 3 slots available for I/O modules.

The 13” rack requires the wide range ac power supply, catalog number IC600PM500.

Basic Unit Configuration

The Series Six Plus PLC basic CPU unit, as received from the factory, consists of a rack with cable tray,

a

power supply, an I/O Control module, an Arithmetic Control module and connecting ribbon cable (to the Logic Control module), a module extraction/insertion tool, an I/O terminator plug, rack mounting brackets and hardware,

and

a Series Six Plus

User’s Manual.

Any blank faceplates that are required must be ordered separately. The

Logic Control module must be ordered separately for the required level of functions, either Advanced, Expanded, or Expanded II. One of six available Combined Memory modules must also be selected and ordered separately. The required power supply for the

19” rack must be specified and can be either the wide range ac version or one of the two dc versions (24 V dc or 125 V dc). The only power supply currently available for the 13” rack is the wide range ac supply. The Expanded II functions require the IC600CB524

Arithmetic Control module, the IC600CB610 8-slot CPU rack, or a 19" CPU rack having a date code later than 10/87, and one of the lC600LX logic memory modules (8K minimum

registers.


Physical Equipment Configuration

GEK-96602

S L O T 1 1 1 1 S L O T S F O R M O D U L E S

SLOT 1

2-3

a41058

Figure 2.2 BASIC CPU RACK CONFIGURATION FOR

THE SERIES SIX PLUS PLC

~6830 124

Figure 2.3 BRACKETS IN POSITION

FOR RACK MOUNTING

Figure 2.4 BRACKETS

IN

POSITION

FOR WALL OR PANEL MOUNTING


2-4


GEK-96602

POWER SUPPLY FOR THE SERIES SIX PLUS PLC

The rack power supply is mounted at the extreme right of the rack as shown in the illustration in figure 2.2. The power supply provides

regulated

+12, -12 and +5 V dc to the rack backplane. It is used. to power the GE Fanuc supplied modules contained in the rack. Input and Output field devices must be supplied with their own source of power at the proper voltage levels.

The power supply is a high-capacity supply and is available for the 19” rack in three versions, wide range ac, 24 V dc, or 125 V dc. The 13” rack requires the wide range ac supply. The current capacity of each power supply is 275 units of load.

Each unit of load corresponds to approximately 60 mA of current consumption.

The ac power supply (catalog number IC600PM500) is a wide range switching supply, that will accept an ac input ranging from 95 to 260 V ac at 47 to 63 Hz. The two dc power supplies that are available can be operated directly from a dc power source, such as batteries or inverters, that provide dc power in the range of 20 to 32 V dc (catalog number IC600PM541), or 100 to 150 v dc (catalog number lC6OOPM546). Each power supply has several user items mounted on the faceplate.

Figure 2.5 illustrates the power supplies (ac version shown), identifying user items. A

C

and dc version faceplates are both shown for reference.

s6830116/117

s6840224/244

-

1. Internal Terminal Strip

2. Chassis Ground Terminal

3. 18-Pin Connector: Connects signal cable from rack backplane.

4. Front-Panel Connector Block

5. Power Switch/Circuit Breaker

6. CPU RUN/STOP Key Switch

7. MEMORY PROTECT Key Switch

8. POWER Light.

Figure 2.5 ILLUSTRATION OF POWER SUPPLIES



GEK-96602

2-5

Each of the power supply user items shown in the preceding illustration is described below. For detailed information on installation of a power supply, refer to the applicable data sheet in the Data

Sheet manual; wide range ac supply (GEK-83505), 24 V dc supply

(GEK-90761), or 125 V dc supply (GFK-0065)

.

Table 2.1 POWER SUPPLY USER ITEMS

USER

ITEM

LOGIC POWER

SWITCH

CPU RUN/STOP

KEYSWITCH

MEMORY

PROTECT/WRITE

KEYSWITCH

POWER LIGHT

TERMINAL BLOCK

DESCRIPTION

This switch is used to switch the ac or dc power source to the supply ON and OFF.

This keyswitch is used to put the CPU in either the RUN or STOP mode. With the CPU in the RUN mode, normal scanning operation takes place and outputs are activated.

In

the STOP mode, scanning is halted and outputs are deactivated.

This keyswitch is used to allow user memory to be written to (new program entered or existing program edited) when in the WRITE position.

When in the

MEMORY PROTECT position, the user memory can not be accessed.

This is a safeguard against unauthorized or inadvertent changing of the user program.

This is a visual indicator that the dc voltages provided by the power supply are available and have reached their proper operating levels,

The LED is viewed through the translucent lens on the faceplate.

ON The voltage levels of the 3 dc outputs (+5,

+12 and -12 V dc) are available and are within t h e s p e c i f i e d t o l e r a n c e .

OFF One or more of the 3 dc voltages is out of tolerance.

A terminal block is mounted at the bottom of the power supply faceplate. Two groups of 7 screw terminals are located on the block. These terminals provide the connections for the source of power, either ac or dc, 2 sets of alarm relay contacts and an external auxiliary battery. The auxiliary battery is optional and is used to provide battery back-up of the CMOS-RAM memory on the combined memory module.


2-6


GEK-96602

Terminal Block Connections

Figure 2.6 is an illustration of the terminal block. The 3 bottom terminals on the right group of terminals are for connecting the input source of power, either ac or dc, depending on whether an ac or dc power supply is selected. The 4 remaining terminals on the right side have no internal connections to the power supply.

70tmpll a41063

KY

CONTACTS llSDLATEDl

LINE I ILII

LINE 2 tL21

Gf?OUND IGI

k%

CONTACTS fISOLATI

INOpCUT

2D ToD3R2 "OC

Figure 2.6 CPU TERMINAL BLOCK CONNECTIONS

The optional external auxiliary battery, if included in a system, is connected to the 2 top terminals on the left group of terminals. The auxiliary battery voltage is routed through a regulator in the power supply, which provides a regulated voltage to back-up the

CMOS-RAM memory circuitry in the event of a no power condition to the supply.

The remaining 5 terminals on the left group of terminals provide external signals when certain internal faults are detected by the CPU. The minor alarm (terminals 1N0 and

1NC) faults are advisory in nature and do not affect the operation or reliability of the

PLC. The major alarm (terminals 2N0 and 2NC) faults are an indication that the CPU has detected a fault affecting normal operation and has halted its scanning in order to prevent unreliable or unpredictable operation of the PLC. If a fault does occur, status indicators on various modules will point to the specific cause of the fault.

NOTE

During normal operation the alarm relays are energized. When an alarm condition is detected, the contacts 1N0 and 2N0 open, and the contacts 1NC and 2NC close.

The alarm relay logic is located on a terminal

board

in the power supply. The alarm relay provides isolated outputs rated at 115 V ac or 28 V

dc,

1 amp resistive load. The major alarm causes the CPU status to be set to stop.

The minor alarm causes an error indication to be recorded, but the CPU status is not set to stop. Table 2.2 lists some of the problems that can cause the alarm relays to switch.





-

2-10


GEK-96602

I/O CONTROL MODULE

The purpose of the I/O Control module (catalog number lC6OOCB503) is to provide an interface between the CPU backplane bus and the main I/O bus. It is also the interface

to and controls data transfers between the CPU and certain peripheral devices. Logic on

this module includes command,

status,

port select and data latches, a status multiplexer, and control and timing circuitry. The I/O Control module must always be placed in slot 1, which is adjacent to the power supply.

User Connections

There are two 37-pin connectors located on the front of the module. The programming device for the Series Six Plus plugs into the top connector, which is labeled PP/DPU. The bottom connector, labeled l/O, provides the connection to the main I/O chain. The l/O

Control module is connected through a parallel I/O cable to the top connector of an l/O

Receiver or Advanced I/O Receiver located in the first I/O rack in a CPU station or

Local I/O station. The last rack of a CPU l/O station can be located up to 50 feet from the I/O Control module.

If a Redundant Processor Unit (RPU) is to be included in the control system, the bottom connector of the I/O Control module is connected to the CPU1 or CPU2 connector on the

RPU’s CPU Switch module, depending on whether the CPU is the main or back-up CPU.

The main CPU connects to the CPU1 connector and the back-up CPU connects to the

CPU2 connector on the RPU. When an RPU is included in a system, the I/O chain (or chains) connects to the I/O Switch module in the RPU, rather then to the l/O Control module.


There are 4 LED indicators on the front of the module, viewable through the lens on the faceplate. The LED indicators provide system status and are an aid to troubleshooting, should a problem occur.

Table 2.4 I/O CONTROL MODULE INDlCATORS

INDICATOR

CHAIN

OK

PARITY

ENABLED

DEFINITION

ON when all stations in the main I/O chain have continuity and have received good output parity.

ON when Input data parity is good.

ON when the CPU is in the RUN mode with outputs enabled.

DPU ON when the optional Data Processor Unit is connected and operating properly.

NOTE

With no I/O chain connected to the l/O Control module, the l/O Terminator plug supplied with each CPU must be connected to the bottom connector in order to terminate the I/O chain.



2-12 Physical Equipment

Configuration

GEK-96602

LOGIC CONTROL MODULE

The Logic Control module contains the CPU system clock, a microprogram sequencer, and Programmable Read Only Memory (PROM). It provides timing and control signals to the CPU backplane for use by other modules, and microprogram instructions to the

Arithmetic Control module through a ribbon cable. The time base for the timer functions in the PLC are derived from a crystal clock on this module. PROM memory on the module is programmed with an instruction set, which is accessed by the CPU when executing the user programmed instructions.

The Logic Control module also contains circuitry which allows the CPU to access all 16K of Register memory.

Three versions of the Logic Control module are available, the difference being the level of the instruction set contained in each one.

The Advanced Logic Control module

(catalog number IC600CB525) contains instructions that are accessed by the CPU to allow execution of the basic and advanced functions.

The Expanded Logic Control module

(catalog number IC600CB526) contains instructions in PROM that are accessed by the

CPU in order to execute the basic, advanced and expanded functions.

The Expanded II Logic Control module (catalog number lC600CB515) contains all of the instructions that are on the Expanded Logic control module. In addition it provides a dynamic user program memory checksum calculation for enhanced memory checking, has microcode changes to allow faster execution of ladder logic programs, contains new instructions for accessing a new 1/O system to be available in the future, support of 64K user program, and Auxiliary I/O overrides.

The Logic Control module must be placed in slot 2, immediately to the left of the t/O

Control module.

The Logic Control module works in conjunction with the Arithmetic Control module to generate timing and control signals and must be next to it in the rack, since they are linked together through a short length of ribbon cable. This short ribbon cable is included with the basic CPU rack.

NOTE

Do not attempt to operate the system without the ribbon cable connected between the Logic Control and Arithmetic Control modules. If the cable is not connected, the CPU will operate unpredictably.

The Logic Control module has no status indicators or other user accessible items. Figure

2.10 is an illustration of a Logic Control module.

NOTE

The Expanded II Functions require the IC600CB524 Arithmetic Control module, Logic Memory modules IC600LX (8K minimum registers), a 13” rack, or a 19” CPU rack with a date code later than 10/87.



2-14 Physical Equipment Configuration

GEK-96602

ARITHMETIC CONTROL MODULE

The Arithmetic Control module, catalog number lC600CB500, (IC600CB524 required with

Expanded II functions) contains circuitry that performs arithmetic and logical operations on data and address lines. There are 4 hardware registers on the board. The continuity and buffer registers are each 1 bit wide, while the accumulate and preset registers are each 16 bits wide. These registers are operated on internally by the CPU and are not user accessible registers.

The primary hardware for performing the arithmetic and logic functions on this module is a 16 bit Arithmetic Logic Unit. The Arithmetic Logic Unit works in conjunction with the

Logic Control module to generate timing and control signals and must be next to it in the rack, since they are linked together through a ribbon cable connector. The AM2903 is a 4 bit expandable bipolar microprocessor slice, which is especially useful for arithmetic oriented processors.

In addition, it provides a special set of instructions that ease the implementation of multiplication, division, and other time consuming operations.

The Arithmetic Control module must be placed in slot 3 in the CPU rack, immediately to the left of the Logic Control module.


There are 2 LED status indicators, labeled RUN and CHECK, on the front of the board which are viewable through the translucent lens on the faceplate. The executive routine in the scan execution sequence contains a self-test that is executed once per scan. The

RUN LED, when ON, is an indication that the execution sequence is normal, the self-test has passed, the I/O scan is completed at least once every 300 ms +/-50 ms, and the CPU is in the RUN mode.

The CHECK LED is ON when the self-test has been completed successfully at least once each l/O scan, the system clock is operating normally, or if the scan time is no than 300 ms +/-50 ms.

longer

Table 2.5 ARITHMETIC CONTROL MODULE STATUS INDICATORS

INDICATOR

RUN

CHECK

DEFINITION

ON:

Execution

sequence proceeding normally, self-test has passed, least once every 300 the RUN mode.

ms +/-50 ms and the CPU is in

OFF: CPU is in the STOP mode.

ON: Execution sequence proceeding normally, self-test has passed at least once each 300 ms

+/-50 ms. CPU can be in RUN or STOP mode.

OFF: CPU self-test has not passed within

300 ms +/-50 ms, or user program takes longer than

300 ms to execute.

CPU

goes to STOP mode and I/O chain is reset.




Physical Equipment Configuration 2-17

GEK-96602

The status table stores bits representing the ON or OFF status of the 1000 inputs and

1000 outputs in the main I/O chain when in Normal mode. In the Expanded mode of operation, the status table stores the status bits of the 1000 inputs and 1000 outputs in the main I/O chain from a programming standpoint, but in Channel 0 from a real I/O point-of-view. The transition table stores the logic state of the inputs to counters and one-shots in the main I/O chain when in the Normal mode or for Channel 0, when in the

Expanded mode. The override table stores the status of overridden input or output bits in both the Main

and

Auxiliary I/O chains in the Normal mode. An overridden bit in the status table is

not

changed when the CPU reads inputs or solves outputs. The internal

memory is stored as 8 bits of data and 1 bit of parity.

Detection of Active Overrides in System

With the Expanded

II

functions, a means of detecting if there are any active overrides in the system is available. Two bits in the Main status table are used for this purpose.

Output O1015 is defined as the Override Active in System Enable bit and O1016 is defined

as

the Override Active in System Report bit. Once each sweep O1015 will be checked by

the

CPU. tf the bit is not set to a 1, the CPU will skip the active Override search. If the bit is set, the CPU will initiate a search of the Main and Auxiliary Override Tables in search of an active override bit (bit that has been set to a "1"). The search will continue until either an active override is found or the end of the override tables is reached. If an active override is found, bit O1016 will be turned ON (the user can check O1016 for a “1” or

a “0” to

determine if there are any active overrides in the system).

If

the end of the override tables is reached without finding an active override, O1016 will be turned OFF.

If O1015 is turned OFF, then O1016 will not be modified.

Scratch Pad Items

The Scratch Pad storage area contains miscellaneous data pertaining to CPU operation.

The Scratch Pad display, as viewed on the Workmaster computer, includes these items and the current status of each one. Some of the items can be changed by the user, others are configured by the CPU and cannot be altered by the user.

Table 2.7 SCRATCH PAD STORAGE ITEMS

ITEM

CPU ID

MEMORY SIZE

CPU MEMORY

SUBROUTINES USED

CPU STATUS

FUNCTIONS

WORDS USED

WORDS AVAILABLE

REGISTERS

CPU VERSION

CPU ERROR FLAGS

DESCRIPTION

A number assigned to the CPU when there is more than

Number of words of

State

memory in the

key switch on the CPU.

Number of subroutines in the user’s program.

Current operating status of the CPU, either run enabled, run disabled or stop.

,

II.

Length of current user program in 16-bit words.

Number of unused 16-bit words left in user memory.

N umber of 16-bit Register memory locations in CPU.

Revision level of the CPU software.

A group of 24 bits in Scratch Pad memory used by the CPU to indicate the type and location of

faults detected by the

CPU during its normal

operation or self checking.



GEK-96602

Type of Memory Used

The Combined Memory modules use CMOS-RAM integrated circuit memory as the storage devices. CMOS-RAM is an integrated circuit memory that uses low power.

CMOS-RAM memory is volatile, i.e, its contents are lost under no-power conditions. In

order to maintain the contents of memory when power fails or is turned off, a

Lithium-Manganese Dioxide battery (usually referred to as a Lithium battery) is provided as a power back-up for these devices. The Lithium battery is located on the module, along with circuitry to monitor the batteries voltage level.

Battery Status Indicator

The Lithium battery (catalog number IC600MA507) provides about 1 year of data protection under no-power conditions.

One of the 2 LEDs on the board is an indication of the battery condition. This LED is labeled, BATTERY. With power applied to the CPU, the LED w ilI be ON, if the battery condition is normal. The normal fully-charged voltage of a Lithium battery is 2.95 V dc @ 1 .OO amp-hours.

If the battery voltage is low (between 2.55 V and 2.75 V), the LED will flash. When this happens, the battery should be replaced as soon as possible. The CPU will continue running if the battery voltage is low. If the CPU stops, it can be restarted. If the battery voltage drops below 2.55 V, the LED will turn OFF. If the CPU stops, it cannot be restarted under this condition. Instructions for replacing a defective battery can be found in Chapter 5, System Maintenance.

Table 2.8 COMBINED MEMORY MODULE STATUS INDICATORS

INDICATOR

BATTERY

PARITY

STATUS

UN

FLASHING

OFF

ON

OFF

DEFINITION

Condition of Lithium backup battery is normal.

Battery voltage is low. CPU continues running.

Alarm 2 (Advisory) is activated. To protect the memory contents, replace the battery as soon as possible - before It fails.

Battery failed. CPU continues running, but will not restart if stopped. Alarm 2 remains activated.

Contents of memory wfll be lost if power Is turned off or lost for any reason.

Normal operation, no parity errors detected by CPU.

Parity error detected in either Logic, Register, or

Internal memory. A bit will be set in the CPU Error

Flag and displayed on the Workmaster computer screen in the Scratch Pad display An error message will be displayed which will interpret the content of the error flags.

An address will be displayed in

Hexadecimal format to pinpoint the location of the defective module.



GEK-96602

2-19

A jumper on the Combined Memory Module allows the user to use an external auxiliary backup battery connected to the terminal block. With the external battery configuration, the on-board battery need not be connected.

Location in Rack

The Combined Memory Module must be placed in slot 4, which is directly to the left of the Arithmetic Control Module in the Series Six Plus CPU rack.

NOTE

Existing versions of the Series Six PLC Combined Memory module (catalog numbers IC600CM552 and IC600CM554) can be used in a Series Six Plus CPU

rack.

Additionally, all Series Six Plus PLC Combined Memory modules can be used with a Series Six PLC model 60 CPU, however, there is no parity check with this combination.

Precautions When Handling Memory Modules

When installing or removing a Combined Memory module, it is recommended that you use the extraction/insertion tool (lC600MA504) provided with each CPU.

Relatively small amounts of excess charge can cause very intense electrostatic fields in Metal-Oxide-Semiconductor (MOS) devices, damaging their gate structure.

Avoid handling the circuit board under conditions favoring build-up of static electricity. Failure to observe this caution could result in destruction of the CMOS-RAM devices in this module.

A bottom board cover provided with each Combined Memory module acts as an electrical noise shield and helps protect the battery circuits from accidental discharge. This cover should not

be

removed during operation or handling of the board.

Do not allow the bottom of the module to come in contact with a conductive

(metal) surface when the board cover is removed. Failure to observe this caution could result in the discharge of the non-rechargeable lithium battery and the loss of memory contents.

Memory

Protection

A two-position key switch located on the power supply is provided for protecting logic and override memory that has been written into.

The two positions are MEMORY

PROTECT and WRITE. In the WRITE position,

the

user can write into logic memory to enter or change programs.

When in the MEMORY PROTECT position, logic memory cannot be written into, thereby protecting any user program previously entered from being changed or destroyed.

Once a program

has

been entered and debugged, it is advisable to place the key switch in the MEMORY PROTECT position.




GEK-96602

2-21

BUS CONTROLLER MODULE

The Bus Controller module is the required interface between a Series Six Plus PLC and the Genius l/O blocks when they are included in the PLC’s I/O system. The Bus

Controller module can be placed in any I/O slot in the CPU or in a high-capacity I/O rack located in a CPU station or local I/O station up to 2000 feet (600 meters) from the CPU.

Multiple Bus Controllers can be placed in one rack. Since each Bus Controller consumes

20 units of load, up to 5 modules can be placed in a CPU rack, or 10 modules in a high capacity I/O rack.

A Bus Controller can be placed in an I/O rack in a Remote I/O station if the CPU scan time is greater than 10 ms. However, because of the reduced capacity of the serial I/O communications link, window commands would not be supported. Each Bus Controller can interface up to 30 Genius I/O blocks to the Series Six Plus CPU by twisted pair communications up to 2000 feet 6 0 0 meters).

The only limit to the number of Bus

Controllers in any one PLC system is the I/O capacity of the Series Six Plus CPU. Each

Bus Controller, similar to any I/O module, has access to all I/O references on its I/O chain.

A 4-segment DIP switch located on the module is used to enable channel selection for

Expanded I/O addressing.

If Normal (non-expanded) addressing is used or if channel selection is made through I/O Transmitter Modules, no switch setting is necessary.

The Genius l/O bus must be terminated at the Bus Controller by its characteristic impedance.

The enhanced version Bus Controller provides three selectable on-board impedances, 100 150 or 750 Ohms Three jumpers (JP1, JP2, and JP3) on the module are used to select one of the listed values, or to select no impedance.

Versions of Bus Controller

Two versions of the Bus Controller are available, they are:

1.

Catalog Number IC660CBB901 (lC660CBB903 has enhanced features). Interfaces with the Genius l/O blocks and provides normal Genius I/O status information and

Hand Held Monitor support.

It requires one byte of input address (8 references) for transfer of its status to the CPU.

2, Catalog Number lC660CBB900 (lC660CBB902 has enhanced features). Provides all functions of the IC660CBB901 Bus Controller plus a wide range of diagnostic data and system functions for the entire Genius I/O system. This Bus Controller requires

6 addresses for diagnostic input data (48 references) provided to the CPU and 4 addresses for command output data (32 references) received from the CPU.

Addresses are selected by the DIP switches at the rear of each I/O slot.

For detailed information on the Bus Controller modules, refer to the Genius I/O System

User’s Manual, GEK-90466.


2-22


GEK-96602

COMMUNICATIONS CONTROL MODULES

The Communications Control Modules (CCM2, CCM3, I/O CCM, I/O Link local) provide a serial interface between the Series Six Plus PLC and any intelligent device that can initiate communications based on the CCM protocol and CCM electrical interface requirements.

A brief description of each of these modules is provided in this manual.

For detailed descriptions of these modules and pertinent data communications information, refer to GEK-25364, which is the Series Six Data Communications Manual,

GEK-90505, which is the Supplement To The Data Communications Manual, and

GEK-90824, which is the data sheet for the Input/Output Communications Control

Module.


The CCM2 (catalog number IC600CB516) has 2 serial ports that provide RS-232 and

RS-422 electrical interface capability. RS-232 is normally used for direct connections at a maximum distance of 50 feet (15 meters).

The RS-422 interface allows direct connection up to 4000 feet (1200 meters). The CCM2 can be connected directly to short haul or telephone line modems through the RS-232 interface, if transmission distances greater than the 4000 feet allowed by RS-422 are required. The CCM2 can operate at speeds up to 38.4K baud, and can originate messages with control by the ladder diagram logic, using the Serial Communications Request (SCREQ).

Examples of intelligent devices that can be interfaced to the CCM2 include:

- Color-graphics terminals

- G E n e t Factory LAN

The CCM2 also provides an interface to the following devices: facilitate recording or loading of CPU user’s programs at the Series Six Plus PLC location. The STR-LINK Ill tapes are interchangeable with PDT tapes.

- A handheld Operator Interface Unit (OIU), which allows an operator to monitor and modify the register contents of the CPU, monitor and modify timers and counters, and monitor, modify, and override Input and Output (l/O) points.

The CCM2 is capable of initiating data transfers to and from any Series Six Plus PLC memory type, including register tables, input and output tables, override tables, scratch pad, and user logic. When a Series Six Plus CPU is connected through a CCM2 to a host computer or other device that is not a Series Six Plus PLC, the user must either write or purchase the software necessary to communicate with the CCM2.

STR is a trademark of Electronic Processors, Inc.



GEK-96602

2-23

System Configuration

Three types of system configurations are supported by the CCM2: point-to-point, multidrop, and GEnet . A point-to-point configuration allows only two elements

to

be connected to the same communications line. Using this configuration, the CCM2 protocol allows either peer-to-peer or master-slave communications.

In the multi-drop configuration, one CCM2 or host device is configured as the master and one or more

CCM2s are configured as slaves; only the master-slave protocol can be used. The GEnet

Factory LAN (Local Area Network) is a Local Area Network through which many devices can be connected. A Bus Interface Unit (BIU) allows Series Six Plus PLCs to access the

GEnet Factory LAN, and can support a maximum of 4 CCM2s. By using multiple BIUs, a maximum of 254 Series Six Plus PLCs with CCM2s can be connected to the network.

User

Items

The CCM2 requires 1 slot in the Series Six Plus PLC rack, and must be installed in slot 5.

At the top of the module are 2 switches used during communications with a STR-LINK

IIA or STR-LINK III tape recorder.

The 2 connectors on the board are both capable of

RS-232 and RS-422 operation. J1 is a 25-pin "D” type female connector and J2 is a 9--pin

“D” type female connector.

If a STR-LINK tape recorder is to be used, it must be connected to the J1 connector.

Four LEDs on the board, viewable through the faceplate lens, are indicators of the operating state of the module. Table 2.9 is a description of the indicators. Figure 2.14 is an illustration of the CCM2 module.

Table 2.9 CCM2 STATUS lNDlCATOR DEFINITIONS

INDICATOR STATUS

DEFINITION

BOARD OK ON Board has passed power-up properly.

FLASHING Invalid configuration or CPU number.

OFF Power-up test failed, indicating a hardware failure.

MATCH OK ON Good compare between tape and CPU has been made.

TAPE OK

Indicator also turns off.

DATA OK ON

FLASHING

OFF

TAPE OK ON

OFF

Data transmission normal.

Data is being transferred.

Data incorrect because of parity, overrun or framing errors, bad data block or the serial link has timed out.

A CCM2/CPU communications failure will cause this light and the BOARD OK light to turn off.

Tape data transmission normal.

Data stream interruption caused by parity, framing or overrun errors, unsuccessful tape comparison or timeout on the tape link.




GEK-96602

2-25


The CCM3 (catalog number IC600CB517) provides all of the functions of the CCM2 plus the protocol required to communicate with selected process control systems. Physically, the CCM3 is similar to the CCM2. Refer to the illustration, figure 2.14, on the preceding page. Options for baud rate, protocol, turn-around-delay, and parity can

be selected

for the CCM3 in the same manner as with the CCM2, by hardware, using DIP switches and by software, using configuration registers. The primary difference between the two modules is in the software, which for the CCM3 includes 2 modes of operation: CCM2 mode and

CCM3 Remote Terminal Unit (RTU) mode. Information on the installation, operation, and protocol of the CCM3 can be found in GEK-90505, which is the Supplement To The

Data Communications Manual.

CCM2

Mode

When the CCM3 is in the CCM2 mode, the CCM3 operates the same as the CCM2 module, except that the following protocol options of the CCM2 are not available to the CCM3:

- Test 1 on port J2

This is because the DIP switch settings and the bit pattern for the software configuration registers, which are on the actual CCM2 are used to select the options listed above, are reserved on the CCM3 to select RTU mode for ports J1 and J 2 If any protocol selection for a CCM3 port is made other than RTU, that port will operate as a CCM2. When configuring the CCM3 in CCM2 mode, follow the directions found in Chapter 3,

Communications Control Module (CCM2) in GEK-25364, which is the Series Six Data

Communications Manual

.

CCM3

Remote Terminal Unit (RTU) Mode

In RTU mode, the CCM3 is a slave device designed to be used on a link with a host computer or other intelligent device capable of emulating RTU master protocol. When using this mode, the CCM3 is capable of accessing the following Series Six Plus PLC memory types: register tables, input and output tables, override tables, scratch pad and user logic.

In addition, several Serial Communications REQuests which do not use RTU protocol, the unformatted Write and Read Character String commands, can be initiated by application programming when in RTU mode. These communications requests are included in CCM3

(RTU) software for application programming.

Dual Mode Usage

One CCM3 communications port can be configured in CCM2 mode at the same time that the other port is configured in RTU mode.

Restrictions regarding the use of two ports in different modes are given in the section, Simultaneous Port Operations, in the CCM3

Supplement, GEK-90505.


2-26


GEK-96602

I/O Communications Control Module (l/0 CCM)

The I/O CCM (catalog number IC600BF948) is a communications module for use as an additional communications interface between the CPU in a Series Six Plus PLC and external devices.

The I/O CCM should be used when the primary communications module

(CCM2 or CCM3) has both ports committed and additional ports are required for an appl icat ion.

The l/O CCM has two ports, labeled PORT 1 and PORT 2, for asynchronous serial communication at data rates from 300 to 19.2K baud using CCM (master, slave, or peer) or RTU (slave only) protocol.

Unformatted read and write can also be used. Both ports support RS-232 and RS-422.

In addition, Port 1 also supports active or passive 20 mA current loop. The two ports can be independently configured by module hardware.

The I/O CCM does not support STR-LINK tape recorders, the Operator Interface Unit, or port configuration from registers.

However, it can interface to most other devices and perform the same tasks as the CCM2 and CCM3 modules. The l/O CCM must be inserted in a high capacity I/O rack or an I/O slot in a Series Six Plus CPU rack.

Detailed information on the I/O CCM can be found in GEK-90824, which is the data sheet for the Input/Output Communications Control Module.

Figure 2.15 is an illustration of the I/O CCM.

a 4 0 5 2 8

1. LED Status Indicators.

2. Bank A DIP Switches.

3. Bank B DIP Switches.

4. Bank C DIP Switches.

6. J2 Connector: 25pin D-type female connector (Communications Port 2).

7. J2 Communication selection DIP package:

RS-232 or RS-422 configuration. Read

5. J1 Connector: 25pin D-type from top of imprinted label.

female connector (Communications 8. Faceplate.

Port 1).

Figure 2.15 ILLUSTRATION OF l/O CCM MODULE



GEK-96602

2-27

~~

I/O Link Local Module

The l/O Link Local module (catalog number IC600BF947) provides a communication link with diagnostics from a Series Six Plus PLC to a slave Series One PLC and Series Three

PLC input and output devices.

The l/O_Link Local module can be connected to as many as seven remote Series One or Series Three racks (or a combination of both) in a single chain. It can access a maximum of 96 I/O points from a Series One rack and 224 l/O points from each Series Three rack.

The I/O Link Local module can be inserted in the I/O portion of a Series Six Plus CPU rack or in a Series Six high capacity I/O rack. The connection to the Series One or Series

Three I/O is made through the I/O Link Remote module in a Series One or Series Three

I/O rack.

A maximum of 4 I/O Link Local modules can be installed in the I/O portion of the CPU rack. With this configuration, no other l/O modules can be resident in the CPU rack.

This is because of the power consumption (in units of load) of the I/O Link Local modules. A maximum of 5 I/O Link Local module can be installed in a high capacity I/O rack. In this configuration, there are 175 units of load remaining for I/O modules with +5

V dc power only.

The actual physical connection between the I/O Link Local module and the remote Series

One or Three racks is a 2-wire (plus ground) RS-422 multidrop. The maximum distance between the I/O Link Local module and the last remote rack in the chain is 3300 ft (1 km).

The I/O Link Local module must be configured for each application by setting DIP switches located on the module. The DIP switches determine the starting address of a configuration table in the CPU.

For detailed information on the use and configuration of an I/O system using the l/O Link

Local module and Series One or Three l/O, refer to GEK-90825, which is the Series Six

PLC I/O Link Local User’s Manual. Figure 2.16 is an illustration of a typical I/O communications link between a Series Six Plus PLC and Series One and Three I/O.

a 4 2 0 8 4

Figure 2.16 I/O LINK LOCAL MODULE TO SERIES ONE

OR SERIES THREE REMOTE I/O RACKS


n

2-28


GEK-96602

Figure 2.17 is an illustration of the physical layout of the l/O Link Local module.

a4047 7

SSOR

LED

‘DRT 1

0

9:0.

::9::*

.*.:::*

0

1 LINK

ICAL

<

IARD

‘l-l

MM ic 1

7E-i

ic 2 lANs

BATTERY NOT REQUIRED -

BOARD OK-

CPU COMMUNICATIONS -

NOT

USED

RECEIVE 1 -

TRANSMIT 1 -

RECEIVE 2 -

TRANSMIT 2 -

8

CONFIGURATiON

T A B L E A D D R E S S p

D I P SWtTCHES f

C

PORT NOT USED

-[

I

i

;

I

8

I i

L

/

Figure 2.17 I/O LINK LOCAL MODULE



GEK-96602

2-29

I/O STRUCTURE FOR THE SERIES SIX PLUS PLC

The I/O structure for the Series Six Plus PLC provides the user with many options of system configurations and a large variety of discrete and special I/O modules designed to fit the needs of virtually any application.

Any of the rack-based Series Six l/O modules can be used in a Series Six Plus PLC system and can be placed anywhere within the I/O structure, except that devices such as the ASCII/BASIC module requiring windows from the CPU cannot be used in Remote I/O stations. The 19” CPU rack has 6 slots in which

I/O modules may be placed and the 13” rack has 3 slots for I/O modules. When an application requires more l/O than can be contained in the CPU rack, an optional I/O rack or racks can be added. This allows a system to use the maximum I/O points available in a configuration.

I/O RACKS

All I/O modules, other than those in the CPU rack, are housed in an I/O rack. The l/O rack uses the same mechanical packaging as the CPU rack and is available in both 13” and

19” racks. The l/O racks can be mounted in the same manner as the CPU racks and can be either rack or panel mounted. Two 13” racks can be mounted side-by side in a NEMA

12 wide rack. Each rack is supplied with reversible mounting brackets for mounting as required by the user.

With the brackets attached to the front of the rack, it can be mounted in a standard 19” or 13” rack, as applicable. By rotating the brackets

90” and

mounting them on the rear of the rack, the rack can then be wall or panel mounted.

81pc51

1. 7 Position DIP Switch (10 Per Rack).

5. I/O Power Supply.

2. 41-Pin Connector (11 Per Rack).

6. Terminal Board

3. Logic Power On/Off Circuit Breaker.

7. Tray For Containing Field Wiring.

4. Power On Indicator.

8. Cardguide (11 Per Rack).

Figure 2.18 TYPICAL I/O RACK


2-30


GEK-96602

Each I/O rack provides regulated dc power and backplane signals from the power supply for I/O modules, and is available in three versions: ac standard and ac or dc high-capacity

(13” rack requires the high-capacity ac supply). The difference being the total current supplied from the power supply. A standard I/O rack provides adequate current for modules for most applications. When an application requires I/O modules that collectively would draw more than 6.1 amps, a high-capacity rack must be used.

Table 2.10 I/O RACK AND POWER SUPPLY SPECIFICATIONS

Rack

Dimensions (19", 11 slots)

Rack Mount

Panel Mount

Weight (Empty)

Rack Dimensions (13", 8 slots)

Rack Mount

19.0(W) x 14.0(H) x 10.

3(D) inches

(483 x 356 x 261 millimeters

20.0(W) x 14.0(H) x 10.3(D) inches


30 Pounds (13 Kg)

16.0(W) x 13.25(H) x 9.3(D) inches


Rack Mount with Brackets for standard 19" Rack

19.0(W) x 13.25(D) x 9.3(D) inches


Panel Mount (Brackets on sides) 16.0(W) x 13.25(H) x 9.3(D) inches

Panel Mount (Brackets on Top and

Bottom,

Side-By-Side Mount

13.25(W) x 16.1(H) x 9.3(D) inches


Power Supply

Input Requirements

AC - Standard, IC600YR501

Frequency

Voltage

Maximum load

AC

- High Capacity, IC600YR511

47 to 63 Hz

95 - 132 V ac

190 - 269 V ac

80 VA

>

Jumper

Selectable

Voltage and Maximum Load

DC - High Capacity, IC600YR514

95 - 260 V ac (Wide Range), 250 VA

Voltage and Maximum Load 20 to 32 V dc, 180 VA

DC - High Capacity, IC600YR546

100 to 150 V dc, 180 VA Voltage and Maximum Load

Power Supply Voltages to Rack

Standard (100 Units of Load) (1) +5 V dc, 6.1 A (maximum)

High Capacity (275 Units of Load) +5 V dc, 16.5 A (maximum)

+12 V dc, 1.5 A (maximum)

-12 V dc, 1.0 A (maximum)

Allowable Power Interruptions AC: 33 mSec (min) - 115 V ac line

DC: 10 mSec (min) - 20 V dc line

4 mSec (min) - 100 V dc line

Operating Temp. (Outside of Rack) 0 to 60°C (32F to 140" F)

Storage Temperature -20 to + 8 O C (-4 to 176°F)

Humidity (Non-Condensing)

Noise Immunity

5% to 95%

Meets requirements of NEMA

ICS 2-230 and ANSI C37.90A

Altitude Up to 10,000 Feet (3000 meters)

above

Sea Level

(1) 1 unit of load = 60 mA.

Calculations based on worst case, all inputs or outputs on.





GEK-96602

2-33

Normal Mode I/O Addressing

The Series Six Plus PLC allows I/O to be configured in either the Normal I/O mode or the

Expanded I/O mode. Selection of the mode is made through the Configuration Menu screen, using Logicmaster 6 software.

In the Normal I/O mode, one I/O chain per CPU is permitted (this is the factory default setting). In this mode, available I/O is 1000

Inputs/l000 Outputs in the Main I/O chain, plus an additional 1000 Inputs/l000 Outputs in the Auxiliary l/O chain, if an Auxiliary l/O module is included in the system.

The ON or OFF state of the 1 K Inputs and 1 K Outputs in the main I/O chain is maintained in the I/O Status Table. The ON or OFF states of I/O points in the Auxiliary I/O chain are maintained in the Auxiliary I/O Status Table which is mapped into the first 128 words of Register memory. ROOOI to R0064 contains the Auxiliary Output Table, and R0065 to

R0128 contains the Auxiliary Input table.


When the Expanded I/O mode is selected, a total of 8K Inputs and 8K Outputs in the Main

I/O chain are available to the user. In addition, if the Auxiliary I/O chain is selected

(requires an Auxiliary I/O module) 8K Inputs and 8K Outputs are available in the Auxiliary chain. The total real I/O available through the use of both chains is 16K Inputs and 16K

Outputs (32K total points). I/O points in the Expanded mode are selected in 1K (1 K tnputs and 1 K outputs) increments, referred to as channels.

An I/O Transmitter module is required for each channel of l/O, with the exception that if channels 0 and 8 are the only Expanded mode channels selected, an I/O Transmitter is not needed since the I/O is scanned the same as the Main and Auxiliary I/O chains in the

Normal mode. If more than two channels are to be used, I/O Transmitters are required.

A jumper on each l/O Transmitter module must be configured for either Normal mode or

Expanded mode. The CPU scans only those channels that have been selected. The channel number to be associated with each l/O Transmitter is selected by setting the first

3 switches (switches 1,2, 3) on the DIP switch package on the backplane adjacent to the module.


The channels are numbered from 0 to F; the Main I/O chain channels are referenced 0 through 7 and the Auxiliary I/O chain channels are referenced 8 through F.

The format for addressing I/O in the Expanded mode must include a channel number, either I or O, a real I/O state (+) or internal discrete status ( - ) reference identifier and the l/O number. The exception to this is for channel 0 and 8; channel 0 programming references are O0001 - O1024 and I0001 - I1024, channel 8 programming references are

AO0001 - AO1024 and Al0001 - Al1024). References O0+000l to O0+1024, I0+0001

to

I8+0001 to

I8+1024 cannot be used as real I/O references, but are available for use as discrete programming references.


2-34


GEK-96602

Thus, the format for real I/O points for channel 3 in the Main I/O chain is (for example)

I3+0001 to I3+1024 for Inputs and O3+0001 to O3+1024 for Outputs. Each IK channel requires 64 words of memory (64 words x 16 bits = 1024 l/O). Note that although 1024 bits are available in each channel, 0001 to 1000 are used for actual l/O points. 1001 to

1024 are reserved for special use.

Real I/O Memory Allocation

In the Expanded mode, the real I/O points for Channel 0 are scanned on the Main I/O chain (references 10001 - I1024 and O0001 - O1024) and their status is maintained in the

Main I/O status table. Channel 8, which is the first Auxiliary I/O channel in Expanded mode, is scanned on the Auxiliary I/O chain (references Al0001 - AI1024 and AO0001 -

AO1024) and its I/O status is maintained in Registers R0001 through R0128, which is the

Auxiliary I/O status table. Channels 1 through 7 of real I/O are mapped into Registers

R0129 through R0961 and the Auxiliary channel real I/O, Channels 9 through F are mapped into Registers R1153 through R2048. This mapping scheme is valid for systems having either 8K or 16K words of register memory. For mapping of 1K or 256 register systems, refer to Chapter 4. There you will find illustrations of memory allocation for each register configuration.

The override tables are associated only with the I, Al, O, and AO references. The transition tables, which are required for operation of one-shot and counter functions, are associated only with the O and AO references.

Internal Discrete Reference Memory Allocation

The internal discrete references (I/O states) for Channels 0 through 7, which can be used for program references, but are not available to real world inputs or outputs, are mapped into Registers R2049 through R3072.

The internal discrete references for Auxiliary channels 8 through F are mapped into Registers R3073 through R4097 for systems having

8K or 16K of registers.

Expanded Mode I/O References

Table 2.11 is a list of Expanded Mode I/O point references for each channel and their memory location. There is a total of 66K of discrete references supported by the Series

Six Plus PC. These references include 4K in the Main and Auxiliary I/O chain (I, O, Al,

AO), 30K of real I/O, and 32K of internal references when in the Expanded mode. Any reference that is not used as a real I/O point can be used for internal reference or retentive data storage (registers).



2-36


GEK-96602

I/O SYSTEM CONFIGURATION

A Series Six Plus PLC I/O system can be configured as 3 types of interconnected l/O groupings of racks referred to as stations.

The 3 systems (stations) are described in the following pages. I/O racks are connected by interface modules located in the CPU or I/O racks. Interfacing is through the parallel bus channel using a 16-pair shielded cable for

CPU I/O stations and Local l/O stations. Interfacing to the Remote l/O station is through a serial communication channel using a 2-pair shielded cable or an RS-232 modem link.

points required by the application.

The maximum number of I/O points in a system is determined by the mode of operation, either NORMAL or EXPANDED, and the number of selected channels in the system.

Each I/O rack contains a power supply, an interface module and up to 10 additional modules. The station configuration will be shown in detail in the illustration included in this section for each l/O station.

I/O Rack Interconnections l/O racks are interconnected in a system by using combinations of I/O Receivers,

Advanced I/O Receivers, l/O Transmitters, Remote I/O Drivers or Remote I/O Receivers, depending on the number of l/O points required, the grouping, and location of the racks.

Racks are grouped together in either a CPU station, a Local I/O station or a Remote I/O station depending on their physical location and distance from the CPU and from other

I/O racks.

Each I/O rack requires a receiver which isolates the I/O data cable from the backplane bus and performs error checking.

A receiver does not require an address and is normally inserted in the left slot; however, a receiver can be placed in any l/O slot. Two of I/O racks in a daisy chain can have no more than 50 feet (15 meters) separating the first rack from the last and there can be a maximum of ten I/O racks in the chain.

The last rack in a daisy chain requires termination of the I/O signals. This is done by configuring the DIP shunts and jumper pack on the last I/O Receiver module in the daisy chain. Optionally, the Workmaster computer can be connected to the bottom connector of the last rack in a CPU station or Local I/O station.

Transmitter, through a 16 pair cable to an I/O Receiver

or

Advanced l/O Receiver in the first I/O rack of a chain of no more than ten racks. A total of four Local I/O stations can feet (600 meters) from the originating CPU.



GEK-96602

2 - 3 7

A Remote I/O system allows l/O racks to be located up to 10,000 feet (3 km) from any rack in a CPU station or a Local l/O station by direct cable connection. A Remote I/O

Driver placed in a slot in a CPU station or Local station is connected through a two twisted pair serial cable to a Remote I/O Receiver located in the left slot of a remote station. Any number of Remote I/O Drivers and Remote l/O Receivers can be used in a system. Up to 243 inputs and 248 outputs can be located in a Remote l/O station.

Additionally a CPU station or Local station can be connected to a remote station at distances greater than 10,000 feet (3 Km) by using a communications fink consisting of

RS-232 modems.

CPU I/O Station

The CPU I/O station, as illustrated in figure 2.21, consists of a Series Six Plus CPU with up to 10 I/O racks. The racks are daisy chained on the parallel I/O bus (to the l/O Control module) with the last I/O rack located physically no more than 50 feet from the CPU.

Each I/O rack in the chain includes a Power Supply module (standard ac or high-capacity

ac

or dc in a 19” rack, or high-capacity ac in a 13” rack), an I/O Receiver or Advanced

I/O Receiver module and up to 10 additional modules in a 19” rack or up to 7 additional modules in

a

13” rack, The modules in the I/O rack are determined by the system configuration required.

The modules can be

a

combination of the following modules:

Each I/O rack must have one, (and only one) l/O Receiver or Advanced I/O Receiver.

If more than 10 I/O racks are required in a system, one or any of the I/O racks in the CPU station may contain any combination of l/O Transmitter or Remote I/O Driver modules for connection to additional I/O racks.

A Workmaster or Cimstar I computer, or PDT can be plugged into the l/O Control module station or

a

Local I/O station. The Workmaster or Cimstar I computer can also be plugged into an I/O Transmitter in a CPU station or Local I/O station. When connected to an I/O Transmitter, the Workmaster or Cimstar I computer can be connected through

t

he 100, 200 or 500 foot lengths of I/O cable. The PDT can only be used in the Normal mode and only with the Advanced functions.





GEK-96602

Remote I/O Station

A Remote I/O station consists of I/O racks connected in a daisy chain through the parallel

I/O bus. A combination of l/O modules with a total of either 120 inputs and 120 outputs or 248 inputs and 248 outputs (jumper selectable) can be located in a Remote l/O station.

The first and last rack in a Remote I/O station daisy chain can be separated by no more than 50 feet (15 meters) of cable.

In addition to the racks on the daisy chain an I/O Transmitter located in a rack in the

Remote I/O station can be the first in a link of l/O Transmitters connecting to additional groupings of racks.

An I/O Transmitter can be connected to the first rack in a group of racks by a 16-pair parallel cable with a length up to 500 feet (150 meters). Up to four links can be connected in this manner, thereby extending the Remote l/O station an additional 2000 feet (600 meters).

NOTE

The total number of l/O points assigned to a Remote I/O station (either

120/120 I/O or 248/248 I/O) cannot be exceeded regardless of the rack configuration.

A Remote l/O station connects to an upstream I/O rack in either a CPU station, Local

I/O station or to an l/O slot in a CPU rack. The connection is made through a serial communication channel by a two-twisted pair shielded cable or through an RS-232 compatible

modem I

ink. The system interface module in the CPU rack, the CPU l/O station or Local I/O station is a Remote I/O Driver and the system interface module in the Remote I/O station is a Remote I/O Receiver.

The serial communications link to the Remote I/O station can be up to 10,000 feet (3 Km) using a two-twisted pair cable. With an RS-232 modem link, the distance between local and remote I/O is virtually unlimited.

NOTE

A Remote I/O Driver module cannot be installed in a Remote I/O station. A

Workmaster or Cimstar I computer, or PDT cannot be connected to a Remote l/O stat ion.

Figure 2.23 illustrates a typical configuration for a Remote l/O station. The illustration shows how a Remote I/O station can be extended an additional 2000 feet (600 meters) by using l/O Transmitters to connect additional racks to the parallel bus.





2-44


The I/O Receiver module receives signals through the parallel bus link, modifies the signals to update the status of inputs and outputs, then relays those signals to the next rack in a chain.

Racks can be connected when they are more than 50 feet (15 meters) from a CPU by connecting an I/O Receiver in the first rack of the distant grouping to an

I/O Transmitter through a 16-pair twisted cable on the parallel bus. The length of this cable can not exceed 500 feet (150 meters). This distant grouping of racks at the end of a parallel bus cable is referred to as a Local I/O station. Again, up to 10 I/O racks can be daisy-chained in a Local I/O station with no more than 50 feet (15 meters) of cable separating the first and the last rack.

The maximum distance an I/O Receiver can be located from the originating I/O Control or Auxiliary l/O Control module is 2000 cable feet (600 meters). In a Remote I/O station, an I/O Receiver is used when connecting racks on the daisy chain in the station if more than one I/O rack is required in the station.

An l/O Receiver is normally installed in the leftmost slot of an l/O rack; however, it could be inserted into any I/O slot in an l/O rack if required. An I/O Receiver can be installed in any I/O rack except the first I/O rack in a Remote l/O station, this rack requires a Remote l/O Receiver.

I/O Chain Signal Continuation or Termination

Before installation of an I/O Receiver in an I/O rack, it must be determined if the module is to be in the last rack of an I/O station daisy chain or in a rack within the chain. An l/O

Receiver, as received from the factory, is configured to continue the I/O chain signals through the module toward the next I/O Receiver in the chain. If the module is to be the last I/O Receiver in the daisy chain a jumper pack must be removed from its socket at location D1 and DIP shunts inserted into the sockets at locations C1 and D1. When installed in these locations, the DIP shunts wiII cause the I/O chain signals to terminate.

Figure 2.25 shows the location of these jumpers.

L

~6840114

Cl EMPTY

I I c

Factory Setting

(Cont inues l/O Chain Signals)

Last l/O Rack in Daisy Chain

(Terminates l/O Chain Signals)

Figure 2.25 l/O RECEIVER DIP SHUNT/JUMPER RACK CONFIGURATION



GEK-96602

2-45

If an I/O Receiver should be removed from the last rack in a daisy chain and moved to a rack upstream, the jumper pack and DIP shunts must be reconfigured to continue the I/O chain signals. Conversely, if an I/O Receiver is moved from a rack within the chain to the last rack in the chain, the jumper pack and DIP shunts must be reconfigured to terminate the I/O chain signals.

When a jumper pack is not inserted in location D1 or the DIP shunts are not installed in locations Cl and D1, they should be inserted in spare sockets located at the bottom of the printed circuit board. These spare sockets are in board locations F2 and F3.


Two 37 pin D-type connectors are mounted on the front edge of the module. The bottom connector connects to downstream l/O racks. The top connector connects to the next upstream l/O rack, to an I/O Transmitter at the opposite end of a parallel bus cable, or to an I/O Control module in’ a CPU rack.


There are three edge-mounted LEDs which provide a visual status of certain fault indications on the I/O chain. The LEDs are viewed through the lens on the faceplate.

Table 2.13 defines the status provided by each LED.

Table 2.13 l/O RECEIVER STATUS INDICATORS

INDICATOR

DEFINITION

POWER ON when station power is present, continuity is

ON present and all stations downstream are OK.

CHAIN

PARITY

ON when all downstream statlons have received good parity.

LOCAL

PARITY

ON when the I/O Receiver has received good output parity.


2-46


GEK-96602

Advanced l/O Receiver

The Advanced I/O Receiver module allows the I/O connected to a Series Six Plus CPU to be more versatile in how I/O failures are detected and enables the Series Six Plus CPU to respond to these faults. When using this module, all levels of Series Six Plus software can be programmed using relay logic to respond to l/O faults, such as a power supply failure or a break in the I/O cable. When this module is used with CPU software level 105 or above, relay logic can also be used to address the problems of input and output parity errors.

If any of the advanced diagnostics are to be used, an Input and Output address must be selected by setting two sets of DIP switches located on the board. The Inputs provide status information to the CPU relative to the Advanced I/O Receiver. The state of the output data is controlled by CPU relay logic programmed by the user. Any valid I/O address can be selected. The Input and Output addresses do not have to be the same; however, identical addresses can be selected.

In many applications it is desirable to allow the user program to decide whether the CPU should stop on an I/O system error or continue to run under controlled conditions. This module allows that decision to be made.

A decision can also be made to select a particular I/O chain (usually the chain that contains the fault) to be shut down while allowing the balance of the system to continue to run.

The Advanced l/O Receiver module provides status information accessible to the CPU user program indicating where in the I/O system an error occurred, and what type of error it was. Using this information the CP U can be programmed to respond in a controlled manner based upon the type of error include input and output parity, power supply faiI detected. Errors sensed by this module ure, and I/O cable failures.


The Advanced I/O Receiver module has two 37-pin connectors available through the faceplate, The top connector receives an I/O cable that is connected to an upstream I/O rack or directly to the CPU.

If coming from another upstream I/O rack, it may be connected to a standard or Advanced I/O Receiver module, or to a Local I/O Transmitter module. The bottom connector can be left unconnected, connected to a standard or

Advanced l/O Receiver module, or be connected to a Workmaster computer or Program

Development Terminal.

Any of the modules mentioned above can be connected and intermixed to meet the requirements of a given application.

On both the standard and Advanced l/O Receivers, the top and bottom connectors are connected together internally, thus, data signals can pass through them even though the

I/O rack may be non-functional.

In the Advanced module, data can also pass through even if the power supply is turned off.



GEK-96602 ~-

2-47

I/O Signal Continuation or Termination

Located

on the Advanced I/O Receiver module are two identical DIP resistor pacs. The location of these DIP pacs determines if the module is used in an intermediate l/O rack or used in the last rack of an I/O chain. The module is configured for use in an intermediate rack when the DIP resistor pacs are located in sockets U7 and US (default positions).

When configured as the last rack in an I/O chain, the resistor pacs must be located in sockets U12 and U 5 0 The resistor pacs are identical and thus can be interchanged.

Figure 2.26 is an illustration of the Advanced I/O Receiver, showing the location of user items.

a40205

1.

D-type 37-pin connector to upstream modules.

2. D-type 37-pin connector to downstream modules.

3. Resistor pac locations for last I/O rack in chain.

4. Resistor pac locations for intermediate I/O rack in chain.

5. Dip switch for selection of module options.

6. Dip switch for selection of Input address.

7. Dip switch for selection of Output address,

8. Location of 12 LED diagnostic indicators.

9. Location of external Reset pushbutton.

Figure 2.26 LOCATION OF USER ITEMS


2-48


GEK-96602

Status and Diagnostic Indicators

Twelve LED diagnostic indicators, visible through the faceplate, are mounted on the

Advanced I/O Receiver module. These LED's are used to indicate status and the results of diagnostic routines executed by the module. The last six indicators are latched-in (or turned off) when a fault is sensed as some faults may be transitory or intermittent.

These latched-in fault indications can be reset (if the fault is cleared) by depressing the

RESET pushbutton that is accessible through the faceplate, or by CPU logic sending a latch reset signal through the I/O chain. This signal is read by the module via the I/O addresses that have been previously set and enabled. Cycling the power of the rack that contains the module will also reset the LED indicators. Note that the power supply OK

LED indicator will be latched off when this is done. The following table describes the function of each diagnostic indicator.

Table 2.14 STATUS AND DIAGNOSTIC INDICATOR DEFINITIONS

CHN OK

CHNPAR

LOCPAR

BLANK

CHAIN OKAY, ON if power is okay in all downstream racks, and if cable continuity is okay to all downstream racks; OFF if one of the above conditions is not met.

CHAIN PARITY, ON 1f Output Parity is okay on rack backplane; OFF if

Output Parity Error is sensed from a Local Transmitter or Remote I/O

Driver in this rack.

LOCAL PARITY, ON if Output Parity 1s okay in this rack; OFF if this module has detected an Output Parity Error entering from an upstream rack.

The state of this LED is controlled by CPU logic and transmitted to the module via its I/O address. The default state of this LED is ON.

ADDPAR

DATPAR

ADDRESS PARITY, ON if no error 1s detected in the I/O address transmitted from the CPU through the I/O chain; OFF if a Parity Error is detected in the I/O address transmitted from the CPU. Successful retransmission of the address will clear the Parity Error.

DATA PARITY, ON if no error is detected in the I/0 data transmitted from the CPU through the I/O chain; OFF if a Parity Error is detected in the I/O data transmitted from the CPU. Successful retransmission of data will clear Parity Error.

XMITOK

CHN OK

TRANSMIT OKAY, ON if power is okay and cable continuity is okay to all downstream racks connected to a Local Transmitter or Remote I/O

Driver module that is located in this rack; latched OFF if the above conditions are not met in one or more of the connected racks.

CHAIN OKAY, ON if power and cable continuity is okay to all downstream racks directly connected to this Advanced I/O Receiver; latched OFF if the above conditions are not met in one or more of the connected racks.



GEK-96602

2-49

Table 2.14 STATUS AND DlAGNOSTIC INDICATOR DEFINITIONS (Continued)

PS OK POWER SUPPLY OKAY, ON If power supply in this rack is within tolerance; latched OFF if power supply should fall out of tolerance.

LED will-be latched off when power is applied to power supply.

IN PAR INPUT PARITY, the source of Input Parity Error is determined by the settings of SW6 and SW7 of the diagnostic dip switch; the LED is ON if no Input Parity Error is sensed; latched OFF if an Input Parity

Error is sensed from either a Local I/O Transmitter or Remote I/O

Driver module mounted In this rack, or from any downstream I/O rack that may be connected directly to the Advanced I/O Receiver module in this rack.

W DOG WATCH DOG TIMER, ON when communications to CPU is okay; latched OFF if the module has not communicated to the CPU within the last one second.

OUTPAR OUTPUT PARITY, ON if no Parity Error is detected in either the

I/O

address or I/O data transmitted from the CPU; latched OFF if a Parity

Error is detected.

This is a latch for ADDPAR and DATPAR indicators previously discussed.

For detailed information on operation of the Advanced I/O Receiver, refer to GEK-90771, which can be found in the Series Six Data Sheet Manual, GEK-25367.

I/O Transmitter

The I/O Transmitter module (figure 2.27) provides an interface between the rack backplane signals and the I/O bus to a downstream Local I/O station. In addition, the mode of operation, either NORMAL or EXPANDED, must be specified by jumper configuration.

In the NORMAL mode, there is 1 Main and 1 Auxiliary I/O chain

(maximum of 2000 Inputs/2000 Outputs) per CPU.

In the EXPANDED mode, there are up to 8 I/O chains (16 with Auxiliary I/O) per CPU. In this configuration, up to 16K Inputs and 16K Outputs (including Auxiliary I/O), are allowed per system. In the EXPANDED mode, if only Channels 0 and 8 are selected, an I/O Transmitter is not required to drive those channels. However, if more than 2 channels are selected, each channel must be driven by an I/O Transmitter*

Any l/O Transmitters located downstream from the first one in a link must be configured to the N0RMAL mode of operation. In other words, if an

I/O Transmitter in the CPU rack or the first I/O rack has been configured for

EXPANDED mode, any other I/O T r a n s m i t t e r s o n t h a t l i n k m u s t b e c o n f i g u r e d f o r

NORMAL mode. Likewise, when the first l/O Transmitter in a link is configured to the

NORMAL mode, all other II0 Transmitters downstream must also be configured to the

NORMAL mode.

An I/O Transmitter must be used to interface to a Local I/O station if l/O racks are required beyond the capacity of a CPU station (10 I/O racks), an existing Local I/O station or a Series Six Plus CPU rack. Any number of I/O Transmitters can be installed in a rack as long as the l/O load for the rack and the distance limitations are not exceeded.

An I/O Transmitter can be installed in a Remote I/O station and linked to additional l/O

Transmitters up to 2000 feet 6OO meters), thereby extending the Remote I/O capability by that distance.

Each I/O Transmitter link cannot exceed 500 feet (150 meters). No more than four I/O Transmitter links can be used with the 2000 foot limitation on the parallel I/O chain.



GEK-96602

Data received at the CPU from each I/O Transmitter is placed in the input status table for input bits IX+1017 through IX+1024 for the addressed channel. The data in this status byte is: bits 1-3, channel number; bit 4, card present; bits 5 and 6, set to 0; bit 7, fault trap enable; bit 8, fault present. If the I/O Transmitter does not respond when addressed, nothing will be written to the input locations for that channel. The channel will be scanned regardless of whether the module responded or not.

When the I/O Transmitter receives its address in the output data (to address 127 (I/O points 1017-1024)) during the l/O scan it connects its channel, as selected by DIP switch setting, to the CPU’s I/O chain, thereby enabling its I/O channel. When the data to address 127 is changed to a value other than the DIP switch setting, the I/O Transmitter disconnects its l/O channel from the CPU’s I/O chain. When the value 80H (Hexadecimal) is written to address 127 by the CPU, it is interpreted as a command to all of the I/O

Transmitters to connect their channels to the CPU’s l/O chain (but will not cause them to send input data to the CPU).

a 4 0 7 5 7

1 D - T y p e 3 7 - P i n C o n n e c t o r t o I / O

R e c e i v e r o r A d v a n c e d I / O

R e c e i v e r i n D o w n s t r e a m L o c a l

I /O station.

2 C H A I N O K L i g h t :

3 C H A I N P A R I T Y L i g h t :

4 ISOLATED POWER Light:

5 FAULT ENABLE Li ght:

6

CHAIN ACTIVE LIGHT:

N o t v i s i b l e w i t h f a c e p l a t e i n p l a c e , f o r u s e i n s y s t e m s e t u p o n l y .

ON for EXPANDED I/O MODE.

7 F A U L T E N A B L E / D I S A B L E S e l e c t o r :

8

NORMAL/EXPANDED I/O SELECTOR: a . P l a c e t h e j u m p e r (JP2) o v e r p i n s 1 - 2 f o r N O R M A L I / O .

O n e n o n s e l e c t a b l e I / O c h a i n .

b .

P l a c e t h e j u m p e r ( J P 2 ) o v e r p i n s 2 - 3 f o r E X P A N D E D I / O

S e l e c t a b l e 1 t o 8 c h a i n s .

Figure 2.27 I/O TRANSMITTER MODULE

Isolation Circuitry

The l/O Transmitter translates the I/O rack backplane signals into isolated, balanced signals at a level suitable for transmission up to 500 feet (150 meters) and with sufficient power to drive up to 10 l/O Receivers. Optocouplers on the module isolate signals passing through the module and a DC to DC converter provides a +5V dc isolated supply voltage to those circuits connected to the parallel l/O bus. This method of isolation ensures that all Local I/O stations are electrically isolated from each other and from the CPU station.



GEK-96602

2-51

Location in Rack and I/O Channel Addressing

An l/O Transmitter can be installed in any card slot in an I/O rack except the leftmost slot which is normally reserved for an I/O Receiver. The seven segment DIP switch on the backplane adjacent to the selected slot for the module does not need to be set for an

I/O address, since an I/O Transmitter does not require an I/O address. However, the first

3 (1, 2, and 3) switches on the DIP switch package must be set to select an I/O channel number, when required by system configuration.


A monitor circuit checks the output level of the isolated +5V dc supply. If the output is not within its specified tolerance, the monitor circuit causes the I/O Transmitter to shut down. An LED indicator (ISOLATED POWER) is on when the voltage is within tolerance.

The status of other LED indicators are defined in table 2.15.

Table 2.15 I/O TRANSMITTER STATUS INDICATOR DEFlNlTlONS

INDICATOR

CHAIN

OK

CHAIN PARITY

ISOLATED

POWER

FAULT

ENABLE

CHAIN

ACTIVE

DEFINITION

ON when station power is OK and continuity is present to all downstream stations.

ON when output parity is OK at all downstream stations.

ON when the output voltage of the +5V dc

.

ON when the module has been configured to stop the system for a local fault condition.

This LED is not visible through the faceplate.

Used for set up only. When ON, indicates that the

EXPANDED I/O chain is active.

Configuration Jumpers

Two items are configurable by placing a jumper plug over the desired set of pins. By configuring JP1, the user can select to enable the system stop for a local fault or not

to

stop the system on a local fault. The second jumper plug, JP2, is used to select the I/O mode of operation for this module, either NORMAL I/O (one non-selectable I/O chain) or

EXPANDED I/O (1 to 8 selectable l/O channels).

Connector

One 37 pin D-type connector is mounted on the bottom front edge of the circuit board. A

16-pair parallel cable plugged into this connector in a Series Six Plus CPU, a CPU station or a Local I/O station connects to the first I/O Receiver or Advanced I/O Receiver in a local I/O station at a distance not to exceed 500 feet (150 meters).


2-52


GEK-96602

REMOTE I/O SYSTEM

A Remote I/O system allows a Series Six Plus system to have an I/O capability that extends beyond the limit of the 2000 feet (600 meters) maximum distance allowed with the parallel l/O bus. A Remote I/O system can be located a maximum of 10,000 feet (3

Kilometers) from a CPU, a CPU station, or a Local I/O station when using a two twisted-pair serial cable. In addition a Remote I/O system can be transmitted over voice grade telephone lines through RS-232 or RS-422 compatible modems to a location a great distance from the originating l/O station.

System Connections

A Remote I/O system consists of a Remote I/O Driver, a two twisted-pair serial cable or modems and a Remote I/O Receiver. The Remote I/O Driver is installed in an I/O slot in a CPU, a CPU station or a Local I/O station. The Remote I/O Driver is then connected by cable or a modem link to a Remote l/O Receiver in the first slot of the first I/O rack in a Remote l/O station.

If the Remote I/O Driver and Remote I/O Receiver are to communicate over a modem link, the Remote Receiver module must be installed in a High Capacity l/O rack and the

Remote Driver must be in either a High Capacity I/O rack or a CPU I/O slot, since a 12 V dc source must be available to conform to RS-232 specifications. Figure 2.28 illustrates the two methods of system configuration described above.

b4106fi

*When connecting to a Remote I/O station through modems (RS-232 interface) the

Remote I/O Driver and Remote I/O Receiver must be installed in High-Capacity I/O racks.

Figure 2.28 TYPICAL REMOTE I/O SYSTEM CONNECTIONS



GEK-96602

2-53

Remote System Response Time

The response time of a Remote I/O system is slightly delayed because of the distance when using up to the 10,000 foot (3Km) maximum cable length. The response time is delayed further when connection to the Remote I/O is made through the communications

link

using modems. Part of the delay is due to the fact that the Remote l/O Driver stores output and input data and provides this data when needed to the Remote I/O Receiver and the CPU. This store and forward technique results in a one sweep delay.

NOTE

A one sweep delay for inputs can be avoided if a DO I/O instruction is executed for the Remote l/O prior to executing any logic using remote inputs.

System response times to the Remote I/O for each of the valid baud rates are summarized in table 2.16. The times as listed are approximate maximum response times and may vary slightly from system to system.

These response times are due to hardware considerations related to communications between a Remote I/O Driver and a Remote

I/O Receiver (component tolerance, cable length, etc.).

Table 2.16 TYPICAL SYSTEM RESPONSE TIMES TO REMOTE I/O

Quantity of

I/O

in Block 110 300

I/O

.6 sec 2 sec

Output Delay 10 sec 4 sec

Input Delay

1 1200

I

2400

.5 s e c .25 sec

.9 sec 0 . 5 sec

248

I/O

Output Delay 18 sec

Input

Delay

11 sec 2 sec

4 sec

1 sec .5 sec

1.6 sec .9 sec

57.6K

20 ms

25

ms

.14 sec 75

ms

30 m

.2

sec .l sec 46 ms

I

(1)

(2)

+l sweep for all baud rates

+2 sweeps for all baud rates

REMOTE I/O ADDRESSING

A Remote I/O system normally responds to a block of 128 inputs and 128 outputs or 256 inputs and 256 outputs.

However, eight inputs and eight outputs are used by the Remote

I/O Driver for system status information, thus allowing a total of either 120 inputs and outputs or 248 inputs and outputs.

The block of either 120 I/O or 248 l/O is selected by positioning of a jumper on the Remote I/O Driver module.


2-54


GEK-96602

The unique I/O points (addresses) for each module in

a

Remote I/O station are selected by setting the seven segment DIP switch on the backplane adjacent to each slot in the I/O rack. However, all I/O points selected must be within the block selected for the Remote l/O station. The I/O points in a remote system must be within one of the blocks as listed in table 2.17.

Table 2.17 I/O POINT RANGES IN REMOTE I/O STATIONS

120 Inputs/l20 Outputs

1 - 128

129 - 256

257 - 384

385 - 512

513 - 640

641 - 768

769 - 896

897 - 1000 (1)

248 Inputs/ 248 Outputs

1 - 256

257 - 512

513 - 768

769 - 1000 (2)

(1) This block selected allows 96 inputs and 96 outputs.

(2) This block selected allows 224 inputs and 224

outputs.

The address selected for the Remote I/O Driver can fall anywhere within the range of I/O points in a block.

All I/O modules in a Remote l/O station (including the Remote l/O

Driver) must have switches 5, 6 and 7 (120 l/O) or 6 and 7 (248 I/O) set the same. By doing this all modules in

a

Remote station are thus tied to that particular Remote

I/O

Driver. More than one Remote I/O station can be programmed to the same l/O block; however, each Remote Driver must have its own unique address. Each Input module must also have

a

unique address; output module addresses can be duplicated. Unused l/O points in a Remote

I/O

station

can

be used by another Remote I/O station,

a

Local l/O station,

a

CPU station or a CPU I/O slot.

Printed Circuit Board Jumpers

There are several printed circuit board jumper plugs which must be properly configured for operation of a Remote I/O system. Jumper plugs are located on both the Remote l/O

Driver and the

Remote l/O Receiver. Factory configuration of these jumpers is set for the following options.

a

?

120 Inputs

and

120 Outputs

Connection up to 10,000 feet (3Km) using two twisted pair serial cable

?

Baud rate - 57.6Kb

?

Halt CPU on communications failure or Remote I/O parity error.

a

Turn all outputs off on communications failure

0

Odd serial parity

If a

block of 248 Inputs and 248 Outputs, or the Remote I/O system is to be linked with

RS-232 compatible modems, or any of the other options are to be changed, the printed circuit board jumper plugs must be reconfigured.

Refer to the applicable data sheet in the Series Six Data Sheet manual, GEK-25367, for board jumper configuration.



GEK-96602

2-55


The Remote I/O Driver module provides control and data signals to a Remote l/O stat ion.

Circuitry on this module converts output data from parallel to serial and input data from serial to parallel, Specifically, a Remote I/O Driver connects the l/O structure in a CPU, a CPU station or a Local l/O station to a Remote I/O station through a serial communications channel by direct connection with a two twisted-pair cable or a communications link using RS-232 compatible modems.

With two twisted-pair cable,

the Remote

I/O station can be located up to

a

maximum of

10,000 feet (3 km) from the Remote I/O Driver. A communications link using modems allows connection over a much greater distance.

An I/O Transmitter located in a rack in the Remote l/O station can be the first of

a

link of up to four 500 foot (150 meters) links

using

f/O Transmitters, thereby extending the remote capability an additional 2000 feet

(600 meters).

a41069

C O N N E C T O R T O

R E M O T E I 0

RECELVER OR-

Figure 2.29 REMOTE I/O DRIVER MODULE

The Remote I/O Driver can drive up to 248 Inputs and 248 Outputs. A Remote l/O Driver module can be installed in any unused l/O slot in a CPU station, a Local I/O station or a

CPU (except the left most slot in

an

I/O rack which is reserved for a Receiver module).

If connection to the Remote I/O station is to be made through a modem link, the Remote

I/O Driver must be installed in a high capacity l/O rack. This is necessary since the

RS-232 specification requires +I2 and -12 V dc for operation.


2-56


GEK-96602

Remote

I/O Driver Addressing

A block of addresses for the Remote I/O station is established by setting the seven segment DIP switch adjacent to the slot selected for the Remote l/O Driver. For

a

block of 120 I/O, switches 5, 6, and 7 are set to select the block and for 248 I/O, switches 6 and

7 are set to select the block of I/O addresses. All I/O modules in the Remote I/O station connected to a Remote l/O Driver must then have the corresponding DIP switch segments set in the same configuration as the Remote I/O Driver. In all cases switches 1 to 4 or 1 to 5 (in addition to 5, 6, 7 or 6, 7) are configured to set a unique address for each module in the Remote I/O station; i.e. 1-8, 249-256, 673-680, etc.

A unique I/O reference (address) must also be set for the Remote l/O Driver and can be the first of any group of eight consecutive valid I/O references within the selected block.

The eight input references provide status information which can be monitored on the programmer by observing the byte in the applicable Input Status Table (Normal mode or

Channel 0) or Register location associated with the I/O channel in the EXPANDED mode.

The eight output references are for future use.

Table 2.18 REMOTE I/O DRIVER STATUS BYTE

INPUT I/O REFERENCE INFORMATION PROVIDED

7

6

2

3

4

1 10297 (1) Input toggles every time new input data is transferred to the CPU.

IO298

10299

10300

Reserved

Reserved

Remote Parity

0= Parity error in Remote

1 = Remote parity good.

I/O

station.

5

10301

10302

Remote OK

0= Fault in Remote System

(Power supply failure, parity error, etc.)

1 = Normal operation, Remote I/O OK

.

Link OK

0= between Remote

I/O

Driver and Receiver.

1 = Communications link good.

10303 Local OK

0 = Fault in Remote

I/O

Driver module.

1 = Remote I/O Driver operation normal.

8 100304 Heartbeat

This input cycles from 0 to 1 (O/1/O/l, etc.), changing with each I/O scan when Remote I/O is operating normally.

If any input status (4-7) is set to zero, cycling stops and the status will contain the last valid data received (0 or 1).

(1) I/O references shown are typical, and are only used as an example.



GEK-96602

2-57


There are four LED status indicators viewed through the faceplate lens. The four LEDs display the same status information as that indicated by the state of Inputs 4 through 7 in table 2.18. These indicators and their meanings are listed below in table 2.19 in the same order as they appear on the module faceplate.

Table 2.19 REMOTE I/O DRIVER STATUS INDICATORS

INDICATOR

LOCAL

OK

LINK

OK

REMOTE

OK

REMOTE

PARITY

DEFINITION

ON

Remote

I/O Driver module operating normally.

OFF Fault in Remote I/O Driver.

ON Communications link between this module and Remote

Receiver good.

Of Communications error between this module and Remote

Receiver.

ON Remote system is operating normally.

OFF Fault exists in Remote

I/O

system. (Power supply failure, cable loose, module not seated properly, etc.

ON Remote system has no parity errors, operation normal,

OFF Parity error detected in Remote

I/O

system, CPU will stop unless option, jumper on this module is set for

CPU to RUN when error detected.

Option Jumpers

Several jumpers located on this module are used for configuration of various options necessary for system and module operation.

Table 2.20 lists the factory and alternate settings for the Remote I/O Driver options.

Table 2.20 REMOTE I/O DRIVER OPTION SETTINGS

OPTION

Block Size

Baud Rate

Serial

CPU Status on

Communications

Failure

Remote I/O

Parity Error

Communications

Link

FACTORY SETTING OPTIONAL SETTING

120 Inputs/l20 Outputs 248 Inputs/248 Outputs

57.6 Kb User Selected

Yes/Odd

STOP CPU

Yes/Even or No

Allow CPU to RUN

STOP CPU

Two Twisted Pair To

10,000 feet (3 Km)

Allow CPU to RUN

RS-232 Modem Link


2-58


GEK-96602


The Remote I/O Receiver module is the interface to the serial communications link for a

Remote I/O station.

It is physically located in the first rack in a Remote I/O station, normally in the left slot since the Remote l/O Receiver does not require an I/O address

(there is no DIP switch on backplane adjacent to the left slot).

A Remote I/O Receiver connected to a Remote I/O Driver through a two twisted pair cable can be installed in any I/O rack. If connection to the Remote I/O station is to be through a communications link using RS-232 compatible modems, then the Remote I/O

Receiver must be installed in a high capacity I/O rack.

a41067

TO-

REMOTE

I/O DRIVER

O R

RS

;-232C MODEM c

TO-

IOWNSTREAM

I/O RECEIVER

OR REMOTE

I/O RECEIVER

Figure 2.30 REMOTE l/O RECEIVER MODULE

Circuitry on this module converts output data from serial to parallel and converts input data from a parallel to a serial format: The Remote I/O Receiver also isolates the serial data cable from the backplane bus and provides error checking circuitry. If more than one I/O rack is required in a Remote l/O station, the additional racks are daisy chained to the Remote I/O Receiver through I/O Receivers or Advanced I/O Receivers.


2-59


GEK-96602

Connectors

A Remote I/O Receiver has two edge mounted D-type connectors. The top connector (25 pin) connects to a Remote I/O Driver at the opposite end of the serial communications link using a two twisted-pair cable or to a modem located no more than 50 feet (15 meters) from the Remote I/O Receiver.

The lower connector (37 pin) provides a connection through a 16-pair parallel bus cable to an l/O Receiver or Advanced l/O Receiver module located in the next downstream rack in a Remote I/O station. If no connection is to be made to the lower connector, the I/O chain signals must be terminated. This is done by reconfiguring three jumper plugs on the printed circuit board which performs the same function as reconfiguring the jumper pack and DIP shunts on an l/O Receiver or Advanced t/O Receiver module.


The Remote I/O Receiver has four LED indicators visible through the faceplate lens. The legends on the faceplate lens are the same as those on the Remote I/O Driver.

Table 2.21 REMOTE I/O RECEIVER STATUS lNDlCATOR DEFlNlTlONS

I

INDICATOR

LOCAL

OK

LINK

OK

REMOTE

OK

DEFINITION

ON Remote I/O Driver module operating normally.

OFF Communications fallure or addressing difference between Local and Remote Stations.

ON Communications link between this module and Remote I/O

Driver established and valid.

OFF Communicat!ons failure between this module and

Remote I/O Driver.

ON Remote system Is operating normally.

OFF Fault in Remote I/O system. (Illegal address block, loose connection, power supply failure)

REMOTE ON Remote system operating normally with no parity errors.

PARITY

OFF Parity error detected 1n Remote I/O system.

Option Jumpers

There are several circuit board jumpers on this module which

are

used for option selection and 1/O chain signal termination. Jumpers are factory set prior to shipment and must agree with the Remote l/O Driver to which the Remote I/O receiver is connected.

Table 2.22 lists the factory and alternate settings for the Remote I/O Receiver options.


2-60


GEK-96602

Table 2.22 REMOTE l/O RECEIVER OPTtONS

OPTION

Baud Rate

FACTORY SETTING CHOICES

57.6 Kb User selected

Parity

Communications

Failure at

Remote I/O

I/O Chain Signals

Yes/Odd

Turn all

Yes/even or no

Hold all outputs outputs Off at last state

I/O Chain Signals have

I Terminate I/O chain continuity through this Signals at this module module.

Instructions for reconfiguring any of the circuit board jumpers to change options can be found in the applicable data sheet (see GEK-25367, Series Six Data Sheet manual) for this module. Jumper options are required when selecting the RS-232 option and are listed in the chapter on installation in this manual.

In addition, there are jumpers reserved for future expansion or production testing and should not be changed.

AUXILIARY I/O SYSTEM

The Auxiliary I/O system allows the total number of I/O points in a Series Six Plus PLC system to be doubled. If an Auxiliary t/O module is inserted into slot 6 or 7 of a CPU rack, an l/O system functionally identical to the main I/O system can be originated at the

CPU. The Auxiliary l/O chain is scanned in parallel with the Main I/O chain. The

Auxiliary I/O chain does not increase the total CPU scan time.

The structure of the Auxiliary l/O system provides the Series Six Plus CPU with an additional 1000 inputs and 1000 outputs when operating in the NORMAL I/O mode of operation. Thus, the total I/O capacity of the Series Six Plus PLC when in the NORMAL

I/O mode, with the Auxiliary l/O system selected is 20 00 inputs and 2000 outputs.

If

the

Auxiliary I/O module and the EXPANDED I/O mode of operation have been selected, an additional 8000 Inputs and 8000 Outputs are available to the PLC system.

~-~ outputs.

The Auxiliary I/O module can be used in either a Series Six Plus CPU rack, or in a Series

Six model 6000 CPU rack. When used with the Series Six model 6000 CPU, the maximum

I/O is 2000 Inputs and 2000 Outputs.

A group of 4 DIP shunts must be inserted in one

of two

locations, determined by which CPU the module is to be used with, either Series Six

Plus or Series Six model 6000.

All information pertaining to use of Input and Output modules, I/O interface modules, cable type and distance allowed between racks and stations is applicable when configuring

an Auxiliary I/O system.

Inputs and Outputs in the Auxiliary I/O chain can be overridden as in the Main I/O chain, (with the Expanded

II

instruction set), when in the Normal mode. When in Expanded l/O mode, only Channel 8 (AI/AO) has overrides.



GEK-96602

2-61

A standard I/O cable, catalog number IC600WDXXX (where XXX is a 3 digit number corresponding to the selected cable length), provides the connection to the Auxiliary I/O chain and is made to a connector located at the bottom of the faceplate of the module.

The cable is connected from the Auxiliary I/O module, through the l/O cable, to the top connector on the l/O Receiver or Advanced I/O Receiver in the first l/O rack in the

Auxiliary I/O chain.

b 4 0 7 6 2

SEFHES

@ S I X

PLUS

::ii::

0:IiI:

II

?

??

??

??

1. D-Type 37 pin Connector to

Auxiliary I/O Chain connects to I/O

Receiver or Advanced I/O Receiver in nearest I/O rack in auxiliary chain.

2. CHAIN OK LED

On: Continuity, power, and output data parity are OK at all I/O stations in the auxiliary chain.

Off: A continuity, power problem or output data parity error exists at one or more auxiliary chain I/O station(s).

3. PARITY LED

On: Input data parity is OK at the

Auxiliary l/O module.

Off: Input data parity error exists.

4. ENABLED LED

On: The outputs are enabled. CPU is operating in the RUN ENABLED mode.

Off: The outputs are disabled. CPU in the RUN DISABLED or the STOP mode.

5. Shunt location A (Factory installed locat ion)

6. Shunt location B

Figure 2.31 AUXILIARY I/O MODULE BOARD LAYOUT


2-62


GEK-96602

WORKMASTER COMPUTER TO SERIES SIX PLUS PLC CONNECTIONS

The Workmaster computer can communicate with a Series Six Plus PLC using either a parallel or serial version of the Logicmaster 6 software. The methods of connection from the Workmaster computer to the Series Six Plus PLC are described in the following paragraphs.

Workmaster to Series Six Interface Adaptor Boards

This is a two-board option which provides high speed parallel communications between the Series Six Plus PLC and the Workmaster computer through the Logicmaster 6 contains the circuitry necessary to format and transfer data between a Workmaster computer and

a

Series Six Plus PLC. This board requires a long slot for instaflation.

which contains the circuitry

to

terminate and protect data lines between the Series Six

Plus PLC and the Workmaster computer. This board requires a short slot for installation.

There are two DIP rocker switches on the board which must be configured as described below.

These two boards are connected together inside of the Workmaster computer by

34-wire ribbon cable. The boards can-be installed in any 2 unused slots in the Workmaster computer with the requirements that the full-size board must be installed in a long slot and the half-size card be installed close enough for the ribbon cable to reach. These

a

boards should

be

installed as instructed in the Workmaster Guide to Operations Manual,

GEK-25373.

Connection to I/O Control or I/O Receiver Modules

The factory setting for the DIP switches on the Terminator board is

ALL

of the switches set to the OFF (open) position. This is the correct setting for connecting a Workmaster computer to the I/O Control module in the CPU rack or to an I/O Receiver or Advanced

I/O Receiver in a CPU station or Local I/O station. The maximum distance for this type of connection is 10 feet (3 meters).

Connection to

an

I/O Transmitter Module

When

ALL of

the switches are set to the ON (closed) position, the parallel l/O bus is properly terminated for long distance communications through an l/O Transmitter module up to 500 feet (150 meters) away. With this configuration, the l/O Transmitter module must be dedicated to communicating with the Workmaster computer.

All of the DIP switches on the Terminator Board must be set properly as described above. Failure to do so may result in the Series Six Plus CPU stopping in an incorrect state or incorrect operation of the I/O bus which may cause the outputs to be directed to

an

incorrect state.


2-63


GEK-96602

The valid connections for the Workmaster computer to the parallel I/O chain are illustrated in figure 2.32.

a41085

1

ONLYONEWORKMASTER

CAN ;#tth$TED

p-‘-‘.-1 .

1

r-I------- -: WCMKMASTER f f

I t ----------I

THE CABLE CONNECTING

WORKMASTER TO THE

SERIES SIX FLUS IS A

STANDARD l/D CABLE

I/o CONTROL

r-

ADVANCED I/O RECEIVER

OR I/o RECEIVER d,ff--j- t/O TRANSMITTER

-i 5Kl*

1 WORKUASTER k-------wem-u-w-1

1

I r

I

I

500 FT.

L - m - -

MAX.

- C~J STATION

ADVANCED I/o RECEIVER

OR I/O RECEIVER

/-----------I

--: WORKMASTER 'I

I

---------s-d i f

?

I

1 WORKbfASTER

LOCAL I/O STATION

Figure 2.32 WORKMASTER COMPUTER CONNECTIONS TO THE SERIES SIX PLUS PLC

Connecting Cable

The cable to be used for connecting the Workmaster computer to a Series Six Plus PLC is a standard parallel I/O bus cable.

Following is a list of catalog numbers for these cables.

CATALOG NUMBER

CABLE LENGTH

IC600WD002

IC600WD005

IC600WD0l0

IC600WD025

IC600CJD050

IC600WDl00 (1)

IC600WDZ00 (1)

IC600CJD500 (1)

2 feet (0.6 meters)

5 feet (1.5 meters)

10 feet

25 feet

(3.0 meters)

(7.5 meters)

50 feet

(15.0 meters)

100 feet (30.0 meters)

200 feet (60.0 meters)

500 feet (150,O meters)

(1) To be used only for direct connection to a dedicated I/O Transmitter module in a

Series Six Plus PLC system.


2-64


GEK-96602

Connections Using the

Serial

Version of Logicmaster 6

The Workmaster computer can also communicate with a Series Six Plus PLC using the serial version of Logicmaster 6 software. The Workmaster computer must be connected to the

CCM2

in the Series Six Plus CPU rack or to a CCM3 operating in the CCM2 mode.

The CCM3 catalog number must be IC6OOCB517C or later.

The CCM2 must be configured for Workmaster protocol. Cable connection to the CCM2 is to the COM1 port on the Workmaster computer. The location of the COM1 port is determined by the type of communication to be used.

When point-to-point communications over distances less than 50 feet (15.0 meters) is used, connection at the Workmaster computer is made to the 9-pin connector on the

Combination Adapter card.

If point-to-point communications over distances greater than 50 feet or multidrop communications are used, the Asynchronous/Joystick card must be used in the

Workmaster computer. When this configuration is used, the Combination Adapter card must be configured as COM2, and the Asynchronous/Joystick card configured as COM1.

For more detailed information on installation and configuration of the above cards, refer to the Logicmaster 6 User’s Manual, GEK-25379.

USING THE CIMSTAR I COMPUTER WITH A

SERIES SIX PLUS PLC

The CIMSTAR I computer can also be used as the programming device with a Series Six

Plus PLC. It can run either the parallel or serial version of the Logicmaster 6 software.

The serial version does not require any additional equipment added to the CIMSTAR I computer. The parallel version requires installation of an additional board set. Both versions require GE-DOS version 1 or later, which is equivalent to MS-DOS version 3.2.

This version of DOS is supplied with the computer. Refer to GEK-25379, the

Logicmaster 6 Programming and Documentation Software User’s manual, Chapter 2 and

Appendix A, and GEK-90527, the CIMSTAR I Industrial Computer Reference Manual, for further information on the CIMSTAR I computer hardware requirements and use.

Parallel Version of Logicmaster 6 Software

The parallel version communicates with a Series Six Plus PLC through a standard l/O interface cable, as with the Workmaster computer.

The following board set must be installed in the CIMSTAR I computer for parallel communications with a Series Six Plus

PLC:

This board set was previously described under “Workmaster to Series Six Interface

Adapter Boards”.



GEK-96602

2-65

Serial Version of Loqicmaster 6 Software

The serial version, when installed in a ClMSTAR I computer, communicates with a Series

Six Plus PLC over a serial communications channel to a CCM module in the Series Six

Plus PLC. Communication is possible over a long distance using a wide range of baud rates, either with or without modems. The system can communicate with a single CCM module and CPU, or be used in a multi-drop configuration having up to eight CCM modules and CPUs.

PROGRAMMING A SERIES SIX PLUS PLC WITH AN IBM PC

The IBM PC version of the Logicmaster 6 software can be used to program a Series Six

Plus PLC when installed in an IBM PC, IBM PC-XT, or IBM PC-AT computer that meets the following requirements:

- 640K of RAM memory later for the IBM PC-AT.

- Either

a

color or monographics monitor adapter card. The software will also support

the

Enhanced Graphics Adaptor (EGA) card.

The Logicmaster 6 software for the IBM PC version is available as a set of three 5.25 inch

360K diskettes. Performance of the software with other versions of DOS or on other IBM

PC-compatible computers is not guaranteed. The system supports the IBM monochrome adaptor board and the asynchronous communications adaptor board. It does not support serial communications adaptors based on the 8250 UART.

An IBM PC-based Logicmaster 6 system communicates with a Series Six Plus PLC through the serial ports, to a CCM module in the Series Six Plus CPU rack. The IBM PC version of Logicmaster 6 software communicates and functions in the same way as does the serial version for the Workmaster computer.

REDUNDANT PROCESSOR UNIT

The Redundant Processor Unit (RPU) monitors the CPU and I/O. When the RPU detects a failure of the CPU or I/O, it switches to a backup CPU and (optionally) to a backup I/O chain. For more information about the module, refer to the Redundant Processor Manual

(GEK-25366).

I/O Addressinq for the RPU

Originally, the RPU used pre-assigned inputs and outputs in the Main I/O Status Tables.

These inputs and outputs could not be changed.

The upgraded version of the RPU uses hardware-selectable I/O addresses.

IBM is a registered trademark of International Business Machines Incorporated


2-66


GEK-96602

The older type of RPU should not be used in a system with Expanded I/O addressing. The older RPU uses 8 outputs (O1017 through O1024) to control its operations. Setting O1017 in the Master will cause transfer to the Back-up CPU (if it is available). lf O1022 is set, outputs from the Main I/O Status Tables and the Override Table are transferred from the

Master to the Back-up. If O1023 is set, register R0254 is transferred from the Back-up to the main CPU. If O1024 is set, a block of registers starting at the address specified by the value in register R0255, and ending at the value in register R0256 will be transferred from the Master to the Back-up. The 8 inputs (I1017 through I1024) and 8 outputs O1017 through O1024) are always mapped into the Main I/O Status Table. Of the 8 inputs, only input 1024 is used. It is set to “1” if the associated CPU is the backup.

Only the upgraded model RPU should be used in an Expanded I/O system. In Expanded addressing, an l/O Transmitter Module in either channel 0 or channel 1 will write data into the references formerly assigned only to the RPU. For example, for channel 0, the status of the l/O Transmitter module maps into Main I/O at addresses I1017 through

I1024. However, I1024 is the input normally used by the RPU to specify the end of the register block to be transferred from the Main CPU to the Back-up CPU. The upgraded model RPU features jumper-selectable addressing.

This allows greater memory

access,

and permits assignment of non-conflicting I/O addresses to

the

RPU.

Proqram References for the I/O Transmitter Module

If the Expanded mode is enabled, the module uses the references listed below. If

Expanded mode is disabled, the module operates without the additional diagnostics, and does not use any I/O references.

Channel Return Status Memory Locations

5

6

7

MAIN I/O CHAIN

Location

I1017-I1024

R256 (high byte)

R384

R512

R640

R768

R896

R1024

AUXILIARY I/O CHAIN

ChanneI Location

R128 (high byte)

R1280

R1408

R1536

R1664

R1792

R1920

R2048

Expanded Addressing for a System with an RPU

Formerly, the Redundant Processor Unit was required to use input I1024, outputs O1017,

O1022, O1023, and O1024, and registers R254-256. Referring to the list above, you can see that there is a conflict with the channel status return memory locations for channels

1 and 2. Using channel 0 or 1 results in information from the I/O Transmitter module on that channel being written into references assigned to the RPU. To avoid this conflict, a system with Expanded I/O addressing should use the enhanced version of the RPU.


Installation Instructions

GEK-96602

3-1

CHAPTER 3

INSTALLATION INSTRUCTIONS FOR THE SERIES SIX’” PLUS


INTRODUCTiON

This chapter contains information which will aid in installing the Series Six Plus

Programmable Logic Controller and preparing the system for use, Included are instructions for unpacking/packing, inspecting, installing in a rack or panel, setting internal switches, and connecting cables.

procedure for the Series Six Plus CPU

to

be followed when bringing up a new CPU for the first time.

At the end of this chapter is a start-up

QUALITY CONTROL

Each Series Six Plus PLC undergoes a thorough quality control inspection and extensive system testing before being shipped. Each part of a system undergoes environmental and operational tests before leaving the factory.

PACKAGING

The method of packing and shipping the components of a Series Six Plus PLC system are outlined in this section.

CPU racks are shipped to include the following modules and other components: Power

Supply, I/O Control, and Arithmetic Control modules, I/O Terminator plug, board extraction/insertion tool, and rack mounting brackets and screws. The power supply,

I/O Control module and Arithmetic Control modules are seated in their proper slots in the rack. The ribbon cable for connecting the Arithmetic Control to the Logic

Control modules is connected to the Arithmetic Control module. Blank faceplates must be ordered separately for the remaining slots and are shipped separately.

The CPU rack is inserted into 2 halves of foam plastic sections. This is then placed in an antistatic plastic bag along with the rack mounting brackets, hardware for mounting the brackets, a printed circuit board extraction/insertion tool, an I/O

Terminator plug and the Series Six Plus User’s Manual. This package is then placed in a shipping container.

The Combined Memory, Logic Control and any optional modules are shipped in a separate container.

Each module is placed in the bottom of a two-section foam plastic package. Two inserts are provided, one for the printed circuit board and one for its faceplate. The top section is added and this package is inserted into a sleeve.

Either 2, 5 or 10 module packages are then placed in a shipping container.

l/O racks are shipped with only the power supply in place. The I/O racks and I/O modules are packaged the same as the CPU rack and modules.


3-2


GEK-96602

The Workmaster or Cimstar I industrial computer is packed in

a

separate shipping container. It is recommended that the shipping containers and all packing material be saved in the event that it becomes necessary to transport or ship any part of the system.

VISUAL INSPECTION

Upon receiving your Series Six Plus PLC system, carefully inspect all shipping containers for damage during shipping.

If any part of the system is damaged, notify the carrier immediately. The damaged shipping container should be saved as evidence for inspection by the carrier.

It is the responsibility of the consignee to register a claim with the carrier for damage incurred during shipment. However, GE Fanuc - NA will fully cooperate with the customer should such an action be necessary.

PREINSTALLATION CHECK

After unpacking the Series Six Plus CPU and I/O racks, all modules, the Workmaster computer, and any peripherals that have been ordered as part of a system, it is recommended that serial numbers of the CPU, Workmaster computer, and any peripherals be recorded. The serial numbers are required if Product Service should need to be contacted for any reason during the warranty period of the equipment.

Verify that all components of the system have been received and that they agree with your order,

If the system received does not agree with your order call your PtC

Distributor or GE Fanuc - NA sales representative for further instructions.

RACK INSTALLATION

The Series Six Plus CPU can be rack, panel or wall mounted. A set of mounting brackets is included with each rack and can be mounted on either the front or rear of each rack.

The method for mounting the brackets is determined by the system mounting configuration. Dimensions and placement of the mounting brackets for racks are shown in figures 3.1 and 3.2.



3-4


CEK-96602

EXTRACTION/INSERTION TOOL

The printed circuit board extraction/insertion tool (board puller), Catalog No.

IC600MA504 included with your Series Six Plus CPU should always be used when installing or removing a module. The boards in the CPU require an insertion force of about 50 Ibs.

(22.68 Kg) and the l/O boards require about 25 Ibs. (11.34 Kg). Use of the extraction/insertion tool should alleviate any problems of possible board damage which could be caused by hand insertion or removal.

Refer to figure 3.3 for identifying features of this tool.

a41115

BOARD PULLER

LOGIC RACK NOTCH

‘p&i

BOARD PULLER

LcK;IC RACK NOTCH

BOARD PULLER t Ixx;IC RACK FLANGE tTcm

BOARD PULLER

BTIJDS

IJLLER

LLK;IC RACK FLANGE

00=-f)

NOTE

It is recommended that power to any rack be turned off before attempting to install or remove any printed circuit board.



3 - 5

GEK-96602

Inserting a Printed Circuit Board

The following instructions should be followed when inserting a printed circuit board into its slot in

a

rack.

connector(s) untiI it has started to seat.

solder side of the board. lnsert the Logic Rack Notch (Bottom) into the short slot beside the bottom of the solder side of the board. See figure 3.4 for proper toof positioning for insertion of a board.

feel the board seat. Visually inspect the board to be sure it has seated properly.

Remove the tool.

a42067

Figure 3.4 POSITION OF EXTRACTION/INSERTION TOOL FOR BOARD INSERTION


3-6


GEK-96602

Removing a Printed circuit Board

The following instructions should be followed for proper removal of a printed circuit board from its slot.

board. Ensure that the board puller surface is flat against the printed circuit board.

The board puller is now 180 degrees reversed from the position for inserting a board. See figure 3.5 which shows proper positioning of the tool.

from the connectors and set loose in the cardguides.

carefully.

a41080

Figure 3.5 POSITIONING THE EXTRACTION/INSERTION TOOL

FOR BOARD REMOVAL

MODULE INSTALLATION

The modules for your system should now be installed in their proper slots in the CPU and

I/O racks. Before installation some of the modules may require configuration of switches or jumpers. Figure 3.6 is provided as a guide to proper module location in the CPU rack.



GEK-96602

00000000

--------

LOGG AAlTti AOGC

0

3-7

13” CPU RACK

19” CPU RACK

Figure 3.6 CPU MODULE LOCATION GUIDE


3-8


GEK-96602


The Combined Memory module for the Series Six Plus PLC combines the functions of internal memory, register memory and logic memory on one module. The Combined

Memory module, should be unpacked and removed from its sleeve. Remove the blank faceplate (if in place) from the slot where the module is to be installed. The Combined

Memory module should then be inserted into slot 4, which is immediately to the left of the Arithmetic Control module. After installing the module, install the faceplate, which is imprinted with the legend LOGIC MEMORY.

The Combined Memory module is a required option, and is available in 6 different versions as shown below in table 3.1. The

Combined Memory modules used in the Series Six model 60 PLC (IC600CM552 and

IC600CM554) can also be used in a Series Six Plus PLC, but do not provide parity checking.

Table 3.1 COMBINED MEMORY MODULES

I

CATALOG

NUMBER

I

MEMORY TYPE

REGISTER

TOTAL

MEMORY

IC6OOlX605

IC600LX612

I

4

4 8

1

12

5

IC600LX616 8 8 16

IC600LX624 16 8 24

IC600LX648 32 16 48

IC600LX680 64 16 80

Battery lnstallation

Before installing a memory module in a CPU rack, the Lithium-Manganese Dioxide battery must be connected unless an external auxiliary back-up battery is to be used.

These modules are shipped from the factory with the battery connector disconnected from the battery. When connecting a battery, the following procedure is recommended.

Refer to figure 3.7, which shows a mounted, connected battery.

on the component side of the module.

facing toward the battery connectors.



GEK-96602

3-9

External

Auxiliary

Battery Selection

If an auxiliary back-up battery is to be used with your system, a jumper on the board must be properly configured. This jumper is JP6 and is located next to the Lithium battery. Factory default is - no auxiliary battery present (JP6 over pins 1 and 2). To change the selection to auxiliary battery present, place JP6 over pins 2 and 3.

In order to use this feature, the user must supply a battery with the proper voltage (6 to 28 V dc) connected to the auxiliary battery terminals on the power supply terminal block.

a42221

m

EXTERNAL AUXILIARY

BATTERY SELECT

Figure 3.7 MEMORY BOARD BATTERY CONNECTiON

Relatively

small amounts of excess charge can cause very intense electrostatic fields in metal-oxide-semiconductor (MOS)

devices,

damaging their gate structure.

Avoid handling the circuit board under conditions favoring

the

buildup of static electricity. Failure to observe this caution could result in the destruction of the CMOS RAM devices in this module.

r


3-10 Installation Instructions

GEK-96602

Do not allow the bottom of a module to come

into

contact

with

a conductive (metal) surface when the board cover is removed.

Failure to observe this caution could result in the discharge of the non-rechargeable lithium battery and the loss of memory contents.

When installing a Combined Memory module or any module, position the component side of the board to your right (towards the CPU power supply). Figure 3.8 shows proper orientation of a printed circuit board.

a41136

.

--a-------

I

.I

P

-

I m

I

L

n

“1

4 i

: a I

.

z

21

I

L

NOTE

Proper orientation of printed circuit boards is with component side towards the power supply.

Figure 3.8 PRlNTED CIRCUIT BOARD ORIENTATION IN A RACK

Install the faceplate by placing the faceplate in the proper position and while pushing in, turn the quarter-turn thumbscrew clockwise until it feels secure.



GEK-96602

3-11


Logic Control Module - Advanced, Expanded, or Expanded II

None of these modules have any devices needing user configuration. The selected Logic

Control module should be installed in slot 2, which is the second slot to the left of the power supply.

The Arithmetic Control module should be installed in slot 3, immediately to the left of the Logic Control module.

A short length of ribbon cable is used to interconnect these two modules through sockets on the lower front edge of each printed-circuit board.

Refer to figure 3.9. Ensure that this cable is in place and that the connectors are seated properly.

NOTE

Operation of the system without the ribbon cable connected between the Arithmetic Control and Logic Control modules will result in unpredictable operation by the CPU.

a41079 figure 3.9 LOGIC CONTROL TO ARlTHMETlC CONTROL RIBBON CABLE

NOTE

To prevent unpredictable operation of your Series Six Plus CPU, the

CPU should be powered-down before installing or removing either module or the connector.


3-12 Installation Instructions

GEK-96602

I/O Control Module

The I/O Control module should be inserted in slot 1, immediately to the left of the power supply. The I/O Control module contains three labeled jumper terminals, which are for selection of board options.

These jumpers are located on the lower right of the component side of the printed circuit board (with component side towards you and LEDs and connectors to the left).

The jumper configuration and definitions are indicated in the following table. To change a configuration, move the jumper plug to the correct pins. Jumpers should be configured to conform to the requirements for a particular application.

Table 3.2 I/O CONTROL OPTION JUMPERS

E

H

H

E

D-E

E-F

G-H

H-J

DEFINITION

DPU Present

DPU Not Present

DPU Fault Trips Alarm No. 1 and

Alarm No. 2. CPU Stops

DPU Fault Trips Alarm No. 2. Provides an Advisory Indication.

Communications Control Fault Trips Alarm

No. 1 and Alarm No. 2. CPU Stops.

Communications Control Fault Trips Alarm

No. 2. Provides an Advisory Indication.

The I/O Control connects to an I/O Receiver or Advanced I/O Receiver in the first l/O rack in a CPU I/O station through a 16 pair parallel cable. Location of the 3 jumpers on the lower part of the board is shown below.

a41076

Xl14 V.-l

JUMPERS

Figure 3.10 I/O CONTROL MODULE JUMPER LOCATION


Installation Instructions 3 - 1 3

GEK-96602

Auxiliary 1/O Module

The Auxiliary I/O module is available as an option and is required if an Auxiliary I/O chain is to be included in a Series Six Plus PLC system. The Auxiliary I/O module can be used in either a Series Six Plus CPU rack, or in a Series Six model 6000 CPU rack.

When used with the Series Six Plus PLC in the Expanded mode of operation, up to 8000

Inputs and 8000 Outputs are available on the Auxiliary I/O chain (in addition to the 8000

Inputs and 8000 Outputs on the Main l/O chain).

When used with the Series Six model

6000 CPU, the maximum available I/O is 2000 Inputs and 2000 Outputs.

A group of 4 DIP shunts must be inserted in one of two locations, determined by which

CPU the module is to be used with, either Series Six Plus or Series Six model 6000.

The Auxiliary I/O module can be installed in slot 5, 6 or 7 depending on whether or not the GEnet Factory LAN Series Six Network Interface 2-slot option is selected. If the

LAN communications option is not selected, install the Auxiliary I/O module in slot 5.

The Auxiliary I/O module connects to the first I/O rack in a CPU I/O station in the

Auxiliary I/O chain through a standard 16-pair parallel bus cable.

Communication Control Modules

If a Communications Control Module, either CCM2 or CCM3, has been selected as an option, it should be installed in slot 5, immediately to the left of the Combined Memory module.

There are jumpers or DIP switches on the Communications Control Modules which should be configured to set operating parameters for the module. For complete details on configuration of any of the communications modules, refer to the applicable manual as listed below.


3-1

4


GEK-96602

CPU Power Supply

The CPU power supply, which is installed at the factory, has 2 terminal boards located on the lower part of the faceplate.

Refer to figure 3.11 which is an illustration of the terminal boards and their connections.

Remove the protective cover and make the following connect ions.

7Otmpll a41063 i%z

CONTACTS

(ISOLATEDI

LlNE I ILlI

LINE 2 IL21

GROUND lG1

AC POWER SUPPLY

E

CONTACTS

(ISOLATED1

INDkT

20 ToDi* VDC

100 TO IS0 "DC

(A!5 APPLiCABLEI

DC POWER SUPPLY

Figure 3.11 CPU POWER SUPPLY CONNECTIONS

for

the wide range ac power supply, 20 to 32 V dc, or 100 to 150 V dc for the dc power supply.

terminals of the terminal

board

on the right.

The power cord plug should proper pin configuration for either 115 V ac or 230 V ac.

have

the

If the same ac power source is used to provide ac power to other racks in a

Series Six Plus PLC system, ensure that all ac input connections are identical at each rack. Do not cross line 1 (L1) and line 2 (L2). A resulting difference in potential can cause damage to equipment.

DC power supply connections: connect

3

wires from the DC power source to the proper terminals on the power supply. These terminals are labeled POS, NEG, and GND. Ensure that these wires are of the correct polarity before applying power.

Connect the alarm relay contacts to external alarm devices as required by system configuration. (Optional)



GEK-96602

3-15

The user devices connected to each set of alarm terminals on the power supply module

should

present a resistive load drawing no more than one amp of current at 115 V ac or 28 V dc. Failure to observe this caution may result in damage to the circuit board.

voltage from 6 to 28 V dc.

This is an option that will provide a back-up to the memory back-up battery mounted on each memory module.

If a memory auxiliary battery is used, the circuit connecting it to the power supply module should be isolated from

the

rest of the system. If this caution is not observed, the battery could be short-circuited.

After these connections have been completed the protective cover plate should be carefully reinstal led.

1 W

ARNI

NG |

Ensure that the

protective cover

is installed over the terminal boards. During normal operation either 115 V ac or 230 V ac is present

on

the ac

Power

supply, or 20 to 32 V dc or 100 to 150 V dc on the dc power supply. The cover protects against accidental shorting of terminals which could

cause

damage to the machine or injury to the operator or maintenance personnel.

SYSTEM GROUNDING PROCEDURES

All

components

of a programmable control system and the devices it is controlling should be properly grounded. This is particularly important for two reasons as stated below.

1. SAFETY CONSIDERATIONS - A low resistance path from all parts of a system

to

earth minimizes exposure to shock in the event of short circuits or equipment malfunction.

2. PROPER EQUIPMENT OPERATION - Some components of

the

Series Six Plus PLC system require a common ground connection between racks to guarantee correct operation.

Recommended Grounding Practices

The following grounding practices are recommended to ensure proper operator safety and correct equipment operation when installing and using a PLC system.


3-16

~ ~. -...


GEK-96602

Ground Conductors

1. Ground conductors

should

be connected in a tree fashion with branches routed to a central earth ground point.

This ensures that no ground conductor carries current from any other branch. This method is shown in figure 3.12.

a41055 r

SERJES SIX PLUS

PC

MOTOR DRIVES

AND OTHER

ELECTRICAL

CONTROL EQUIPMENT

MACHINERY

?

?

?

POINT

5 EARTH GROUND

Figure 3.12 PLC SYSTEM GROUNDING

2. Ground conductors should be as short and as large in size as possible. Braided straps or welding cables (AWG No. 8 or larger) can be used to minimize resistance.

Conductors must always be large enough to carry the maximum short circuit current of the path being considered.

Series Six Plus PLC Equipment Grounding

Rack Grounding - There are 2 important requirements for grounding Series Six Plus CPU,

I/O and associated peripheral racks.

1. Safetv Ground. This connection should be made from the GND terminal or the rack powe; supply directly to system earth ground.

The purpose of this connection is to provide a guaranteed current path to ground in rack or the rack is incorrectly wired. Figure 3.1

the rack safety ground.

case a malfunction occurs within the

3 illustrates recommended wiring for a41 056

CONNECT A SHORT

AND DIRECT SAFETY

GROUND WIRE FROM

THE G (GROUND)

T E R M I N A L T O

GROUNDED PANEL OR

CABINET c SCREW OR

%OLT

Figure 3.13 RACK SAFETY GROUND WIRING



GEK-96602

3 - 1 7

-

2. Signal Ground - All racks that are grouped together as a CPU I/O station or a Local

I/O station MUST have a common ground connection. This is especially important for racks in the same I/O station which are not mounted in the same control cabinet, If this situation exists, the control cabinets MUST be tied together using the shortest possible connect ions.

If racks in a CPU or Local l/O station are distributed among several control cabinets that cannot be directly tied together, it is recommended that I/O Transmitter modules be used to communicate between these cabinets.

The GND terminal of the rack power supply should not be used as the Signal Ground connection between racks.

The best way to provide Signal Ground connections is to ensure that the Series Six Plus PLC rack metal frames are directly connected to the control panels or racks in which the racks are mounted. This can be accomplished by connecting a ground strap from one of the ground lugs on the rack plate on either side of the rack to the control panel or cabinet.

These Signal Ground methods are illustrated in figures 3.14 and 3.15.

a4 1054

I

GROUNDED PANEL OR CABINET

I

-SERIES SIX PLUS

RACK 1

1

STAR WASHERS UNDER

RAIL MOUNTING BOLTS

OR

,2. GROUND STRAP FROM

GREEN GROUNDING SCREW

IN CENTER OF RACK SIDE

PLATE TO PANEL

SAFETY GROU

GROUND 7

Figure 3.14 SERIES SIX PLUS PLC RACK SIGNAL GROUND CONNECTIONS


3-18

FROM

I/O TRANSMITTER

CONTROL CABINET a

InstaIlation Instructions

GEK-96602 a41052

*

GROUND CONNECTIONS

AT EACH RACK

/

CONTROL CAB&JETS MUST IBE TlED TOGET

AND HAVE A COMMON EARTH GROUND

Figure 3.15 I/Q STATION GROUNDING

3. Programming Device Grounding - For proper operation, the programming device,

(Workmaster computer, CMSTAR I computer, or a Program Development Terminal) must have a ground connection in common with the CPU or VO rack to which the PDT or Workmaster computer interface cable is connected. Normally, this common ground connection is provided by ensuring that the programmer’s power cord is connected to the same power source (with the same ground reference point) as the CPU or I/O rack as shown in figure 3.16.

GRWNMD PANEL OR CABMET

a41053

NOTE

????????? ?????

POWER SUPPLY ts A

DC VERSK)N. THE OUTLET wxms

A

SEPARATE

A C P O W E R S O U R C E v o NrmFACL

C A B L E

H

N D

-GROUND CONNECT+DNS

AT EACH RACK

Figure 3.16 PROGRAMMING DEVtCE GROUND CONNECTION



3-19

GEK-96602

I/O SYSTEM CONFIGURATION l/O rack(s) should be rack, panel or wall mounted in the same manner as the CPU rack.

When mounting multiple racks at the same location, enough space should be allowed between racks, both horizontally and vertically, to allow sufficient air flow between racks (minimum of 6 inches vertically), with the exception that the 13” rack can be mounted side-by-side.

I/O Interface modules should be available for installation in racks. The types of I/O interface modules are determined by the number of I/O points required and the location of the racks in a system. Refer to Chapter 2 for a discussion of the 3 types of stations in an I/O system (CPU, Local and Remote). The type of l/O station will determine whether your I/O racks will contain l/O Receivers, Advanced I/O Receivers, l/O Transmitters,

Remote I/O Drivers, Remote I/O Receivers or combinations of these modules. Figure

3.17 is an example of

a

typical l/O rack.

To prevent accidental mating of an I/O module with a faceplate not compatible with that module, all of the l/O printed circuit boards are keyed to match the corresponding faceplates.

1. I/O power supply

2. Power source terminal block

3. DC Power Indicator

4. Logic Power Switch/Circuit Breaker

5. Module Slot 1

6. Module Slot 11

7. I/O System Interface Module

8. Connector to l/O Control, upstream I/O

Receiver, Advanced I/O Receiver, l/O

Transmitter or Remote I/O Receiver.

9. Connector to a downstream I/O

Receiver.

10. Tray to contain field wiring.

Figure 3.17 TYPICAL I/O RACK


3 - 2 0


GEK-96602

I/O Power Supply

The I/O power supply is shipped from the factory installed in the I/O rack. 5 V dc at 6.1 A is provided for the standard I/O rack or 5 V dc at 16.5A, +I2 V dc at 1.5A and -12 V dc at

1.OA for the high capacity I/O rack (13” rack requires a high-capacity power supply).

There is

one

terminal board located on the lower part of the faceplate. Remove the protective cover plate and make the required connections as shown in figure 3.18.

SELECT JUMPER (1) FOR

115 OR 230VAC OPERATION

8m

0-

8c

0

0

8

0 m--m,

.--.-,

/

;,l 1 WAC

r

‘>230VAC

s-w-/

NO CONNECTION

WUNEI

(i-2) LtNE 2 a

GND) G R O U N D I

0

8

0

8

8

0

8

6830122

6830114 a 4 1 0 6 0

QWNE 1 fL2IWE2

(GND) GROUND

1

AC INPUT

95 TO 260 VAC

0

8

0

8

8

0

8

POS

NEG

GND

.

DC INPUT

20 TO 32 VDC

OR

100 TO 1 5 0 V D C

Standard

Power Supply

High Capacity

Power Supply

115/230 V ac CONNECTIONS

24 or 125

V dc CONNECTIONS

Figure 3.18 l/O POWER SUPPLY CONNECTIONS

AC Power Source Connections

-

Select 115 V ac or 230 V ac input by configuring the jumper to the proper terminals as shown (for a standard power supply). The jumper will be configured for 115 V ac when shipped from the factory. The high capacity power supply does not require jumper configuration, since it is a wide range supply and will accept an ac input voltage from 95 to 260 V ac.

When connecting multiple I/O racks to the same ac power source, ensure that all ac input connections are identical at each rack.

Do

not cross line 1 (L1) and line 2 (L2). A resulting difference in potential can cause damage to equipment.


lnstallation Instructions 3-21

GEK-96602

DC Power

Source

Connections

- Connect a DC power source (20 to 32 V dc or 700 to 150 V dc as required) to the proper terminals on the terminal board (POS, NEG, or GND).

After completing the ac or dc connections as required, the protective plastic cover should be reinstalled.

Ensure

that the protective cover is installed over the terminal

board. During

normal operation

either 115 V

ac, 230 V ac, 24 V dc, or 125 V dc is present.

The cover protects against accidental shorting of

terminals which could cause

damage to the machine

or injury

to the operator or maintenance personnel.

I/O System Interface Modules

The I/O system interface modules are the I/O Receiver, Advanced l/O Receiver, l/O

Transmitter, Remote I/O Driver, and Remote I/O Receiver.

Individual functions of these modules are described in Chapter 2, Installation instructions for each of these modules can be found in the individual data sheets for each module. Data sheets for all I/O system interface modules are included in the Series Six Data Sheet manual, GEK-25367.

In addition, individual data sheets are included with each module shipped from the factory.

For reference, the data sheet numbers for each of the I/O system interface module are

Iisted below.

I/O Receiver

Advanced I/O Receiver

I/O Transmitter

Remote I/O Driver

Remote I/O Receiver

GEK-83512

GEK-90771

GEK-83515

GEK-83537

GEK-83537

A summary of installation requirements for the l/O system interface modules is included on the following pages.


3-22


GEK-96602

I/O Receiver or Advanced I/O Receiver

Either an I/O Receiver or an Advanced l/O Receiver module must be installed in slot 11 in a 19” rack or in slot 8 in a 13” rack, which is the leftmost slot in an l/O rack. An I/O address DIP switch is not required for this module (or for any I/O communication modules). The top connector on the I/O Receiver or Advanced I/O Receiver in a daisy chain of racks connects to an I/O Control module in the main I/O chain, to an Auxiliary l/O module in an auxiliary I/O chain, to the next upstream I/O rack, or to an I/O

Transmitter in a CPU, Local or Remote l/O station. The bottom connector connects to the next rack downstream, if additional racks are in the system. The I/O Receiver and

Advanced I/O Receiver modules have 2 DIP shunts and a jumper pack that must be configured to specify whether the module is to pass the I/O chain signals through to the next rack or if it is the last rack in the chain. A 16-pair parallel l/O chain cable of the required length (see table 3.4) connects the I/O Receiver or Advanced I/O Receiver to other modules on the chain.

l/O Transmitter

An I/O Transmitter module can be installed in any slot in an I/O rack or in an I/O slot in a

Series Six Plus CPU rack or in a Series Six model 60 CPU rack. Connect a parallel l/O chain cable from the connector on an I/O Transmitter to the first I/O Receiver or

Advanced I/O Receiver in the next downstream I/O station.

Jumper JP1 must be configured to stop or not stop the system on a system fault.

Enable system stop for a local fault

System does not stop for a local fault

Jumper over pins 2 - 3

Jumper over pins 1 - 2

A jumper (JP2) must be configured to select the I/O mode of operation, either NORMAL or EXPANDED

as

shown below.

NORMAL I/O Mode

EXPANDED I/O Mode

Place jumper over pins 1 - 2

Place jumper over pins 2 - 3

When

in the EXPANDED I/O mode, one I/O Transmitter is required to originate each channel of Expanded I/O. The exception to this, is if only Expanded I/O channels 0 and 8 are to be used. In this case an I/O Transmitter is not required. If more than two channels of Expanded I/O are to be used, an I/O Transmitter module must be used for each channel. Any l/O Transmitters downstream from the originating one must be configured for the Normal mode.

The first 3 positions (1,2,3) of the DIP switch on the backplane adjacent to each I/O

Transmitter must be configured to select the Expanded I/O channel that it is driving. The switch settings are shown below in table 3.3.


Instat lation lnstntctions

GEK-96602

Table 3.3 EXPANDED I/O CHANNEL SELECTION

CHAN

MAIN

CHAIN

0

EL NUMBER

AUXILIARY

CHAIN

8

DIP SWITCH -

POSITION

3 2

1

3-23


A Remote I/O Driver can be installed in any l/O slot (except the left slot) in an l/O rack located in a CPU I/O station, a Local l/O station,

a

Series Six Plus CPU l/O slot or a model 60 CPU I/O slot. Before installing this module, the seven segment DIP switch on the backplane adjacent to the selected I/O slot for the module must be configured to select the group of I/O references for the Remote I/O station.

NOTE

Both the Remote l/O Driver and the Remote I/O Receiver must be placed in high capacity I/O racks to operate with RS-232 devices.

Either a standard or high capacity I/O rack can be used when the link connections are with twisted-pair cable.

Switches 5,6, and 7 are used to establish the I/O references for groups of 120 Inputs and

120 outputs.

If the option is selected for 248 Inputs and 248 Outputs, then switches 6 and

7 will establish the l/O references. The remaining switches, either 1, 2, 3 and 4 or 1, 2 and 3 respectively, are used to select a unique address for the Remote I/O Driver. The unique address will assign 8 consecutive I/O points to the Driver which will be used to provide status data to the CPU for the Remote I/O station.

A group of jumper plugs must also be configured for proper system operation. These items configured by the jumpers include the following:

Quantity of l/O (120/120 or 2481248)

Remote I/O Parity Error Effect on the CPU (STOP or Continue to RUN)

Communications Failure Effect on the CPU (STOP or Continue to RUN)

Even or Odd Parity

Specify Parity Check (Yes or No)

Baud Rate (Selectable from 110 baud to 57.6K baud)

Carrier Detect (No or Yes)

Clear To Send (No or Yes)

Output Mode (Twisted Pair or RS-232)

Input Mode (Twisted Pair or RS-232)

Sensitivity (Medium or Minimum)

For detailed instructions on jumper configuration for a Remote I/O Driver module, refer to the Remote I/O module data sheet, GEK-83537.


3-24


GEK-96602

Remote l/O Receiver

A Remote I/O Receiver must be installed in the left slot (slot 11 in a 19” rack or slot 8 in a 13” rack) of the first I/O rack in a Remote I/O station. The Remote Receiver does not require an I/O address. Before installing a Remote Receiver module, several jumper plugs on the printed circuit board must be configured to be compatible with the Remote

I/O Driver to which it is connected. The jumper locations are arranged on the board in groups of three pins and are identified by the center pin.

If direct connection to the Remote I/O Driver is to be through a serial two twisted-pair cable at a distance up to 10,000 feet (3Km), the end of this cable at the Remote I/O station should be connected to the top connector.

If connection is to be through an

RS-232 modem link, a cable, not to exceed 50 feet (15 meters) in length should be connected from the top connector to the modem in the Remote l/O station.

If there is to be more than one l/O rack in the Remote l/O station, the next downstream rack in the daisy chain will connect to the bottom connector using a 16 pair parallel I/O chain cable. This cable wilI in turn connect to an I/O Receiver in the next rack. If the rack containing the Remote Receiver is the only rack in a Remote Station, terminate the

I/O chain signals by configuration of jumpers on the Remote Receiver printed circuit board.

For detailed information on jumper configuration, refer to the Remote I/O module data sheet, GEK-83537.

Parallel I/O Chain Cables

Cables may be ordered in standard lengths for interconnection between racks on the parallel I/O chain.

The maximum cable lengths in a system configuration are determined by the type of I/O station used.

For cable limitations refer to Chapter 2 in this manual.

Table 3.4 lists the standard length I/O cables available.

Table 3.4 PARALLEL i/O CHAIN CABLE CATALOG NUMBERS

Lenqth

Feet Meters

Catalog

Number

2 0.6

IC600WD002A

5 1.5 IC600WD005A

10 3.0 lC6OOWD010A

25 7.5 IC600WD025A

5 0 15.0

100 30.0 IC600WD100A

200 60.0 IC600WD200A

300 90.0 IC600WD300A

400 120.0 IC600WD400A

500 150.0 IC600WD500A



GEK-96602

3-25

Parallel I/O Cable Conf iguration

Figure

3.19 is an illustration of the Parallel l/O Chain cable used to connect a CPU to I/0 rack or to connect racks in a daisy chain in a CPU I/O station, a Local I/O station or I/O racks within a Remote I/O station.

2 IN. TUBING OVER SHIELD

\

70126

NOUWTtl MMOWME I2 tEl4 WINECTOR~

PLUG RI WlRE TnBLE

PM #I N O

PIY #2 B L U E - W I T

P I N #3 WT-BLU

PIN #4 1 mu-WIT

Pltdf5 WT-ORN

P I N #6 BRN-W-T

PIY #? WIT-&tN

PM It8 Wtr-WIT

WIRE TMLE FOR ALL C&LE LEtifffi

PLUC#2 PLUG #I WIRE TABLE

!iOCXETWZ

SOCKEt#3

1 SOCKEf#4 ]

SOCUETRS

SOCKETt6 j SOCKETkt7

1 SDCKEtlC8

PIW # 21 RED-6RY

PIN # 22 BLU-BLX

1

PM #23 BLK-BLU

PIN # 24

DRN -BFK

PJlt #2’S BLK-ORY

PM #26 MN-BLK

1

PIW

#27 1 BLK-6RN

P L U G #2

SOCKEf#20

$CtUET#2I

SOCKET#22

SOCKET#23 fOCKET#24

SOCKET#25

SOCKETb26 i SOCKEl#Z271

SOCKET# I4

5oCKET#C6

1 PIN #32 1 BLU-YEL

I socKn#3zl

PIW #I4 ORn -RED

PIW#lSA RED-oaw r

S lo

2s so rt4

YETERS

0.6

I5

3.0

7.5

IS.0

LEI

FEET

2

1 PIN #37j SHIELD

30.0

CO.0

SOD l20.0

150.0

lcGwwoIooA

K6wwD2w~ moomlaoA l-#oA lc6oom5ooA

NOTE

Minimum conduit size for running this cable (with the hoods in place) should be no less than 2 inches.

Figure 3.19 PARALLEL I/O CHAIN CABLE


3-26


GEK-96602

Serial Link Cable To Remote I/O System

The following data is provided as an aid to the user for assembling and wiring a twisted-pair cable for connecting a Local l/O system to a Remote l/O system over a serial Iink.

70110

SHIELD

RECEIVED +

DATA _

C

SHIELD

15

3

/-\ PAIR #2 9

1 ! I 1

IW

' IO

REo”RStX&O

REMOTEMl

RECEIVER

CABLE SPECIFICATIONS

Length, Maximum - 10,000 Feet (3 Kilometers)

Two Individual Shielded,Twisted pairs

22 AWG, Minimum

15 pf/foot, Maximum

Cable Type - National Electric Cable Co. 22P1SLCBT or equivalent

Connector (Driver and Receiver End) - D-Subminiature Type, Cannon DBC25P with

207908-7 Hood or equivalent connector and hood

Figure 3.20 REMOTE l/O TWISTED PAIR CABLE

DATA

TERMINAL

70111

TRANSMIT

DATA

RECEIVE DATA

SIGNAL GROUND

CLEAR TO SEND

CARRIER DETECT

UARK

SPACE

I

I

I

M O D E M

DR

REMOTE I/D

IVER OR RECEIVER

CABLE SPECIFICATIONS

Length, Maximum - 50 feet (15 Meters)

Overall Shield

24 AWG, Minimum

Connector, Driver or Receiver End - D-Subminiature Type, Cannon DBC25P with

207908-7 Hood or equivalent

Connector, Modem - User selected

Figure 3.21 REMOTE I/O CABLE FOR RS-232 MODEMS



GEK-96602

3-27

I/O POINT SELECTION

After I/O racks have been installed, cables run, and AC or DC power cables connected, the racks are ready for installation of l/O modules.

The I/O module starting l/O point reference numbers should now be programmed by setting the DIP switches on the rack backplane adjacent to the connectors. Refer to figure 3.22, as a guide to configuration of the DIP switches for 8 circuit modules.

The I/O point number selected is the first of eight consecutive I/O points (one l/O address) starting with that number. For modules requiring different switch settings, such as High Density or Analog modules, refer to the installation instructions on the applicable data sheet for each module for proper DIP switch configuration.

After configuring the DIP switches, install the I/O modules in their respective slots as determined by your program.

The actual I/O reference used for each I/O point in your program depends on whether the I/O system is in the Normal or Expanded I/O mode. If the Expanded l/O mode is selected, the applicable channel number is added before the reference number as described previously.

NOTE

There are limitations on the combination of types of I/O modules which may be instal Ied in an I/O rack. This is determined by the load placed on the power supplyr by the various modules.

70.97

,

Al IAl 1 1 AIA

I 111111

Figure 3.22 DIP SWITCH SETTINGS FOR I/O POINT SELECTION

FOR 8 CIRCUIT MODULES


3-28

Installation instructions

GEK-96602

POWER SUPPLY LOAD CAPACITY

The load capacity of the power supply in a Series Six Plus CPU rack is the sum of the internal loads placed on it by each of the CPU modules as well as the l/O modules and is expressed as units of load, with 1 unit of load being equal to 300 milliwatts of power.

Each unit of load of 300 milliwatts can also be expressed in terms of current as follows:

+5 Vdc = 60 mA of current

+12 V dc = 25 mA of current

-12 V dc = 25 mA of current

Load Capacity for a Series Six Plus CPU Rack

The power supply in a Series Six Plus CPU rack is a high capacity supply with 3 outputs having capacities as follows:

Table 3.5 CPU RACK POWER SUPPLY CAPACITIES

I

I

VOLTAGE & CURRENT UNITS OF LOAD

+5 V dc at 16.5 Amps 275 units of load

+12 V dc at 13 Amps

-12 V dc at 1.0 Amps

60 units of load

40 units of load

I

I

I

NOTE

In addition to the units of load listed for each voltage type, the total load on all outputs of the supply must not exceed 300 units of load (90 watts of total power.

The number of I/O modules that can be used in a rack is determined by adding up the loads of all CPU modules and subtracting that load from the total load capacity. The remaining capacity in a Series Six Plus CPU rack usually allows up to 100 units of load

for

I/O modules to be contained in the rack. The total load of those I/O modules must not exceed

the

remaining current capacity.

Do not exceed any of the following limits:

1. The total current capacity (units of load) of each supply (+5, +I 2 and -12

V

dc).

2. The sum of units of load for all supplies must not exceed 300 units.


Installation Instructions 3-29

CATALOG

NUMBER

IC600CB524

IC600CB525

IC600CB526

IC600CB515

IC600CB503

IC600CB513

IC6OOLX605

IC6OOLX612

IC6OOLX616

IC6OOLX624

IC6OOLX648

IC6OOLX680

IC600CB516

IC600CB517

IC650AELOOO

IC650AEMOlO

The available units of load for each

module to be located in the CPU rack are listed in

Table 3.6.

Table 3.6 SUMMARY OF UNITS OF LOAD FOR CPU RACK MODULES

MODULE

DESCRIPTION

UNITS OF LOAD (1)

+5 v +12 v -12 v

Arithmetic Control

Logic Control (Advanced)

Logic Control (Expanded)

Logic Control (Expanded II)

I/O Control

Auxiliary I/O Control

17

9

Logic Memory 24

Logic Memory 24

Logic Memory

Logic

Memory

Logic Memory

Logic Memory

24

24

24

24

Communications Control (CCM2)

Communications Control (CCM3)

17

17

LAN Interface Controller Board

20

LAN Interface Modem Board 17

30

12

12

12

16

2

4

4

1

4

4

2

(1) For +5 V dc, 1 unit of load = 60 mA (300 mw of power)

For +12 V dc, 1 unit of load = 25 mA (300 mw of power)

For -12 V dc, 1 unit of

load = 25 mA (300 mw of power)


3-30


GEK-96602

Load Capacity for an I/O Rack

The power supply in a standard I/O rack can supply 100 units of load while the power supply load capacity in the high capacity I/O rack is the same as the load capacity for a

Series Six Plus CPU rack (275 units of load for +5 V dc, 60 units of load for +12 V dc, and

40 units of load for -12 V dc). The total load on all outputs for the high capacity supply must not exceed 300 units of load (90 watts of total power). The types of l/O racks

(standard or high capacity) to be used in

a

system are determined by the combination of modules to be installed in the racks. Table 3.7 is a list of the I/O modules and their units of load.

CATALOG

NUMBER

IC600BF800

IC600BF801

IC600BF802

IC600BF804

IC600BF805

IC600BF806

IC600BF808

IC600BF810

IC600BF813

IC600BF814

IC600BF875

IC600BF816

IC600BF817

IC600BF818

IC600BF819

IC600BF827

IC600BF830

IC600BF831

IC600BF841

IC600BF842

IC600BF843

IC600BF900

IC600BF901

IC600BF902

IC600BF903

IC600BF904

IC600BF905

IC600BF906

IC600BF907

Table 3.7 SUMMARY Of UNITS OF LOAD FOR f/O MODULES

T

MODULE

DESCRIPTION

T

UNIT

+5 v

OF LOA

+12 v

I/O Receiver


24 to 48 V dc Input

115 V ac/dc Input

230 V ac/dc Input

12 V ac/dc Input

Interrupt Input

115

V ac/dc Isolated

Type J Thermocouple

Type K+ Thermocouple

Type S Thermocouple

Type T Thermocouple Input

Type B Thermocouple

Type

High Speed Counter

Input

Input

Input

Input

Input

Type E Thermocouple Input

R

Thermocouple Input

Advanced I/O Receiver

High Density Input

0 to 10 V dc Analog Input

+/-10 V dc Analog Input

4 to 20 mA Analog Input

I/O Transmitter


24 V dc Sink Output

48 V dc Sink Output

115 V ac Output

230 V ac Output

12 V dc Sink Output

12 V dc Source Output

10

10

9

42

2

29

29

29

29

19

12

4

29

29

2

29

29

29

2

3

2

2

7

9

7

9

7

29

34

38

7

10 (2)

(I).

For +5

V dc, 1 unit of load equals 60 mA (300 mw of power).

For +12 and -12 V dc, 1 unit of load equals 25 mA (300 mw of power).

(2).

+I2 V and -12 V current is less than 1 unit of load if RS-232 mode is not used.



GEK-96602

Table 3.7 SUMMARY OF UNITS OF LOAD FOR l/O MODULES (Continued)

CATALOG MODULE UNITS OF LOAD (1)

NUMBER DESCRIPTION +5 v +12 v 1 -12 v

IC600BF908


IC600BF909


IC600BF910

115 V ac Isolated Output 8 - -

IC6OOBF912 8

IC600BF914 Reed relay output 13

IC6OOBF915 Axis Positioning Module, Type 1 23 7 3

IC600BF917 Axis Positioning Module, Type 2 21 11 6

IC600BF921

IC6OOBF923

230

V

ac Isolated

Output

5 V TTL Output

10 to 50 V dc Sink Output 3

3

IC6OOBF924 120 V dc Output 5

IC6OOBF929 10 to 50 V dc Source output 3

-

-

I

-

-

1

IC600BF930

IC600BF941

115 V ac Protected Output

0 to 10 V dc Analog Output

8

29

IC6OOBF942 +/-10 V dc Analog Output 29

IC600BF943

IC6OOBF944

IC600BF949

4 to 20 mA Analog Output

ASCII/BASIC Module (12K)

ASCII/BASIC Module (28K)

Loop Management Module

29

20

20

20

12

12

-

IC600BF946 12 -

IC600BF947 I/O Link Loccal 20 12 -

-

-

IC600BF950

IC660CBB900

IC660CB902

IC660CBB901

I/O

CCM 20 12 -

I/O CCM4

Genius Bus Controller

Genius Bus Controller w/Diag.

Genius Bus Controller

20

20

20

20

12

2

2

2

IC66OCB903 Genius Bus Control1 wo/Diaq. 20 2

-

-

-

-

(7) For +5 V dc, 1 unit of load equals 60 mA (300 mw of power).

For +12 and

-12 V dc, 1 unit of load equals 25 mA (300 mw of power).

3-31

After you have completed the installation procedures for all of your hardware and have installed the Logicmaster 6 software on your Workmaster industrial computer, CIMSTAR

I industrial computer, or IBM PLC, PC-XT, or PC-AT Personal Computer, you should proceed to the following START-UP instructions for a new Series Six CPU.

INITIAL START-UP INSTRUCTIONS FOR A NEW SERIES SIX CPU

Any new memory board will usually power-up with a parity error. The reason this happens is that when the lithium battery is first plugged into the board, the RAM memory devices power-up in an unknown state. These parity errors must be cleared before proper

CPU operation can be expected.

The CPU should be cleared even though it appears to run properly when it is first powered-up. The following procedures, when followed, will clear any parity errors present in the CPU memory when starting up a CPU for the first time.


3-32


GM-96602

Unpredictable operation of the

CPU

may occur if the

CPU

is in the RUN mode with an uninitialized memory board. Always place the

CPU

in the STOP mode when installing a new memory board.

1. Install lithium battery on the Logic Memory module.

Before installing a memory module in a CPU rack, the Lithium-Manganese Dioxide

battery m

ust be connected. These modules are shipped from the factory with the battery connector disconnected from the battery.

When connecting a battery, the following procedure is recommended.

component side of the module.

facing toward the battery connectors.

1 CAUTION 1

Relatively small amounts of excess charge can cause very intense electrostatic fields in metal-oxide-semiconductor (MOS) devices, damaging their gate structure.

Avoid handling the circuit boards under conditions favoring the buildup of static electricity. Failure to observe this caution could result in the destruction of the CMOS RAM devices in this module.

before installing the module.

1 CAUTION 1

Do not allow the bottom of a module to come into contact with a conductive

(metal) surface when the board cover is removed. Failure to observe this caution could result in the discharge of the non-rechargeable lithium battery and the loss of memory contents.

the board to your right (towards the CPU power supply) as shown

in

figure 3.8.

NOTE

Proper orientation of printed circuit boards is with component side towards the power supply.


lnstal lation Instructions

GEK-96602

3-33

Install the faceplate by placing the faceplate in the proper position and while pushing in, turn the quarter-turn thumbscrew clockwise until it feels secure.

2. Remove any l/O modules from the backplane of the CPU. Disconnect any expansion racks from the CPU rack and plug the I/O Terminator Plug supplied with the CPU rack into either port of the I/O Control module,

3. Turn the RUN/STOP keyswitch to the STOP position and the MEMORY PROTECT keyswitch to the WRITE position.

4.

Apply power to the CPU rack and turn on the power switch.

5. The CHECK light on the Arithmetic Control module should be on at this time before proceeding to the next step.

If it is not on, power-down, reseat the CPU boards and power-up again.

NOTE

If at any time when the CPU is switched to the RUN mode, it drops out of RUN on a memory parity error, most likely the communication ports are locked out.

To reset the ports, turn the RUN/STOP keyswitch to STOP, power-down the

CPU and power-up again.

If you are using a Workmaster computer with the parallel version of Logicmaster 6 software, proceed with the following steps:

1.

Boot up the Workmaster computer. Display the SUPERVISOR MENU.

2.

Turn the keyswitch to OFFLINE, and connect the cable from the Workmaster computer to the CPU.

3.

Select the US/V function with the F6 key and clear the Logicmaster memory while in that function by selecting the F5 (CLEAR) key.

4.

Return to the SUPERVISOR MENU and go to the Scratch Pad by selecting the

F4 key. Set the Scratch Pad values for Logic Memory and Register memory size to match the memory actually installed in the CPU.

5.

Again go to the L/S/V function and store the blank program (nothing in memory) to the CPU by selecting the F2 key and following the instructions on the screen.

6.

Return to the Supervisor menu and select the UTILITY FUNCTION Menu by selecting the F8 key. From this menu, select the CLEAR PARITY function with the F7 key and follow the screen instructions.

7.

Turn the CPU RUN/STOP keyswitch to RUN. The CPU should be cleared of any memory parity errors at this time.

If e computer, start-up procedures are similar.

Refer to the Logicmaster 6

Programming and Software User’s manual for detailed instructions for start-up with those devices.


3-34


GEK-96602

RUNNING EXPANDED I/O ON THE SERIES SIX PLUS PLC

As Internal Coils Only

Simply type "1” or “0” then CNTL-channel number, followed by the l/O point number.

The I/O is mapped into its corresponding register tables. No [SERIES SIX CONFIGURATION

DATA] command is needed. Channels do not have to be enabled in the CPU Config Menu.

To Be Solved To Real World I/O Points

Program the [SERIES SIX CONFIGURATION DATA] command in rung 1 and then set the number of channels to be scanned in the CPU CONFlG MENU, then transfer to the CPU.

How It Works

When running expanded I/O channels, the CPU generates a code for a particular channel number then does a full I/O scan as it normally does.

The channels are scanned in order from the lowest to the highest enabled channel. Each one takes 6-7 ms. Auxiliary channels are automatically scanned with their corresponding main channel. For example, enabling channels 0-3 also enables channel 8-B.

An l/O Transmitter (lC600YB900C or later) capable of decoding I/O channels must be used to separate the real I/O channels.

One and only one transmitter should be set to decode each channel. These transmitters have a jumper to allow them to run in expanded or normal mode. In expanded mode, they turn on only when their channel is called for.

The channel number is set by the first three dip switches on the rack backplane. In this way, the I/O data for each channel stays separated. No l/O cards, Remote I/O Drivers, or phase A Bus Controller may be installed in any I/O slot that is not downstream of a decoding transmitter.

Any such device would receive data from all enabled channels.

Outputs would respond to all enabled channels, and inputs would report back to all channels that scanned that address.

Phase B Genius Bus Controllers also have the capability of decoding I/O channels and could be placed in a non-decoded slot. Once downstream of a transmitter with a channel selected, all normal rules apply for cable length, number of racks, chain termination, etc. Any other Y8900C transmitters downstream should be set to normal I/O mode.

Also, no other transmitters could decode any other channel. For example, a transmitter in channel 0 could not be set for channel 1. The data for channel 1 is not present in channel 0.

Examples of correct and incorrect configurations for expanded l/O are shown in the following examples.



GEK-96602

#’

* = l/O XMIT

SETTO

EXPANDED hh3DE CHO

SERIES SIX PLUS CPU

SET TO

EXPANDED

MOOE CHl

I

C H O

3-35

a42208

SET TO l/O MODE

I

L

I “‘l”““‘i’ ’

C’ll

I/O

L

Y

CHl

I/O

J

Figure 3.23 EXAMPLE 1 - CORRECT CONFIGURATION


3-36

N O I/0

CARDS

= IN

THESE

SLOTS

* = I/O XMIT

SERIES SIX PLUS CPU

Installation instructions

GEK-96602 a 4 2 2 0 9

I

CHO

I/O

1

CH2

YBQOOC

I/O

TRANSMI-I-I

- SETTO

CH2

I/O

YBQOOA

l/O

TRANSMITTER

Y

CHO

I/O

J

Figure 3.24 EXAMPLE 2 - CORRECT CONFIGURATION



GEK-96602

* EXPANDED CHO

2 EXPANDED CH1

SERIES SIX PLUS CPU

3-37

a42210

CHO

I/O

, CHO

I/O

J

--

CL

I/O

THESE RACKS WOULD

NEVER SEE CHI DATA

Figure 3.25 EXAMPLE 3 - INCORRECT CONFIGURATION


3-38

* = EXPANDED MODE CH1

SERIES SIX PLUS CPU


GEK-96602 a4221 1 t/O IN THESE RACKS RECEIVE

DATA FROM ALL ENABLED

CHANNELS. OUTPUTS APPEAR

CHO

ERRATIC, INPUTS APPEAR IN ALL I/O ’

CHANNELS. EACH CHANNEL MUST

HAVE ITS OWN TRANSMITTER.

Figure 3.26 EXAMPLE 4 - INCORRECT CONFIGURATION



GEK-96602

3-39

System Design Considerations

When programming expanded I/O, use regular l/O references for the primary I/O. Do not use a channel 0 reference in the program. This actually maps into the auxiliary table and should be avoided. Channel 8 maps into user registers starting at 1025. This will never

be solved to real I/O, but could be used as internal points.

The WINDOW command allows you to specify a channel number from 0 - F. The communications window that is opened as a result of executing this command is directed to only one of the Expanded I/O channels on one or the other of the I/O chains (Main or

Auxiliary).

In other words, a WINDOW command to channel BH (Hexadecimal) does not affect any window devices downstream from Expanded Parallel I/O Transmitters which are set for channels 0 - 7 in the Main chain or channels 0 - 2 and 4 - 7 in the Auxiliary chain. Window devices include the ASCII/BASIC Module, I/O CCM, LMM, and Series Six

I/O link local module. The Genius bus controller is also a window device if window commands are issued to it. If no window commands are used, bus controllers may be used in the same address in main and auxiliary channels without conflict.

The ASClI/BASIC Module and its derivatives (LMM, I/O CCM, etc.) always report their status bytes back to the main input table, regardless of what channel they are in. An

ASCII/BASIC Module at address 257 in channel E will report its 8 bits of status to main channel address 1257. Care should be taken not to address any inputs in the main channel

to the same address as any of these devices in the system.



Expanded CPU Operation

GEK-96602

4-1

CHAPTER 4

EXPANDED CPU OPERATION

INTRODUCTION

The Series Six* Plus Programmable Logic Controller operates in one of two user selectable modes, either Normal or Expanded. Selection of the desired mode is made on the Configuration Menu screen on

a

Workmaster* computer using Logicmaster* 6 software. This chapter describes the Expanded functions as they are used with the Series

Six Plus PLC. For detailed information on programming the Expanded functions, refer to the Logicmaster 6 Programming and Documentation Software User’s Manual, GEK-25379.

All existing features, functions, l/O modules, programming devices and peripheral devices currently available for the Series Six PLCs can be fully used by the Series Six Plus PLC.

NORMAL MODE OF OPERATION

In the Normal mode of operation, the Series Six Plus CPU scans the Main I/O chain and the Auxiliary I/O chain in the same manner as in Series Six PLCs. In the Normal mode,

Main I/O chain and 1000 Inputs and 1000 Outputs in the optional Auxiliary I/O chain.

Additionally, direct addressing of all 16K words of Register memory with all Advanced functions is supported.

EXPANDED FUNCTIONS

With the Expanded functions option, the Series Six Plus PLC has access to and can perform many additional functions when compared to the Series Six PLCs. These functions are:

1.

Expanded I/O. Up to 16 channels (8 on Main I/O chain, 8 on Auxiliary I/O chain) of

I/O can be configured within a range of stop and start addresses configured by the user with a Workmaster computer using Logicmaster 6 software. Each channel has

1 0 0 Inputs and 1000 Outputs. The I/O scanning is done exactly as in the Series Six

PLC with the Auxiliary I/O chain scanned in parallel with the Main I/O chain. I/O scanning takes

7

ms for each pair (0 and 8, 1 and 9, etc.) of channels that have been enabled through the Configuration Menu.

In the Expanded I/O mode, only the

Expanded I/O channels that have been enabled will be scanned.

2.

In addition to the existing 4K of discrete references supported by the Series Six PLC

(I, 0, Al, AO), an additional 62K of discrete expanded I/O references are supported

(30K real I/O, 32K internal I/O).

3.

Configurable features. Through Logicmaster 6 software, release 3.01 and later, the user

can

enable configurable features, including the Expanded I/O, Genius II/O/O diagnostics, expanded time reference and the computer mail box.

4. Seven function floating point arithmetic which includes floating point addition, floating point subtraction, floating point multiplication, floating point division, floating point compare, integer to floating point conversion and floating point to integer conversion.


4-2


GEK-96602

5 .

Genius l/O diagnostics. Through user configuration, the CPU maintains a fault status image of the Genius I/O system. Faults are reported and logged in the CPU, then interpreted by Logicmaster 6 software.

6.

A computer mail box is provided for communications with Genius I/O Bus Controllers and intelligent modules.

7 .

Window function.

An enhanced DPREQ function allows the user specification of channel, address and COMM block.

8.

The DO I/O function has been expanded to include the channel number for the start and end addresses.

9 .

Time Reference. This is a real-time clock maintained by the CPU which uses three consecutive registers to keep track of days, hours, minutes, seconds and tenth of seconds. It is used by the CPU to keep track of fault occurrences.

In addition, when the Expanded II functions option is selected, a faster scan rate is provided, instructions are available for accessing an alternate I/O system to be available in the future,

a

dynamic user program memory checksum provides more data integrity by detecting certain types of errors not caught by memory parity checking, and a way to detect if there are any overrides active in the system is provided.

SERIES SIX PLC I/O DIAGNOSTICS FOR SERIES SIX PLUS PLCs

All of the I/O diagnostic features used with earlier models of Series Six PlCs are valid for use with Series Six Plus PLCs. The address recorded for parity errors includes channel number for Expanded l/O systems.

Pad in location SP(10). If a parity error is

a

The channel number is stored in the Scratch detected while the Expanded I/O mode is not selected or while channel 0 or 8 are being scanned, the value in SP(10) will be set to 80H

(Hexadeci mal).

I/O Transmitter Diagnostic Feature

Data received at the CPU from each I/O Transmitter is placed in the input status table for input bits I1017 through 11024 for channel 0, AI1017 through Al1024 for channel 8 and

IX+1017 through IX+1024 for channels 1-7 and 9-F. The data in this status byte is: bits

1-3, channel number; bit 4, card present; bits 5 and 6, set to 0; bit 7, fault trap enable; bit 8, fault present.

If the I/O Transmitter does not respond when addressed, nothing will be written to the input locations for that channel. The channel w i IIl be scanned regardless of whether the module responded or not.

Through user logic, this byte can be cleared each sweep to determine if the I/O Transmitter responded when addressed.

INTERRUPT MODULE LOCATION

A maximum of two Interrupt Input modules can be used (1 in the Main I/O chain and 1 in the Auxiliary I/O chain) in

an

Expanded l/O system.

The Interrupt Input module for each chain can be placed in any channel in each of the chains. The l/O Transmitter modules pass the interrupt signal through to the CPU at all times. The interrupt input data is placed in the Main Input status table in bits I1001 through I1008 for the Main I/O chain



GEK-96602

4 - 3

NORMAL MODE I/O ADDRESSING

The Series Six Plus PLC allows l/O to be configured in either the Normal mode or the

Expanded I/O mode. Selection of the l/O mode is made through the Configuration Menu using Logicmaster 6 software.

In

the Normal mode, one l/O chain per CPU is permitted

(this is the factory default setting). In this mode, available I/O is 1000 Inputs/1000

Outputs in

the

Main I/O chain, plus an additional 1000 Inputs/1000 Outputs in the

Auxiliary I/O chain, if an Auxiliary I/O module is included in the system. It should be noted that each chain actually has 1024 inputs and Outputs, however, only the first 1000 are available for I/O. References 1001 through 1024 are reserved for special use.

The ON or OFF state of the 1K Inputs and 1K Outputs in the main I/O chain are maintained in the I/O Status Table. The ON or OFF states of I/O points in the Auxiliary

I/O chain are maintained in the Auxiliary I/O Status Table which is mapped into the first

128 words of Register memory. R0001 to R0064 contains the Auxiliary Output Table, and

R0065 to R0128 contains the Auxiliary Input table.

EXPANDED MODE l/O ADDRESSING

When the Expanded I/O mode is selected through the Configuration Menu (a jumper must also be configured on each l/O Transmitter that is to drive a chain), a total of 8K Inputs and 8K Outputs in the Main I/O chain are available to the user. In addition, if the

Auxiliary I/O chain is selected (requires an Auxiliary I/O module) 8K Inputs and 8K

Outputs are available in the Auxiliary chain.

The total real I/O available through the use of both chains is therefore 16K Inputs and 16K outputs (32K total points). The l/O references O0001 - O1024, I0001 - I1024 are used as real I/O references for channel 0 and

AO0001 - AO1024 and Al0001 - Al1024 are used as real I/O references for channel 8.

These references, in addition to channel 1 through 7 and 9 through F references for real world l/O and 32K of internal references available in the Expanded mode provide an additional 64K of discrete references in a Series Six Plus PLC.

I/O Channels

I/O points in the Expanded mode are selected in 1 K increments, referred to as channels.

An I/O Transmitter module (configured for Expanded Mode) is required to originate each channel of I/O, with the exception that if channels 0 and 8 are the only Expanded mode channels selected, an l/O Transmitter is not needed for channel origination, since the l/O is scanned in the same manner as the Main and Auxiliary f/O chains when in the Normal mode. If more than two channels are to be used, I/O Transmitters are required. The CPU scans only those channels that have been selected.

chain must be configured for the Normal Mode. This is true for both the Normal and

Expanded Modes of operation.

Any downstream l/O Transmitters in a

A maximum of eight l/O Transmitters are required for channel origination in each of the two chains. If the maximum of 16 I/O Transmitters is used (8 in each chain), 16K Inputs and 16K Outputs are available to the user. The channel number to be associated with each I/O Transmitter is selected by setting the first 3 switches (switches 1, 2, 3) on the

DIP switch package on the backplane adjacent to the module as shown in figure 4.1. The total number of l/O Transmitters is determined by the number required for channel origination plus any downstream l/O Transmitters used in each channel, as determined by the system configuration.


4-4

CHANNEL NUMBER 1 DIP SWITCH


GEK-96602

A dot indicates that

a

switch is in the OPEN position (depressed to the left). All other switch segments should be in the CLOSED position (depressed to the right).

Figure 4.1 l/O TRANSMITTER DIP SWITCH SETTINGS

FOR EXPANDED t/O CHANNEL SELECTION


The individual channels are numbered from 0 to F; the Main I/O chain channels are 0 through 7 and the Auxiliary I/O chain channels are 8 through F.

The format for addressing I/O in the Expanded mode must include either the prefix I or O, a channel number (except for channel 0 and 8; for channel 0 programming references use

OXXXX and IXXXX, for channel 8 programming references use AOXXXX and AIXXXX), a real I/O (+) or internal I/O (-) reference identifier and the l/O reference number. This format is shown in figure 4.2.

I = Input

0 = Output

I C + 0025

I

I-

I/O Reference Number

Channel Number (0 - F)-

+= I/O Reference State (Real I/O)

-r I/O Reference Status (Internal I/O)

Figure 4.2

EXPANDED I/O REFERENCE FORMAT

Thus, for example, the format for real world I/O points for channel 3 in the Main I/O chain is I3+0001

to

I3+1024 for Inputs and O3+0001 to O3+1024 for Outputs. Each 1K channel requires 64 words of memory (64 words x 16 bits = 1024 I/O). Note that although

1024 bits are available in each channel, 0001 to 1000 are used for actual I/O points. 1001 to IO24 are reserved for special use.



GEK-96602

4 - 5

NOTE

Ensure that when referencing an I/O point in a program, a prefix is added to properly address the applicable I/O chain.

Normal

mode references address the

Main and Auxiliary l/O chains, for example I0234, O0346, AI0222, AO0456,

etc. Expanded mode references for channels 1 through 7 and 9 through F include the channel number, for example, I3+0101, O3+0101, lB+0234, OB+0567, etc. The individual module DIP switch settings for I/O points 1 to 1000 are the same for each chain or channel, only the prefix is different.

Real I/O Mapping

In the Expanded mode, the "real world” I/O points for Channel 0 are scanned on the Main

I/O chain and their status is maintained in the Main I/O status table. Channel 8, which is the first Auxiliary l/O channel in Expanded mode, is scanned on the Auxiliary I/O chain with its I/O status maintained in Registers R0001 through R0128, which is the same as the Auxiliary I/O status table for the Normal mode Auxiliary I/O chain. Channels 1 through 7 of real I/O are mapped into Registers R0129 through R1024 and the Auxiliary channel real I/O, Channels 9 through F are mapped into Registers R1153 through R2048.

Internal Mapping of Discrete References

The internal discrete references for Channels 0 through 7, which can be used for program references to control real inputs or outputs or Genius fault status, are mapped-into

Registers R2049 through R3072. The internal references for Auxiliary channels 8 through

F are mapped into Registers R3073 through R4096. The Register Memory, located on the

Combined Memory module is a 16-bit user accessible storage area of memory used for data storage and for data (bit) manipulation by many mnemonic functions. Many of these registers have special significance to system operation.

Register Memory Size

The maximum register storage available in a system is determined by the Combined

Memory module selected. The user must also verify the maximum registers in a system by making a selection on the Configuration Menu with Logicmaster 6 software. The selections available are 256, 1 K, 8K and 16K registers.

Note that if the smaller register sizes are selected, the register use should be such that if a larger register size is later used, the registers used are compatible. Figures 4.3, and 4.4 illustrate register memory use for each of the register sizes.

NOTE

The 256 word register memory option is not currently compatible with Genius

I/O diagnostics and should not be selected for that

use.


4-6


CEK-96602

REGISTER RANGE

8K

16K

ROOOl

ROOOl

REGISTER

CONTENTS

1K OUTPUTS (A00001 - A01024) (1, 3)

1K INPUTS (AI0001 - AI1024)

ROl28

R0129

R0128

R0129

7K OUTPUTS (Ol+OOOl to 07+1024) (3)

7K INPUTS (Il+OOOl to I7+1024)

RI024

Rl025

R1152

R1153

R1024

R1025

R1152

Rll53

USER REGISTERS

7K OUTPUTS (09+0001 - OF+1024) (3)

7K INPUTS (I9+0001 - IF+1024)

R2048

R2049

R2048

R2049

R4096

R4097

R4112

R4113

R4116

R4117

R4119

R4120

R4121

RXXXX

RXXXX

STATUS BITS FOR 32K I/O (or internal

References), (00-0001 to IF-10241

R4096

R4097

R4112

R4113

R4116

R4117

R4119

R4120

R4121

RXXXX

RXXXX

R16314

R16315

BUS CONTROLLER STATUS - BIT MAP

USER REGISTERS

CLOCK

POINTER FOR FAULT TABLE

FAULT TABLE ENTRIES

USER REGISTERS (4)

R8222

R8123

COMPUTER MAIL BOX

R8192

R16384

(1) Channel 8 real I/O is mapped into Registers 1 through 128 (references AO0001 - AO1024 and

AI0001 - AIl024).

(2) Channel 0 real I/O is scanned on Main I/O chain (references O0001 - O1024 and I0001 - I1024).

(3) Expanded discrete references AO0001 through AO1024, AI0001 through AI1024 and Ol+OOOl through OF+1024, and Il+OOOl through IF+1024 are overlaid on the Register table. These registers are available for general use if the above references are not used.

(4) The number of registers available for general use depends on the quantity of Genius I/O fault tables selected.

Figure 4.3 MEMORY MAP FOR 8K AND 16K REGISTERS



GEK-96602

4-7

1K REGISTER

RANGE

ROOO 1

R0128

R0129

R0269

R0270

R0271

RXXXX

RXXXX

R0256

R0257

R0258

R0266

R0267

R0954

R0955

R1024

REGISTER

CONTENTS

1K OUTPUTS (AO0001 - AO1024) (1)

1K INPUTS (AI0001 - AI1024)

1K OUTPUTS (Ol+OOOl - 01+1024) (1)

1K INPUTS (Il+OOOl - Il+lO24)

BUS CONTROLLER STATUS - BIT MAP

USER REGISTERS

CLOCK

POINTER FOR FAULT TABLE

FAULT TABLE ENTRIES

USER REGISTERS (3)

COMPUTER MAIL BOX

(1)

(2)

(31

Expanded discrete references AO0001 through AO1024, AI0001 through AI1024 and Ol+OOOl through 01+1024, Il+OOOl through 11+1024 are overlaid on the Register table.

These registers are available for general use if the above references are not used.

Channel 0 I/O is scanned on the Main I/O chain.

The number of registers available for general use depends on the quantity of Genius I/O fault tables selected.

F i g u r e 4 . 4 M E M O R Y M A P F O R 1K R E G I S T E R S






GEK-96602

4-11

DYNAMIC

USER MEMORY CHECKSUM

The Expanded II function set is provided through selection of the Logic Control module option, IC600CB515. An important feature of this function set is the user program memory checksum.

The purpose of this checksum is to provide more data integrity within the user program memory. This user program checksum will trap certain types of data errors not caught by memory parity checking.

Specifically, the error conditions to be caught through this checksum are; an even number of bits changed in memory and stuck address Ilines.

Memory Checksum Calculation

During normal operation, the CPU can detect when the logic memory has been altered by an external device (such as Logicmaster 6, etc.). When it has sensed that the memory has been changed, the CPU will begin to calculate a checksum by starting at memory location

00000 and working its way through all logic memory.

The checksum is the 16 bit sum of all the words of logic memory in the CPU.

Each time that the internal executive routine is run in the CPU, 64 words of memory are summed. Since there can be a maximum of 64K words of logic memory, it is not possible to complete the entire checksum in one scan. Therefore, the checksum will take a maximum of 1024 scans to be calculated. When the CPU completes the calculation it stores the checksum in the Scratch Pad. It will then recalculate the checksum, and when once again completed, the resulting calculation is compared with the previously stored checksum. If this calculated number disagrees with the number stored in the Scratch

Pad, the CPU will STOP (if it is running) and de-energize Alarm 1. It will also set error flags in the Scratch Pad.

The checksum calculation continues while the CPU is in the STOP mode. The calculation adds about 150 us to the CPU’s executive routine.

The total time for the checksum calculation for the maximum 64K words of memory with a 150 ms sweep is 153 seconds.

Logicmaster 6 Display of Checksum Error

The checksum is displayed on the Scratch Pad screen display if Logicmaster 6 is in the on-line or monitor mode. It is not displayed when Logicmaster 6 is in the off-line mode.

If a checksum error is detected, the message LOGIC MEMORY CHECKSUM ERROR is displayed below the CPU ERROR FLAGS line at the bottom of the Scratch Pad display.

Restarting a CPU Stopped

by

a Checksum Error

The CPU also recalculates the checksum when the CPU is powered-up or switched from

STOP to RUN if the memory protect switch is set to the WRITE position. If the key switch is set to the PROTECT position, the checksum error fault indication will remain in the Scratch Pad and the CPU will not be able to be restarted unless either the keyswitch is switched to WRITE or the fault indication in Scratch Pad locations SP (07) and (09) are cleared by an external device.

A recalculation of the checksum when the CPU is restarted is desired if a Logic Memory board is replaced and the CPU is then restarted.

Normally, the CPU should be left in

PROTECT which allows the checksum feature to catch any memory changes that occurred while the CPU was powered down.


4-12 Expanded CPU Operation

G E K - 9 6 6 0 2

CONFIGURATION OF EXPANDED FUNCTIONS THROUGH

LOGICMASTER 6 SOFTWARE

In order to configure the Expanded Functions, a Workmaster computer, CIMSTAR I required to enable configurable features, which include expanded I/O, Genius reference and the computer mail box. Each of these operation. The required configuration is automatically entered into the first 24 words of the CPU user memory as it is selected and entered from a configuration menu. The first

CONFIGURATION DATA] instruction.

Standard features included with the expanded functions that do not require configuration include expanded discrete and register references, the Window function and floating point arithmetic.

An improved basic compare instruction has been added which allows any reference A to be compared to any reference B.

The previous form of this instruction only allowed registers to be compared.

EXPANDED FUNCTIONS MENU

In order to access the configuration menu, the Expanded Functions screen must first be selected from the Supervisor menu.

When the Expanded Functions (F7) key is pressed from the Supervisor menu, the Expanded Functions screen appears as shown below.

~

L O G I C M A S T E R ( T M ) 6

E X P A N D E D F U N C T I O N S

KEY # FUNCTION

F l - C P U CONFIG . . . . . . . D i s p l a y / M o d i f y C P U C o n f i g u r a t i o n

- I / O F a u l t s . . . . . . . . D i s p l a y / C l e a r G e n i u s I / O F a u l t s

F’;

:;

- C O M M S E T U P . . . . .D i s p l a y / M o d i f y C o m m u n i c a t i o n s S e t u p ( s e r i a l v e r . )

- MSD FUNC . . . . . . .

. D i s p l a y / M o d i f y M a c h i n e S e t u p D a t a

- SUPERV MENU . . . . . . . . . .r e t u r n t o S u p e r v i s o r M e n u

CPU M S D SUPERV

1CONFIG 2FAULTS 3SET UP 4FUNC 5 6

7 8 M E N U

The applicable function key is then pressed to select the desired Expanded functions.

the CPU Configuration menu.

Genius l/O Faults screen.

This function key is displayed only for the Serial versions. Select COMM SET UP to set up the system parameters for communicating with the CCM card.




GEK-96602

Making Entries on the CPU Configuration Set Up Page

The CPU Configuration Set Up Menu is used to enable Expanded I/O scan, Genius l/O diagnostics, and the Computer Mail Box. Entries made on this page change the program file in system memory. They do not change the user program in the CPU.

If the system is in On-Line or Monitor mode, changes are made to the program logic only. If the system is in Off-Line mode, changes are made to the logic and the table data.

To edit this display, move the cursor to the item you want to change, and type in the new value. Refer to the definitions that follow for more information.

Cancelling Entries to the CPU Confiquration Set Up Menu

To cancel entries and return to the Expanded Functions menu, press the Abort key. The screen displays:

PRESS CONFIRM TO ABORT, ANY OTHER KEY TO PROCEED

Press the Confirm key to return to the values that were displayed when the page was entered. Press any other key to cancel the abort.

CPU CONFIGURATION MENU: DEFINITIONS

Refer to the following definitions when changing the CPU Configuration Set Up Menu.

The entries on this page are stored in the Configuration function in the program.

EXPANDED I/O SCAN ENABLED: Y, Default = Y, for Expanded l/O scanning by the

CPU. For normal I/O scanning, enter N. Note that Expanded

I/O is not required for Genius I/O diagnostics on Bus

Controllers located in the Main and Auxiliary status tables.

Expanded I/O must be enabled to use the diagnostics on Bus

Controllers located on channels 1-7 and 9-F.

BEGIN RANGE: If Expanded I/O scanning is enabled, this entry specifies the channel and Point number within the channel where the Expanded I/O scan should begin. The default range is all channels and points. Change these entries to select a smaller scan range.


Expanded

CPU

Operation 4-15

GEK-96602

CPU CONFIGURATION MENU: DEFINITIONS

(Continued)

The I/O structure in an expanded l/O system consists of as many as 8 main channels (numbered 0 - 7) and 8 auxiliary channels (8 - F). Valid entries for Begin Range and End Range

Channel are 0 to 7. Each of these specifies a main/auxiliary channel I/O pair:

GENIUS I/O:

CHAINS: MAIN AUXILIARY

CHANNELS

1

0

2

3

8

9

A

B

4

5

6

7

C

D

E

F

The value for Point is the I/O point from 1 to 1024 in the speci fied channel. The system rounds this value to a byte boundary.

END RANGE: The channel number and Point number within the channel where the Expanded I/O scan should end. This must be greater than the value for Begin Range.

DIAGNOSTICS ENABLED: Default = Y, to enable the minimum Genius I/O diagnostics (for everything except the diagnostic tables). For no Genius I/O diagnostics, enter N.

DIAGNOSTIC TABLES: Default = Y, to cause a Bus

Controller Status Bit Map to contain the locations of Bus

Controllers that have reported errors. In addition, a Point

Status Bit Map will specify any real l/O points that indicate failures by a block, point, or Bus Controller fault. For no

Genius I/O diagnostics tables, enter N.

B/C -> POINT FAULTS: Default = N, to cause Bus Controller errors to tell the CPU to set all 208 input and 208 output point fault bits associated with that Bus Controller to a 1.

The user must exercise caution when referencing any of these points, since all will be set to a 1 following a Bus Controller f ailure.

If all blocks are assigned to addresses within the same 256 register segment as the Bus Controller, then

a

fault of the Bus

Controller equals a fault of all I/O. If all addresses are not assigned as above, this feature should not be used.



GEK-96602

CPU CONFIGURATION MENU: DEFlNITIONS (Continued)

GENIUS I/O: (cont)

DIAGNOSTIC RANGE LIMIT: The range, by channel pairs, of the diagnostics. Range = 0 to

7. Default = 7, which is 8 pairs of channels to be checked.

CPU REGISTER SIZE: Enter the exact register size of the

CPU:

2 5 6 ( C u r r e n t l y n o t c o m p a t i b l e with diagnostics)

1024 (can be represented by entering a 1)

8192 (can be represented by entering an 8)

16384 (can be represented by entering a 16)

Genius

Default = the number of registers indicated by the Scratch

Pad.

The availability of register memory regulates the number of

I/O points on which Genius I/O diagnostics will be performed.

For a register size of 1K diagnostics are performed up to the first 1024 inputs and 1024 outputs of the Main I/O chain.

Maximum register sizes of 8K or 16K allow the CPU to perform diagnostics on the maximum 16K inputs and 16K outputs.

The inputs and outputs included are the Main l/O chain (Main

I/O status table, I/O channels 1+ to 7+) and the Auxiliary I/O chain (Auxiliary I/O status table, I/O channels 9+ to F+).

FAULT TABLE LENGTH: The maximum size of the fault tabte, which depends on the CPU size, and on whether the

Computer Mail Box has been enabled. Maximum table sizes are listed below. Default = 8.

REGISTER

MAXIMUM TABLE LENGTH *

SIZE COMPUTER MAIL BOX ENABLED?

NO YES

1K

8K

16K

75

406

1225

68

399

1218

* Each table entry is equal to IO registers.

BUS STATUS/CONTROL BYTE LOCATION: Some of the bits in the original I/O status table can be used to enable and monitor some of the Genius I/O functions. This is the main

I/O point address where the diagnostics’ discrete status (input table) and control (output table) bytes are located. Allowable entries are 0001 through 1017. Default = 0993.




Expanded CPU Operation 4-19

GEK-96602

GENIUS I/O Fault Table Definitions

If a fault occurs that has more than one cause (see the definition of Fault Category, below) each cause is listed as a separate line in the table. The entries in the table show the following information about a fault:

B/C

ADDR.

BUS CONTROLLER ADDRESS: Displayed for a Bus Controller error. This entry has two fields:

‘t

Channel Number: The number of the channel where the error occurred. A hex value from 0 to F:

I

M A I N A U X I L I A R Y

0 8

1 9

2 A

3 B

4 C

5 D

6 E

POINT

ADDR.

-w---c

I

CIRCUIT NUMBER:

FAULT CATEGORY:

Byte Address: The byte address of the error. Range = 0 to 125.

POINT ADDRESS: Not displayed if the error is a Bus

Controller or Serial Bus fault. This entry has two fields:

Input/Output: The first two characters indicate an input (I) or output (0). Both may appear at the same time.

Address: The address of the error. Range = 1 to 1000.

Displayed only for a circuit fault. Range = 1 to 16.

The number displayed corresponds to a circuit number within a block.

This entry shows the category of error that has occurred:

IOC FAULT

BUS ERROR

CIRCUIT

FAULT

LOSS OF BLOCK

BLOCK ADDITION

ADDRESS CONFLICT

EEPROM FAILURE

???????????????? (displayed for multiple errors)


4-20


GEK-96602

FAULT TYPE:

FAULT DESCRIPTION:

The error type: BLOCK, DISCRETE, or ANALOG.

Displayed only if the Fault Category is CIRCUIT FAULT.

Multiple lines may be displayed. Possible descriptions are:

BLOCK SWITCH FAILED

DISCRETE SWITCH FAILED

OVER TEMP

NO LOAD

OPEN WIRE

OVERLOAD

SHORT CIRCUIT

LOSS OF POWER

ANALOG INPUT HIGH ALARM

INPUT LOW ALARM

OUTPUT UNDERRANGE

OUTPUT OVERRANGE

INPUT

OPEN WIRE

INPUT

UNDE RRANGE

INPUT

OVER RANGE

CHANNEL NUMBER

FAULT TIME:

The day, hour, minute, second, and tenth of a second when the error occurred, derived from the CPU’s real-time clock.

Viewing Additional Fault Listings

In order to display or print additional faults in the table, follow the steps below.

To move the display down one line at a time, press the Next key or the Down Cursor key.

To move the display up one line at a time, press the Prev key or the Up Cursor key.

To move the display down one page at a time, press SHIFT/NEXT or Next Page (F1).

To move the display up one page at a time, press SHlFT/PREV or Prev Page (F2).

To go to the top of the table, press the Top (F4) function key. To go to the end of the table, press the Bottom (F5) function key.

Clearing Faults

Use the Clear Faults (F3) key to clear the Fault Table.

This sets the fault count to zero, and clears the fault data at the Genius l/O blocks. Subsequent incoming faults fill the

Fault Table beginning with the next available location, with the oldest data at the top.

This will cause the Bus Controller to issue a CLEAR ALL FAULT command (see the

Genius I/O System User’s Manual for further information).


4-21


GEK-96602

FLOATING POINT FUNCTIONS

Seven function floating point arithmetic has been implemented as a feature of the

Expanded Functions. The available floating point functions are:

- Floating Point Addition

- Floating Point Subtraction

- Floating Point Multiplication

- Floating Point Division

- Floating Point Compare

- Integer to Floating Point Conversion

- Floating Point to integer Conversion

Floating Point Display Format

Two registers are required to represent each Floating Point reference which is stored in

IEEE format. The display for the Floating Point Arithmetic Functions is in decimal scientific notation as shown in figure 4.5.

1

.234567+12

I

Two digits of exponent

Sign of exponent

Six least significant digits

Decimal point

Most significant digit (1)

Sign of entire number (2)

m

Figure 4.5 FLOATING POINT ARITHMETIC DISPLAY FORMAT

(1) Will only be zero (0) when all digits are zero.

(2) The + (plus) sign is implied and not displayed. The - (minus) sign will always be displayed.

Floating Point numbers are stored in two consecutive registers as shown below.

I

23 bits of mantissa f23

8-bit exponent

Valid Number Format

The display format requires a total of 12 character spaces and is limited to 7 significant digits. With 7 digits, any valid number can be stored in the 32 bits (2 registers) allocated for floating point numbers.

A number greater than 7 digits does not conform to the IEEE


4-22


GEK-96602

32-bit format and is considered to be not a number. The references to infinity refer to the limits for numbers that may be operated on. These limits are +/-3.402823

+38

. An attempt to exceed these limits will be interpreted by Logicmaster 6 software as an overflow.

Programminq Floating Point Arithmetic Functions

All of the Floating Point functions are entered on the programmer using Logicmaster 6, version 3.01 or later software. When entering a Floating Point function, conditional logic to control power flow to the function should be entered before the function. If conditional logic is not entered, the function will execute unconditionally with every sweep.

To access Floating Point Arithmetic, with the programmer, select Advanced Mnemonic

Group (F7), then Expanded Arithmetic (F2), then Floating Point Arithmetic (F6). Next the desired Floating Point Arithmetic function is selected with the applicable soft key.

KEY MNEMONIC FUNCTION

(Fl) FADD

(F2) FSUB


Floating Point Subtract ion

(F3) FMULT Floating Point Multiplication

(F4) FDIV


(F5) FP GREATER THAN

Floating Point Compare

(F6) INTEGER TO FLOATING POINT

Integer to Floating Point Conversion

(F7) FLOATING POINT TO INTEGER Floating Point to Integer Conversion

For detailed information on how to enter the Floating Point functions, refer to the

Logicmaster 6 User’s Manual, GEK-25379.


Program a Floating Point Addition function to add a floating point value in reference A to the floating point value in reference B and place the result in reference C.

Every scan that power is received, the FADD function calculates the result using floating point mathematics. The result is placed in reference C. Only the content of reference C is altered by this function.

The function will output power flow if overflow occurs, if references A and B are opposite signed infinities, or if either reference A or B is not a number.

Floating Point Subtraction

Program a Floating Point Subtraction function to subtract a floating point value in reference B from the floating point value in reference A and place the result in reference

C.



~~

GEK-96602

4-23

Every scan that power is received, the FSUB function calculates the result using floating point mathematics. The result is placed in reference C. Only the content of reference C is altered by this function.

The function will output power flow if overflow occurs, if references A and B are infinities having the same sign, or if either reference A or B is not a number.

Floating Point Multiplication

Program a Floating Point Multiplication function to multiply the value in reference A by the value in reference B and place the result in reference C. Every scan that power flows to the function, the system multiplies the value in reference A by the value in reference

8 and places the signed result in reference C.

The possible sign of the result is shown below.

Reference A

Reference B Reference C

+

+

+ +

Floating Point Multiplication will not normally output power flow, except under the follow ing conditions.

1.

The result is too big to store (overflow).

2.

The result is too small to represent (underflow).

3.

Either reference A or B is infinity and the other is zero.

4.

Either reference A or B is not a number (invalid format).


Program a Floating Point Division function to divide the value in reference A by the value in reference B and place the result in reference C. The possible signs:

Reference A

Reference B Quotient

+

Floating Point Division will not normally output power flow, except under the following conditions.

1.

The result is too big to represent (overflow).

2.

The result is too small to represent (underflow).

3.

Reference B is a zero.

4.

Both references A and B are infinities.

5.

One or both of references A or B is not a number (invalid format).


4-24


GEK-96602

Floating Point Greater Than

Program a Floating Point Greater Than function to compare the value in reference A to the value in reference B.

Every scan that power is received, the Greater Than function compares the content of reference A to the content of reference B. Comparison is based on the signed, floating point values of the contents.

Power flows only if the first value is greater than the second. Some example comparisons are shown below.

Reference A Reference

B

Power Flow ?

+2.34595+1 +2.34595+0

YES

+0.00000+0

+0.00000+0

+9.99999-l

-1 .00000+1

YES

NO

Convert Integer To Floating Point

Every scan that power is received, the integer to Floating Point function reads the integer value of reference A and places the floating point equivalent in reference B.

Power flows only when an error is encountered.

Convert Floating Point To Integer

Every scan that power is received, the Floating Point to Integer function reads the floating point value of reference A, and places the integer equivalent in reference 8.

Power flows only when an error is encountered.

WINDOW (DPREQ)

FUNCTION

The Window Function is a special Data Processor REQuest that supports the 16 channels of the expanded I/O system.

Each scan that power is received, the Window function opens a window to the expanded I/O channel that is specified by the hexadecimal value

FIRST REFERENCE

0

‘~y-=q!

Address: 0 to 7c

|-Channel Address: 00 to 0F, or C0



GEK-96602

4-25

The first reference used by the Window function stores:

In the high order byte, the number in hexadecimal, of the I/O channel to be opened.

The number may be either:

00-0F: valid individual channel numbers as determined by the DIP switch settings on the I/O Transmitter modules in the system.

CO: broadcast channel number.

In the low-order byte, the window address which is the module’s card address as set by the DIP switches on the rack backplane. It may be any address from 0 to 7C. 7D,

7E and 7F are reserved for the Interrupt Input module, DPU and PDT windows, and can not be used in this function.

The second reference is the start of the communications block in register memory.

Power flows out of the Window function only if the window address specified in the first reference is out of range of the configured expanded address, or if the window fails.

Failure may be caused by:

Addressed device not responding (timeout).

Addressed device sends bad header (checksum).

Addressed device fails to close window (timeout).

Entering a Window Function

The Window function can be placed in columns 1 to 9 of a rung.

1.

Enter any logic required to control power flow to the function. If the function is placed at the left rail, it will execute unconditionally upon every sweep.

2.

Select Advanced Mnemonic Group (F7), then Control Functions (F6), then Window

(F7). The DPREQ Window display appears.

3.

4.

5.

+[ WINDOW

ADDRESS COMM BLOCK ]+

The cursor is at ADDRESS. Using the decimal keypad, type in number of the reference. It may

be

any reference type.

After entering the reference, press the

Enter key.

The cursor moves to BLOCK. Enter the register that will store the communications block or computer mail box address. It must be a valid register. Press the Enter key.

Complete the logic for the rung, then press the Accept key. The Edit key functions reappear at the bottom of the screen.


4-26

Expanded CPU

Operation

GEK-96602

USING THE DO I/O FUNCTION TO ADDRESS 16K INPUTS AND OUTPUTS

The DO l/O function as programmed with the Advanced Functions required entering a start and end address for I/O points on the Main or Auxiliary chain to be serviced immediately.

The DO I/O function for use with the Expanded I/O has been expanded to address the full 16K inputs and 16K outputs of the expanded I/O references. When expanded l/O is selected, the bits in the Do I/O function references have the meanings shown below. These can be placed in the start and end references using an A to B Move or similar function.

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1 1 1 X 1 X 1 X 1 X 1 channel # 1 X 1 I/U address

Bit 15 must be set to 1 by the program.

If a constant value is used, bits 14 and 15 must both be set to 1.

Bits 8, 9, and 10 are the channel number, 0 - 7.

Bits 0 through 6 specify the I/O address.

Entering a Do I/O Function

The Do I/O function can be placed in columns 1 to 7 of a rung.

1.

Enter any logic required to control power flow to the function. If the function is placed at the left rail, it will execute unconditionally upon every sweep.

2.

3.

4.

5.

Select Advanced Mnemonic Group (F7), then Control Functions (F6), then Do I/O

(F4). The Do I/O display appears.

+[ DO I/O START END ]+

The cursor is at START, Using the decimal keypad, type in the reference that contains the beginning I/O address. It may be a constant from 1 to 1000, any valid register, or any I/O reference in the range 1-1024. After entering the reference, press the Enter key.

The cursor moves to END. Using the same parameters, enter the reference that contains the final address. Press the Enter key.

Complete the logic for the rung, then press the Accept key. The Edit key functions reappear at the bottom of the screen.

When the DO I/O function is executed, through user logic, the I/O points specified by

START and END will be serviced immediately. When active, bit 15 (or 14 and 15) must have been set to a 1 and the starting channel and address must be equal to or less than the ending channel and address, in order for power flow to be passed through the function. If either of these conditions are not met, the function will not pass power flow.



GEK-96602

4-27

EXPANDED TIME REFERENCE (REAL-TIME CLOCK)

This is a three-word real-time clock maintained by the CPU in three consecutive registers. The exact register address is determined by the total register size in the CPU.

The clock is located in the following registers:

MAXIMUM REGISTERS CLOCK

IN SYSTEM LOCATION

1K R0267, R0268, R0269

8K

16K

R4117, R4118, R4119

R4117, R4118, R4119

The function of the clock is to record elapsed time and maintain an accurate record of the time that Genius I/O faults occur.

Format of the Real-Time Clock

The clock keeps track of time in hundreds of days, days, hours, minutes, seconds and tenths of seconds. Each fault is time stamped with the clock reference and stored in the

Genius I/O Fault Table if it is enabled. The clock stops when power is removed and must be reset by the user when power is restored.

The clock can be synchronized by the user through logic programming.

The clock is updated once per sweep and has a cumulative accuracy of 8 seconds per day.

The format for storing the clock data in the three registers is as shown below. Data entered in each byte of each register is 2 BCD digits.

REGISTER MOST SIGNIFICANT BYTE LEAST SIGNIFICANT BYTE

RXXXX Seconds (00 - 59) Tenth of Seconds (00 - 09)

RXXXX +1 Hours (00 - 23) Minutes (00 - 59)

RXXXX +2 Hundreds of Days (00 - 99) Days (00 - 99)


4-28


C E K - 9 6 6 0 2

GENIUS

I/O DIAGNOSTICS

The Genius I/O diagnostics must be enabled from the Configuration Menu in order to be fully utilized by the CPU. The diagnostic features which can be enabled are: Diagnostic

Tables, Bus Controller Point Faults, Diagnostic range Limit, Fault Table Length, and Bus

Status/Control Byte Location. Enabling of these features was previously described in the discussion on the Configuration Menu.

The following discussion describes the diagnostics and the interface between the CPU, Bus Controller and the Genius I/O Blocks.

DIAGNOSTIC FAULT TABLE

The first function is a diagnostic fault table which automatically stores any fault reported by a Bus Controller, along with the time that the CPU received the fault. Ten registers are used to store data related to each fault.

The fault table can be as long as desired, limited only by the quantity of registers available in the CPU. The location and maximum length of the fault tables can be determined by referencing the memory maps for 1 K, 8K and 16K registers (figures 4.3, 4.4).

REGISTER MEMORY SIZE VS GENIUS I/O DIAGNOSTlCS

The register memory size specified by the entry in the Configuration Menu tells the CPU the amount of Genius l/O diagnostics to perform.

Care should be exercised by the user when specifying register sizes in order to ensure upward compatibility. For a register size of 1K, diagnostics will be performed up to the first 1024 inputs and 1024 outputs.

Maximum register sizes of 8K or 16K will allow the CPU to perform diagnostics on the maximum of 16K inputs and 16K outputs.

References other than those specified for diagnostics are available for general use by the user.

Fault Table Pointer

A counter located at the top of the fault table (first register in the table) is a pointer that indicates how many faults have been stored in the table. When the table is full, no additional entries are allowed until the counter is cleared or reduced in content by the user’s program, thus indicating that space is available for new entries. The actual content of the table is not cleared to zero. The pointer returns to the first register and the next data is loaded into the pointer location.

Any new data written to a register writes over the old data. New data is loaded into the next available location, with the oldest data at the top. The fault table length is specified in multiples of ten registers.

For example, a length of 27 indicates 271 registers assigned to the fault table. Each fault recorded is represented by 10 words (registers).

Input Data From Bus Controller

Each Bus Controller with diagnostics uses 6 bytes to provide status information to the

CPU. The content of each

of

the bytes is described following figure 4.6. Bus Controllers without diagnostics use only one Byte in the input table to provide status information.





GEK-96602

4-31


CIRCUIT FAULT - This input, when on, indicates a fault in one of the circuits on a

Genius l/O block. Bytes 3 and 4 of the 6 input bytes indicate the I/O reference (0001 through 1000) that has been assigned to the circuit.

-

Byte 2 (inputs 9 and IO) indicate whether the circuit is an input or output.

Input 9

ON indicates that the circuit is an input, Input 10 ON indicates that the circuit is an output. If both are On, the circuit is an output with feedback.

-

Byte 3 contains the least significant byte of the l/O reference (Input 17 contains the least significant bit, LSB).

-

Byte 4 contains the most significant byte of the I/O reference (Input 26 contains the most significant bit, MSB).

on the I/O block.

Inputs 33 - 36 (with 33 the LSB) can display the value 0 through 15; however, only 0, 1, and 2 are used. The value 0 indicates a fault with the EEPROM in the block’s terminal assembly. The value 1 indicates that the circuit fault is on a discrete I/O block and the value 2 indicates that the circuit fault is on an analog I/O block.

Inputs 37 through 40 indicate the relative circuit number on this I/O block. The value 0 represents the top circuit of the block; 7 or 15 the bottom circuit for discrete blocks and

5 the bottom circuit on analog blocks). On the analog blocks, the values 0 to 3 indicate input channels 1 to 4; 4 and 5 represent output channels 1 and 2.

-

Byte 6 (Inputs 41 through 48) are individual bits that indicate the type of fault. Only one of these bits will be on at a time.

Table 4.5 defines the faults represented by the inputs 41 through 48. Notice that they are decoded differently for discrete and analog blocks, as indicated by the fault type in Byte

5 (inputs 33 - 36).

Table 4.5 DECODING OF BYTE 6 FOR CIRCUIT FAULT TYPES

RELATIVE

INPUT

NUMBER *

41

42

43

44

45

46

47

48

SIGNIFICANCE IF O N

DISCRETE I/O BLOCK ANALOG I/O BLOCK

Loss of Circuit Power

Output: Short Circuit

Output: Overload

If Input: Open Wire

If Output: No Load

Over Temperature

Failed Switch not used not used

Low Alarm

High Alarm

Input Underrange

Input Overrange

Open Wire

Output Underrange

Output Overrange not used

* Adjust as necessary for different Bus Controller I/O reference assignments.


4-32


GEK-96602


LOSS OF BLOCK

- This input, when ON, indicates that the Bus Controller has detected the loss of an I/O block that had been operating.


ADD A BLOCK -

This input, when ON, indicates that the Bus Controller has detected that a block has been added to the bus where there had previously not been a block.

-

Both input 4 and 5 will be on for at least one CPU scan for each detected loss or addition of a block, but they will never be on at the same time.

Byte 2 (Inputs 9 and 10) indicates whether this l/O block is an input only block (Input

9 ON), output only I/O block (Input 10 ON), or combination input/output I/O block

(Inputs 9 and 10 both ON).

the I/O block.


ADDRESS CONFLICT

- This input indicates a conflict between two I/O blocks on the bus trying to use the same l/O reference. A block has been added with a reference used by a block already on the bus. This conflict may be for two blocks with references overlapping either partially or totally.

Input 16 will be On for one scan for each conflict to be reported. The last block with the conflicting address wilI be ignored.

-

-

- Byte 2 (Inputs 9 and IO) indicates whether this I/O block is an input only block (Input

9 ON), output only I/O block (Input 10 ON), or combination input/output l/O block

(Inputs 9 and 10 both ON).

Bytes 3 and 4 indicate the reference (0001 to 0993) of the lowest reference involved in this conflict.

Bytes 5 and 6 provide the device numbers (0 to 31) of the two conflicting I/O blocks.

Byte 5 (Input 33 = LSB, Input

37 =

MSB) contains the device number for the I/O block that was not accepted. This l/O block is rejected by the system (no inputs accepted/no outputs activated) and is left in

a

default state.

Byte 6 (Input 41 = LSB, Input 45 = MSB) contains the device number for the existing I/O block.

Bus Controller Status Byte 1 (Address 0) - Inputs 7 and 8

These two inputs provide data independent of the other inputs. They can be turned on as needed for indication of system status regardless of the ON and OFF state of the other inputs.



GEK-96602

4-33

Input

7 , PULSE TEST ACTIVE

- This input is turned on for one scan after the Pulse Test is commanded by the CPU and remains on until all discrete I/O blocks configured for the

Pulse Test have completed the test.

Faults detected during this test are provided to the

CPU through Input 3, Circuit Fault, which is described above. This allows circuit faults to be identified as normal random actions or as faults identified as part of a pulse test.

Input 8,

FORCED CIRCUIT -

This input is on any time that at least one discrete I/O circuit or Analog circuit is forced by the Genius I/O Hand Held Monitor (HHM). This input can be used by the CPU to alert operators that a forced condition exists. The operator can then determine if the forced condition is proper or should be removed, if necessary, with the HHM. There is no indication as to which l/O block or reference contains the forced reference.

Only forced conditions set by the HHM on blocks controlled by this Bus Controller affect input 8.

NOTE

When analyzing the data provided by the 48 input references, first examine the lower 8 inputs of the reference (first byte). Input data in higher bytes (2 through 6) is used only if one of the Inputs 3 to 6 is ON. Inputs 1, 2, 7, and 8 are independent and can come ON or go OFF as required, regardless of the state of the other inputs.

If Input 1 is OFF, all other inputs have no validity.

Fault Table Reqisters

The content

of

each of the registers is further described numbered from 0 through 15.

Bits 0 through 7 are the Least bits 8 through 15 are the Most Significant Byte.

below. The bits are

Significant Byte and

Register 1 - Genius I/O Bus Controller Address Decoding

The first register contains the I/O address of the

Bus Controller that reported the fault.

The Bus Controller address is decoded by the state of the bits in this register. The register contains the I/O channel (bits 12 -15, range 0 through F) in which the Bus Controller is placed and its starting I/O reference (bits 0 - 9, with a range of 0 through 1023). Bits 10 and 11 are unused.

Register 2

The second register contains the I/O channel number in Hexadecimal (0-F) and the l/O reference of the

faulty circuit

or starting reference of the faulty I/O

block.

If the fault is with the Bus Controller or the Genius I/O communication bus, the reference value will be 0. Bits 10 and 11 in register 2 indicate whether the circuit fault is with an input (bit 10 on) or output (bit 11

on)

circuit, or l/O blocks containing all inputs or outputs.

If bits 10 and 11 are on, the circuit is an output with feedback or an I/O mixed block.






GEK-96602

4-37

Output 2 (Bit 1) Definition, Clear All Faults

This bit clears all faults that are currently being stored in the I/O blocks connected on this controllers bus. All faults will be cleared once for each transition of the Clear All

Faults output.

Output 3 (Bit 2) Definition, Clear Circuit Fault

Output 3 performs a function similar to Output 2, except it is limited to one circuit per scan. Only the circuit identified in addresses 2 and 3 (bytes 3 and 4) by the I/O reference

1 to 1000 (input 17 = LSB, input 32 = MSB) will be cleared at the I/O block. No other faults will be affected.

Since the analog circuits do not have a specific l/O reference assigned to them, the circuits are identified by the first six references assigned to the block as shown in table

4.7. The example in the table assumes that the Analog I/O block starts at I/O references

10225.

Table 4.7 ANALOG I/O BLOCK REFERENCE EXAMPLE

I/O REFERENCE ANALOG CIRCUIT EXAMPLE

Starting Reference Input Circuit 1

0225

Starting Reference +l Input Circuit 2 0226

Starting Reference +2 Input Circuit 3 0227

Starting Reference +3 Input Circuit 4

Starting Reference +4

Output Circuit 1

0228

0229

Starting Reference +5 Output Circuit 2 0230

To clear more than one circuit (either discrete or analog) Output 3 must go from an off to on transition (a one-shot could be used for this) and change the values in Bytes 3 and 4 to reflect the actual individual circuits to be cleared.

Output 4 (Bit 3) Definition, Pulse Test

This output activates the pulse test. If this output is on for one scan, it will cause all

Outputs configured to ignore this signal, input only blocks and analog I/O blocks will not perform the pulse test.

The pulse test begins at device number 0 and as fast as it receives a test complete signal from that device, proceeds to each block until it reaches device number 31. Faults detected during this test are recorded by the CPU as circuit faults. When the test has been completed by all l/O blocks on the bus, Input 7 (Pulse Test Active) wi I I be turned off .


4-38


GEK-96602

If this output is on when one test is completed, another will immediately begin. It is not recommended that this output be left on for a continuous pulse test. It is recommended that the pulse test be activated a minimum of once each 5 minutes. Input 7 will then toggle as each pulse test is completed. The advantage of turning output 4 on for only one scan is that only one test will be conducted as timed by input 7.

Output 9 (Bit 0 of Byte 2) Definition, Circuit Type

The state of this output is determined by the Circuit type (either Input or Output). If the

Circuit Reference indicated by the values in bytes 3 and 4 is an Input, this bit is set to a

1. If the Circuit Reference is an output, the bit is set to a 0.

POINT STATUS BIT MAP

Another Genius I/O diagnostic option selected when the Diagnostic Tables are enabled through the Configuration Menu, is a point status bit map for each input and each output.

The status bit initial value will be zero. It is set to a one if a fault is received, which affects this circuit or its entire I/O block (that is - loss of block).

Once set, status bits remain on until reset by the user’s program, even if the fault is corrected, thus allowing a Matrix Compare function to monitor the status of all l/O circuits, and identify a faulty circuit quickly and without extensive logic.

If faults are found with analog blocks, they will be indicated in the status by a special pattern since there is no direct relationship between the fault circuit and an individual

I/O reference. The status for analog inputs is shown below for its three l/O addresses (24 bits).

Table 4.8 BIT STATUS MEANING FOR ANALOG BLOCKS

BIT

NUMBER

ADDRESS 0 ADDRESS 1 ADDRESS 2

1

0

Input 1 Low Alarm Input 2 Underrange Input 3 Open Wire

Input 1 High Alarm Input 2 Overrange Not Used (OFF)

2 Input 1 Underrange Input 2 Open Wire Input 4 Low Alarm

3 Input 1 Overrange Not Used (OFF)

Input 4 High Alarm

4 Input 1 Open Wire Input 3 Low Alarm Input 4 Underrange

6 Input 2 Low Alarm Input 3 Underrange Input 4 Open Wire

7

Input

(OFF>



4-40


GEK-96602

Output Control Definitions

On the output side, when the first output is set on, all Bus Controllers connected to the

CPU will begin to clear faults stored at the I/O blocks as well as in the Bus Controller.

When this master reset is removed, new faults can be recorded and reported to the CPU.

The second output causes a bit to be set which initiates a pulse test of alI Genius I/O discrete outputs connected to the CPU, except those blocks configured to ignore the test. If left energized, the second output will cause continuous pulse tests to be conducted as soon as the previous test is completed.

COMPUTER MAIL BOX

The Computer Mail Box is an automatic communications window to the Genius I/O system. The default entry for this option is N.

To use the Computer Mail Box, change this entry to Y.

If set to Y, the CPU will open a communications window to any valid address located in the first of 70 consecutive registers for the Computer Mail Box. The window is opened once per sweep, when the CPU is in the RUN mode.

Using the Computer Mail Box to Communicate

with Genius I/O

Bus Controllers

The CPU interprets data in the first of 70 consecutive registers as an address to open communications with a Genius Bus Controller.

The registers in the CPU that are allocated for the Computer Mail Box are used for transfer of data between Genius l/O

Bus Controllers and a Series Six Plus CPU in the Expanded mode. The window address of the Bus Controller is placed in the first register and command data is placed in the next five registers.

The remaining 64 registers provide a buffer area for data to be communicated. An illustration of the registers and their content is shown below.

a41086

RXXXX4 BUS CONTROLLER ADDRESS 1

FIRST REGISTER

IN GROUP OF70

CONSECUTIVE

REGISTERS

1 TARGET BLOCK START ADDRESS 1

IMAILBOX ADDRESS FOR DATA 1

IDATABUFFER LENGTH IN BYTES 1

I

FIRST DATAREGISTER

I

COMMAND

+ DATA,

REGISTERS

DATA c BUFFER

Figure 4.9 REGISTER FORMAT FOR COMPUTER MAIL BOX



GEK-96602

The CPU, at the end of its sweep, detects that a command is waiting and opens an executive window for communications. The addressed device can then either read data from the mail box or place data for the CPU in the mail box. The window that allows a

Bus Controller to access the Computer Mail Box is generated automatically by the CPU at the end of each sweep if commanded to do so by enabling the Computer Mail Box option through the CPU Configuration Set Up menu.

NOTE

The following description of the mechanism for operation of the Computer Mail

Box is for use only with Genius I/O Bus Controllers.

Operation of the Computer Mail Box

The sequence outlined below describes the the content of each of the 70 registers is.

operation of the Computer Mail Box and

Communications Window Opens

The window to the referenced Bus Controller (channel 0 to F, address 1 to 1000) is opened at the end of each CPU sweep if:

1.

The Computer Mail Box has been enabled through the CPU Configuration Set Up

Menu using Logicmaster 6 software in a Workmaster computer.

2.

If the content of the window address register in the CPU is in the range of 00001 to

16360.

Register R - Bus Controller Address

The Computer Mail Box address of the Bus Controller to be communicated with is placed in the

first

of the group of 70

registers.

The actual address to be entered into this register is calculated by using the following formula:

Mail Box Window address = Channel number (0 to F) x 1024 + l/O address (1 to 993) of the Bus Controller. Use the decimal equivalent of the channel number. For channels

A to F, use the decimal equivalent (A = 10, B = 11, etc.) of the hexadecimal value in your calculation.

Example: Bus controller at I/O location 257 in channel 4 (4 x 1024 + 257 = 4353).

Enter 4353 in the first register of the Computer Mail Box.


4-42


GEK-96602

Command Data Registers

The next 5 registers contain command data. This data, which is in the form of numerical values, provides control information, which includes:

- What function is performed.

I/O system is to be stored in the CPU.

The content of each of the five command registers is described below.

Register R+1 - Operation (Read or Write)

-

-

The second register must contain an operation (command) number which indicates which of the following operations is to be performed when communications is opened (DPREQ receives power flow).

- 1 =

3=

4=

- 5 =

Idle, no operation performed

Read the configuration of the I/O block or Bus Controller (into CPU registers) specified in the fourth register. Immediate command *.

Write the configuration of the I/O block specified in the fourth register (from

CPU registers). Not an immediate command.

Read diagnostic data of the l/O block or Bus Controller (into CPU registers).

Immediate command *.

Reserved for future use.

- 7 =

- 8=

- 9

=

Read analog status (all analog inputs from a block into the CPU registers).

Immediate command *.

Reserved

Read Status Table Reference. Immediate command *.

Reserved

* Immediate only if the specified Status Table address is that of the Bus Controller.

Register R+2 = Communications Status

The third register is loaded with a number by the CPU to indicate the status of the communications (DPREQ). The register should initially be cleared to zero and will be loaded by the CPU at the end of each scan when a status is available. The content of this register as loaded by the CPU can be:

- 0 = Not accepted. The CPU or addressed Bus Controller is busy with the previous communications request (DPREQ).

- 1 = The operation is in process but not completed.

- 12= The operation has been terminated due to a syntax error in the DPREQ registers.

- 20=

??

Other error. Any errors that are involved in executing the command, such as a communications timeout, NAK, internal Bus Controller error, etc.



.- ~.

GEK-96602

4-43

Register R+3 - Target Block Start Address

The content of the fourth register is an I/O reference to indicate the starting location of the desired I/O block or Bus Controller. The register must contain a value between 1 and

993, which must be a valid I/O address.

Three devices can be addressed: discrete I/O blocks, analog l/O blocks, and the Bus Controller.

Register R+4 - Mailbox Address for Data

The fifth register indicates where the received data from the Genius I/O system should be stored in the CPU for read operations (operations 2, 4, and 7 in register R+1).

Consecutive registers, beginning with the specified register, will be used until all received data is stored. For write operations (operation 3) this register indicates where the data to be sent to the Genius I/O system from the CPU, is to be stored.

Each device requires a different number of registers to store the configuration data in a

16-bit format. An 8-circuit discrete I/O block uses 6 CPU registers, a 16-circuit discrete I/O block uses 10 CPU registers, an analog I/O block uses 42 registers, and the

Bus Controller uses 18 registers.

Register R+5 - Data Buffer Length

The sixth register specifies the length of the number of bytes to be read or written to by the Bus Controller in a Read Device or Write Device command.

Data Registers

The remaining registers in the group of 70 registers in the Computer Mail Box may contain the data to be read from or written to the specified Bus Controller and are moved in one command.

Command Verification

The Bus Controller then verifies the command block for valid command syntax and the absence of a command of that type already in execution.

If a syntax error does exist, the

Bus Controller writes an error code into the status code of the third register of the command block in the CPU. If a command of the same type is already being executed, the Bus Controller will not modify the status code in a subsequent Computer Mail Box window when the busy condition disappears.

If the command number specifies a write command, the Bus Controller must read the specified amount of data from the CPU register memory and store it in the serial bus output queue.


4-44


GEK-96602

Terminating Computer Mail Box Communications

The Bus Controller will then close the communications window by issuing a Close Window command, which terminates execution of the Computer Mail Box. The window address of the Bus Controller (in the first register) that was communicated with is cleared when the value placed in the status register (third register) by the CPU is not equal to 1 (any valid number, except 1).

USlNG THE DPREQ FUNCTION TO COMMUNICATE WITH GENIUS I/O

The CPU can communicate with the Genius I/O system through a window opened during the logic solution of the CPU’s sweep. When this window is opened is determined by programming Data Processor Request (DPREQ) functions in the user program with a constant parameter, which is a pointer to a group of registers that contain the command block. The command block contains the Bus Controller’s window address (which corresponds to its address defined by the DIP switch setting on the backplane), a command number, and associated operands for the command.

Typical DPREQ Operation

The sequence below describes the operation of a typical DPREQ instruction.

1.

The window to the addressed Bus Controller is opened at the beginning of the DPREQ instruction.

2.

Any pending data transfers from the Genius I/O serial bus are copied to or from the

CPU registers by the Bus Controller. Examples of these transfers are actions such as the Hand Held Monitor reading a CPU register or the Bus Controller completing a previously issued command.

3.

4.

Any communications or other error resulting from the previous command will be flagged to the user in the status register.

The Bus Controller will then read the CPU Scratch Pad memory (address 35 and 36).

If bit 7 in location 35 is set to a 1, then the window is interpreted as an executive or

Window instruction type. The Bus Controller then uses the lower 14 bits of the two

Scratch Pad addresses as a pointer to the command block in the registers.

If bit 7 of location 35 is reset, the Bus Controller will use the two bytes as a pointer to the DPREQ instruction located in user memory that contains the 16-bit pointer to the command block in register memory.

The Bus Controller will then read the registers as described below.



GEK-96602

4-45

In the Series Six Plus ladder logic, the DPREQ function references six consecutive registers. Data to be communicated to the Genius l/O system must be placed in these registers before the DPREQ function is executed. This data, in the form of numerical values, provide control information, which includes:

Genius I/O system is to be stored in the CPU.

Contents of First Register

When programming a DPREQ function, the first register referenced indicates which Bus

Controller is to be accessed or through which the intended function is to occur. The contents of this register must be equal to the Bus Controller’s first status reference plus

1000. For example if the first status reference is 425, and the Bus Controller is in the

Main I/O chain, enter the value 1425.

Contents of Second Register

The second register must contain an operation (command) number which indicates which of the following operations is to be performed when the DPREQ receives power flow.

- 1= Idle (no operation performed)

-

2=

Read the configuration of the I/O block or Bus Controller (into CPU registers) specified in the fourth register.

CPU registers).

- 5= Reserved for future u se.

- 6=

Reserved for future use.

Contents

of Third Register

The third register is loaded with

a

number by the CPU to indicate the status of the

DPREQ. The register should initially be cleared to zero and will be loaded by the CPU at the end of each scan when a status is available. The content of this register

as

loaded by the CPU can be:

- 0 =

Not accepted. The CPU or Bus Controller is busy with the previous DPREQ.

- 1=

The operation is in process but not completed.

-

2=

Operation has been completed successfully.

- 12= The operation has been terminated due to a syntax error in the DPREQ registers.

- 20= Other error. Any errors that are involved in executing the command, such as a communications timeout, NAK, internal Bus Controller error, etc.


4-46


GEK-96602

Contents of Fourth Register

If the second register contains a 2, it will read the configuration of the l/O block or Bus

Controller specified in the fourth register. The content of the fourth register is an I/O reference to indicate the starting location of the desired I/O block or Bus Controller.

The register must contain a value between 1 and 993, which must be a valid l/O address.

Three devices can be addressed: discrete I/O blocks, analog l/O blocks, and the Bus

Controller.

Each device requires a different number of registers to store the configuration data in a

16-bit format. An 8-circuit discrete I/O block uses 6 CPU registers, a 16-circuit discrete I/O block uses 10 CPU registers, an analog I/O block uses 42 registers, and the

Bus Controller uses 18 registers.

Contents of Fifth Register

The fifth register indicates where the received data from the Genius l/O system should be stored in the CPU for read operations (operations 2, 4, and 7). Consecutive registers, beginning with the specified CPU register, will be used until alI received data is stored.

For write operations (operation 3) this register indicates where the data to be sent to the

Genius I/O system from the CPU, is to be stored.

5.

6.

7.

The Bus Controller then verifies the command block for valid command syntax and the absence of a command of that type already in execution. If a syntax error does exist, the Bus Controller writes an error code into the status code of the third register of the command block in the CPU.

If a command of the same type is already being executed, the Bus Controller will not modify the status code in a subsequent DPREQ when the busy condition disappears.

If the command number specifies a write command, the Bus Controller must read the specified amount of data from the CPU register memory and store it in the serial bus output queue.

The Bus Controller will then close the communications window by issuing a Close

Window command, which terminates execution of the DPREQ instruction. The window address of the Bus Controller (in the first register) that was communicated with is cleared when the value placed in the status register (third register) by the

CPU is not equal to 1.

NOTE for a more detailed description and examples of using the DPREQ function to open communications with the Genius I/O system, refer to Chapter 6 in the

Genius I/O System User% Manual, GEK-90486.


Troubleshooting and Repair

GEK-96602

5-1

CHAPTER 5

TROUBLESHOOTING AND REPAIR

INTRODUCTION

This chapter is a guide to the basic troubleshooting and repair information required if a malfunction of your Series Six Plus PLC system should occur.

Section 1 contains information on troubleshooting and repair of the Central Processing Unit, while Section 2 contains information on troubleshooting and repair of the I/O system. Parts lists are included as a reference for ordering renewal parts.

MINIMUM DOWNTIME

The technology used in the design of the Series Six Plus programmable logic control system is such that under normat operating conditions few hardware failures are expected. If any failures should occur, they can quickly be isolated and the defective assembly replaced with minimum downtime. If GENIUS i/O blocks are included as part of your l/O structure, downtime is reduced to an absolute minimum for the I/O structure.

LOGICAL TROUBLESHOOTING

Troubleshooting is accomplished by thinking logically of the function of each part of the system and how they relate to each other. A basic understanding of the various indicator lights will usually quickly isolate the problem to the CPU rack, an I/O rack, the programming device or any peripheral device in the system.

By use of the programming device, which can be a Workmaster industrial computer,

CIMSTAR I industrial computer, IBM PC, PC-XT, PC-AT, or Program Development

Terminal (PDT cannot be used with the Expanded functions) in conjunction with the CPU, troubteshooting of the program is easily accomplished. Most inputs or outputs can be looked at and changed or overridden as required.

The GENIUS l/O diagnostics provide a great deal of information about faults that may occur in the Genius I/O system.

For use of the GENIUS I/O diagnostics, refer to Chapter

4 of this manual.

For complete information on G E N U S l/O hardware, refer to the

GENIUS l/O System User’s Manual, GEK-90486.

The total system must be considered when problems occur. The CPU, Workmaster computer, PDT, or other programming device, Redundant Processor Unit, I/O modules,

GENIUS l/O blocks and external devices connected to or controlled by the PLC must all be operating and connected properly. All screw-down or soldered connections should be checked carefully as well as all cable connections.

Troubleshooting procedures for the RPU and other peripheral devices can be. found in the user’s manual for the particular device.


5-2 Troubleshooting and Repair

GEK-96602

TROUBLESt300TING

The troubleshooting and repair information contained in this chapter is designed to help you isolate and correct any problems that may arise in your Series Six Plus programmable logic control system.

It is recommended that all maintenance and programming personnel become familiar with this manual and all applicable related manuals so that if a problem does arise it can be isolated quickly and the defective part replaced, thus minimizing downtime of the system.

However, we realize that troubleshooting isn’t always that simple. Sometimes you need someone to talk to who can answer your questions.

When you do, don’t hesitate to call your local authorized GE Fanuc - NA Programmable Control Distributor. If you are unsure of the location of your nearest authorized Distributor, then call your local GE

Fanuc - NA Sales Office.

Replacement Module Concept

The troubleshooting and maintenance techniques described in this manual promote the concept of complete board replacement.

The prime objective of this concept is to minimize system downtime.

lsolate the Problem

When a problem arises, first isolate it to the major assembly (programmer, Central

Processing Unit, I/O rack, etc.), then to the defective module within that assembly. The defective module is then replaced from a duplicate set of modules maintained on site.

Your production line or system is back up fast.

The defective module can be returned through normal channels under warranty or for service without keeping your production line or system down for an extended period of time. The replacement concept minimizes downtime to minutes as opposed to days. The potential savings far outweigh the comparatively small cost of duplicate modules.

If you did not purchase a duplicate set of modules with your initial system, we recommend that you contact your local GE Fanuc - NA Programmable Control

Distributor or GE Fanuc - NA Sales office and do so. Then, with the help of this manual and adequate spare parts, you will be able to troubleshoot and repair just about any problem that may arise.



GEK-96602

5-3

SECTION 1

CENTRAL PROCESSING UNIT TROUBLESHOOTING

FAULT ISOLATION AND REPAIR

The malfunction causing the improper operation of

a

CPU can be isolated by checking the condition of status indicator lights and key switch positions. The status indicator lights and key switches indicate the current operating condition of the CPU and l/O system.

Check Condition of Status Indicator Lights

The normal condition of the status indicator lights is the ON state. If any of the status indicator lights are not on, check the troubleshooting sequence in this section for the proper course of action. Tables are provided throughout this section which provide definitions of the ON/OFF status of each of the indicator lights.

Table

5.1 is an indicator chart that gives a quick reference to the normal condition and definition of the status indicator lights

for the

Series Six Plus programmable logic controller’s CPU.

Check Position of Key Switches

Be sure

to

note the positions of the key switches

on the

CPU, Workmaster computer, or

CIMSTAR I industrial computer,

and

any pertinent switches on other programming devices, which can be the IBM PC, PC-XT, PC-AT Personal Computers, or the Program

Development Terminal.

Refer to Figure 5.1 which is an illustration of

a

Series Six Plus programmable logic controller’s CPU showing the location of the status indicator lights and the key switches.

The numbers that point to indicators and switches on the illustration are for reference purposes and refer to the same number in the troubleshooting sequences on the following

pages.


5 - 4


GEK-96602

MODULE

POWER

SUPPLY

I/O

CONTROL

RUN

ARITHMETIC

CONTROL

CHECK

LOGIC

MEMORY

INDICATOR

POWER

T a b l e 5 . 1 C P U I N D I C A T O R C H A R T

NORMAL

CONDITION

ON

DEFINITION

Power is applied, all dc voltages are within tolerance.

CHAIN OK ON

PARITY

ENABLED

DPU

ON

ON

ON

All I/O stations in primary chain have continuity, good output parity and power supply is good.

Input data parity is good.

CPU is in the normal Run Enabled mode

(outputs enabled).

DPU

connected and operating normally.

(If no DPU in system and

DPU

present jumper is configured, light will be on).

BATTERY

PARITY

AUXILIARY PARITY

I/O

ENABLED

ON

ON

ON

ON

ON

ON

CHAIN OK ON

User program is running with a sweep time of less than 300 ms 250 ms.

CPU

passed self-test routine which is executed once per sweep, and user program executes in less than 300 ms.

Status of CMOS RAM back-up battery.

Parity error in Logic, Register or

Internal memory.

All I/O stations in auxiliary chain have I/O continuity, good output parity and power supply is good.

Input data parity is good.

CPU is in the normal Run Enabled mode

(outputs enabled).



5-6

~~~


GEK-96602

(1) CPU RUN/STOP KEY SWITCH

Position

STOP

RUN

Definition

CPU is unconditionally in the STOP mode.

CPU is in the RUN mode unless this condition has been altered by commands from the programmer or other device or by the state of various control signals. When this switch is turned from STOP to RUN, the system will start with the outputs enabled. IF THE CPU WILL NOT

RUN, CHECK OTHER STATUS LIGHTS.

(2) MEMORY PROTECT KEY SWITCH

PROTECT

WRITE

Definition

The contents of Logic Memory and Override Tables are protected from beinq chanqed.

The user program stored In the Logic memory may be changed and an overrIde condition may be added to or removed from inputs or outputs through the Override

Table.

If key switches in steps 1 and 2 do not operate and all status indicator lights are OK, check the P2 connections on the CPAX board in the power supply module (See figure 5.2).

(3) POWER LIGHT - CPU POWER SUPPLY

Status

ON

OFF

Definition

The voltage levels of all 3 dc outputs V, +12V,

-12 V) are present and within the specified tolerance.

One or more of the voltage levels is out of tolerance.

The CPU RUN and ENABLE status indicator lights should also be off.

Alarm Number 1 switches.












































Appendix A - Glossary of Terms A - 1

GEK-96602

APPENDIX A

GLOSSARY OF TERMS

Address - A series of decimal numbers assigned to specific program memory locations and used to access those locations.

In the Series Six Plus, the addresses can range from

0000 to a maximum of 65534.

Analog - A numerical expression of physical variables such as rotation and distance to represent a quantity.

A N D - An operation that places two contacts or groups of contacts in series. All contacts in series control the resultant status.

ASCII - An 8-level code (7 bits plus 1 parity bit) commonly used for exchange of data which is the American Standard Code for Information Interchange.

Backplane

- A group of connectors physically mounted at the back of a rack so that printed circuit boards can be mated to them. The connectors are interconnected by wire wrapping.

Baud - A unit of data transmission speed equal to the number of code elements (bits) per second

.

BCD (Binary Coded Decimal) - A 4-bit system in which individual decimal digits (0 through 9) are represented by 4-bit binary numerals; for example, the number 43 is represented by 0100(4) 001 1(3) in the BCD notation.

Binary - A numbering system that uses only the digits 0 and 1. This system is also called base 2.

Bit - The smallest unit of memory.

Can be used to store only one piece of information that has two states (for example, a One/Zero, On/Off, Good/Bad, Yes/No, etc.). Data that requires more than two states (for example, numerical values 000-999) will require multiple bits.

B

US

- An electrical path for transmitting and receiving data.

Byte - A group of binary digits operated on as a single unit. In the Series Six Plus PLC, a byte is made up of 8 bits.

CHECK Light - An LED indicator on the Arithmetic Control module which, when on, indicates that the execution sequence is normal and the self-test routine has passed at least once every 200 milliseconds, +/-50 milliseconds.

CMOS - An acronym for Complementary Metal Oxide Semiconductor. A read/write memory that has a low power consumption but requires a battery in order to retain its content upon loss of power.

CPU (Central Processing Unit) - The central device or controller that interprets user instructions, makes decisions and executes the functions based on a stored program. This program specifies actions to be taken to all possible inputs.


A-2

Appendix A - Glossary of Terms

GEK-96602

CPU Station - An I/O system consisting of a maximum of 10 l/O racks daisy chained on the parallel I/O bus through the I/O Control module (or Auxiliary I/O module in an

Auxiliary l/O chain) to an l/O Receiver or Advanced l/O Receiver located in the rack nearest to the CPU rack. The last rack can be no more than 50 feet from the CPU.

Counter - A function within the PLC that records- events based upon the On/Off transition of a signal.

A coil associated with the counter is energized at a user determined preset value.

DIP Switch - An acronym for Dual-ln-Line Package, which is a group of miniature toggle or slide switches arranged side-by-side in a single package. Commonly used as the physical device for setting the configuration of various parameters necessary to the operation of electronic equipment.

Data Link

- The equipment including interface modules and cables that allow transmission of information.

Discrete - Consisting of individual, distinct things such as bits, characters or

circuit

components. Also refers to On/Off type of t/O modules.

Field Devices - User supplied devices typically providing information to the PLC (Inputs: pushbutton, limit switches, relay contacts, etc.) or performing PLC tasks (Outputs: motor starters, solenoids, indicator Iights, etc.).

Firmware - A series of instructions contained in ROM (Read Only Memory) which are used for internal processing functions only. These instructions are transparent to the user.

Hardware - All of the mechanical, electrical and electronic devices that comprise the

Series Six Plus programmable controller and its application(s).

Hardwired - Interconnection of electrical and electronic devices directly through physical wiring.

Hexadecimal - A numbering system, having 16 as a base, represented by the digits 0 through 9, then A through F.

Input - A signal, typically ON or OFF, that provides information to the PLC. Inputs are

usually generated by devices such as limit switches and pushbuttons

.

Input Module - An I/O module that converts signals from user devices to logic levels used

by the CPU.

Interface - To connect a programmable logic controller with its application devices, communications channels, and peripherals through various modules and cables.

I/O (Input/Output)

-

That portion of the PLC to which field devices are connected.

Isolates the CPU from electrical noise.

I/O Electrical isolation - A method of separating field wiring from logic level circuitry.

Typically accomplished through the use of optical isolation devices.

I/O Module - A printed circuit assembly that interfaces between user devices and the

Series Six Plus programmable logic controller.



GEK-96602

A - 3

I/O Scan - A method by which the CPU monitors all inputs and controls all outputs within a prescribed time.

K- An abbreviation for kilo or exactly 1024 in the world of computers. Usually related to

1024 words of memory.

,

LED - An acronym for Light-Emitting-Diode, which is a solid state device commonly used as a visual indicator in electronic equipment.

Ladder Diagram - A representation of control logic relay systems. The user programmed logic is expressed in relay equivalent symbology.

Latch - A PLC function that causes a coil to stay on and remain on even if power or the input is removed.

Referred to as a retentive function.

Local I/O Station - An I/O system configuration consisting of a maximum of 10 I/O racks interfaced to a Series Six Plus programmable logic controller through an l/O Receiver or

Advanced I/O Receiver module to an I/O Transmitter module in a CPU station or another

Local I/O station. The last Local l/O station in a chain can be located up to a maximum of 2000 feet from the originating l/O Control or Auxiliary I/O module in a CPU station.

Logic - A fixed set of responses (outputs) to various external conditions (inputs). All possible situations for both synchronous and non-synchronous activity must be specified by the user. Also referred to as the program.

Logic Memory - In the Series Six Plus PLC, dedicated CMOS RAM memory accessible by the user for storage of user ladder diagram programs.

Memory - A grouping of physical circuit elements that have data entry, storage and retrieval capability.

Memory Protect - A hardware capability that prevents user memory from being altered by an external device. This capability is controlled by a key switch on the CPU power supply

?

Microprocessor - An electronic computer processor section consisting of integrated circuit chips that contain arithmetic, logic, register, control and memory functions.

Microsecond (us) - One millionth of a second. 1 x 10-6 or 0.000001 second.

Millisecond (ms) - One thousandth of a second. 1 x 10-3 or 0.001 second.

Mnemonic - An abbreviation given to an instruction, usually an acronym formed by combining initial letters or parts of words.

Modules - A replaceable electronic subassembly usually plugged in and secured in place but easily removable in case of fault or system redesign. In the Series Six Plus PLC , a combination of a printed circuit board and its associated faceplate which when combined form a complete assembly.

Nanosecond (ns) - One billionth of a second. 1 x 10-9 or 0.000000001 second.

Noise - Undesirable electrical disturbances to normal signals, generally of high frequency content.


A-4


GEK-96602

Non-Retentive Coil - A coil that will go off when power is removed.

Non-Volatile Memory -

A memory capable of retaining its stored information under no-power conditions (power removed or turned off).

OFF-Line - Equipment or devices that are not connected to a communications line; for example, the Workmaster computer, when off-line, operates independent of the Series Six

Plus CPU.

ON-Line - Descriptive of equipment or devices that are connected to the communications Iine.

OR

- An operation that places two contacts or groups of contacts in parallel. Any of the contacts can control the resultant status.

Optical Isolation -

Use of

a

solid state device to isolate the user input and output devices from internal circuitry of an I/O module and the CPU.

Opto-Isolator -

A semiconductor device that isolates input

or

output circuits from the control circuitry on an I/O module. These circuits are coupled together by transmission of light energy from a sender (LED) to a receiver (photo-isolator).

Outputs -

A signal typically ON or OFF, originating from the PLC with user supplied power, that controls external devices based upon commands from the CPU.

Output -

Information transferred from the CPU, through

a

module for level conversion, for controlling an external device or process.

Output Devices -

Physical devices such as motor starters, solenoids, etc. that receive

data

from the programmable logic controller.

Output module -

An I/O module that converts logic levels within the CPU to a usable output signal for controlling a machine or process.

PLC

- Commonly used abbreviation for Programmable Logic Controller.

Parity

- The anticipated state, either odd or even, of a set of binary digits.

Parity Bit -

A bit added to a memory word to make the sum of the bits in

a

word always even (even parity) or always odd (odd parity).

Parity Check -

A check that determines whether the total number of ones in a word is odd or even.

Parity Error -

A condition that occurs when a computed parity check does not agree with the parity bit.

Peripheral Equipment -

External units that can communicate with a PLC, for example, programmers, printers,

etc.

Preset

- A numerical value specified in

a

function which establishes

a

limit for a counter or timer. A coil will energize when this value is reached.

Program -

A sequence of functions entered into a programmable logic controller to be executed by the processor for the purpose of controlling

a

machine or process.



GEK-96602

A - 5

Programmable Logic Controller or Programmable Controller - A solid-state industrial control device which receives inputs from user supplied control devices such as switches and sensors, implements them in a precise pattern determined by ladder diagram based programs stored in the user memory, and provides outputs for control of processes or user supplied devices such as relays and motor starters.

Programmer - A device for entry, examination and alteration of the PLC’s memory, including logic and storage areas.

PROM - An acronym for Programmable Read Only Memory. A retentive digital device programmed at the factory and not readily alterable by the user.

RAM - An acronym for Random Access Memory.

A solid-state memory that allows individual bits to be stored and accessed. This type of memory is volatile; that is, stored data is lost under no power conditions, therefore a battery backup is required. The Series

Six Plus PLC uses a Lithium Manganese Dioxide battery or an optional external back-up battery for this purpose.

RS-232C - A standard specified by the Electronics Industries Association (EIA) for the mechanical and electrical characteristics of the interface for connecting Data

Communications Equipment (DCE) and Data Terminal Equipment (DTE).

RUN Light - An LED indicator on the Arithmetic Control module which, when on, indicates that the execution sequence of the PLC is proceeding normally and the I/O scan is completed at least once every 200 milliseconds, +/-50 milliseconds.

Read - To have data entered from a storage device.

Reference - A number used in a program that tells the CPU where data is coming from or where to transfer the data.

Register Memory - In the Series Six Plus PLC, dedicated CMOS RAM memory accessible by the user for data storage and manipulation.

Relay Line - A line of logic in a ladder diagram used to simulate the effect of mechanical relays. The coil in a relay line is energized when continuity is complete from the left to right vertical rail of a ladder diagram.

Remote I/O Station - An I/O system configuration allowing access to a maximum of 248 inputs and 248 outputs at a location distant from a CPU station or Local I/O station.

Connection is made through a serial communications interface consisting of a Remote I/O

Driver, a two-twisted pair shielded cable, and a Remote l/O Receiver. The serial link can be located up to 10,000 feet from the originating Remote I/O Driver. When used with an RS-232C modem communications link, the distance is virtually unlimited.

Retentive Coil - A coil that will remain in its last state, even though power has been removed.

Rung - A sequence or grouping of PLC functions that control one coil. One or more rungs form a ladder diagram.

Scan - The technique of examining or solving all logic steps specified by the program in a sequential order from the first step to the last.


A - 6


GEK-96602

Serial Communication - A method of data transfer within a PLC, whereby the bits are handled sequentially rather than simultaneously as in parallel transmission.

Significant Bit - A bit that contributes to the precision of a number. The number of significant bits is counted beginning with the bit contributing the most value, referred to as the Most Significant Bit (MSB), and ending with the bit contributing the least value, referred to as the Least Significant Bit (LSB).

Sol id State - Electronic circuitry using only transistors, diodes, integrated circuits, etc.

This circuitry has high reliability and low power consumption when compared to electro-mechanical devices.

Storage - Used synonymous with memory.

Terminator - A device or load connected to the output end of a transmission line to terminate or end the signals on that line.

In the Series Six Plus PLC, DIP shunts and jumper packs connect on-board resistors which terminate the I/O chain signals on an I/O

Receiver or Advanced l/O Receiver if it is the last Receiver in any I/O chain.

Thumbwheel Switch - A rotating numeric switch which can be used for inputting numeric data to a PLC in the form of BCD digits.

Unit of Load - An expression used to describe the load placed on a power supply by an I/O module or a CPU module. Also the amount of current or load capacity available from a power supply.

Unlatch - A PLC function that causes an output previously turned on by a latch function to turn off no matter how briefly the function is enabled.

User Memory - Term commonly used when referring to the memory circuits within the

PLC used for storage of user ladder diagram programs.

Volatile Memory - A memory that will lose the information stored in it if power is removed from the memory circuit devices.

Watchdog Timer - A hardware timer within the PLC used to ensure that certain hardware conditions are met. Used as a system check.

In the Series Six Plus PLC, the duration of the watchdog timer is 300 milliseconds, +/-50 milliseconds.

Word - A measurement of memory length, usually 4, 8, or 16 bits long (16 bits for the

Series Six Plus PLC).

Write - To transfer, record, or copy data from one storage device to another.


Index

GEK-96602

I-1

A

ASCII/BASIC module 1-17

Adaptor Unit 1-21

Addressing l/O 2-31, 2-33

Advanced I/O Receiver 2-46

I/O chain signal continuation or termination 2-44 illustration of 2-47 status and diagnostic indicators 2-48 troubleshooting with 5-39 to 5-49

Advanced functions 1 - 1 0

Alarm conditions \ 2-7

Applications, list of typical 1-20

Arithmetic Control module description of 2-14 illustration of

2-15

Arithmetic Control to Logic Control cable 3-11

Auxiliary I/O module 2-61 illustration of 2-62

Auxiliary I/O system, description o f 2 - 6 1

Axis Positioning modules 1-1 7

Basic functions 1-9

Battery installation 3-8

Battery status indicator 2-18

Blocks, Genius I/O 1-13

Bus Controller module, description

C o f 2 - 2 1

C C M 2 2 - 2 2

C C M 3 2 - 2 5

Cimstar I computer 2-64

CPU I/O station 2-37 illustration of 2-38

CPU alarm conditions 2-7

CPU configuration set up menu 4-13

Genius l/O 4-15

Genius I/O fault table

4-16, 4-18

Genius I/O fault table definitions

4-19 bus controller locations page 4-l 7 computer mailbox 4-17

INDEX definitions 4-14 displaying and clearing Genius I/O f a u l t s 4-18 expanded I/O scan

4-14

CPU module installation 3-7

CPU rack mounting 3-3

CPU troubleshooting 5-3

RUN/STOP key switch 5-6

Arithmetic Control module 5-12, 5-13

Combined memory module, battery l i g h t 5 - 1 5

Combined memory module, parity l i g h t 5 - 1 4 alarm relay

5-18 battery replacement 5-15, 5-16,

5-17 fault isolation and repair 5-3 indicators and switches, location of

5 - 5 indicator chart 5-4

I/O Control/Auxiliary I/O modules

5-9, 5-10 memory protect key switch

5-6 power supply

5-6 to 5-9 start-up instructions

3-31

Channel reference numbering 2-33, 4-4

Channels of I/O 4-3 selection of 4-4

Checksum, dynamic user memory

4-11

Combined Memory module 2-16 catalog numbers 2-16 description of 2-16 illustration of 2-20 location in rack 2-19 memory protection 2-19 precautions when handling 2-19 status indicators 2-18

Communicating to Genius I/O system through the DPREQ function 4-44

Communications Control modules 2-22 description of 2-22 type 2 (CCM2) 2-22 type 2 (CCM2), illustration of, 2-24 type 3 (CCM3) 2-25 type 3 (CCM3), CCM2 mode 2-25 type 3 (CCM3), RTU mode 2-25

I/O C C M 2 - 2 6

I/O Link Local 2-27

Communications networks 1-18


l-2 Index

GEK-96602

INDEX

Compatibility guide, Series Six Plus vs Series Six 1-22

Computer mail box 4-40

Configuration of expanded functions,

4-12

Configuration of the Series Six Plus

C P U 2 - 2

Configuration set up menu 4-13

D

DIP switch settings for I/O points

2-32

DO l/O function, addressing 16K I/O points, 4-26

DPREQ function, communicating with

Genius I/O system, 4-44

DPREQ register references 4-45, 4-46

Datagram Communications Service 1-20

Definition of terms

Discrete references, internal 2-34

Dynamic user memory checksum 4-11

E

Enabling of expanded functions 4-14

Expanded CPU operation 4-1

Expanded functions 1-10, 4-1

Expanded functions menu 4-10

Expanded mode I/O addressing

2-33,

4-3

Expanded mode I/O references

2-34,

2-35

Expanded mode I/O references, table of 4-8

Expanded time reference 4-27

Extraction/insertion tool 3-4

F

Fault isolation and repair 5-3

Features of Series Six Plus 1 - 4

Figures, list of xvi to xviii

Floating point functions 4-21 addition 4-22 convert floating point to integer

4-24 convert integer to floating point

4-24 display format 4-21 division 4-23 greater than 4-24 multiplication 4-23 programming of 4-22 subtraction 4-22

Functions, advanced 1-10

Functions, basic 1-9

Functions, expanded 1-10

G

Genius l/O Bus controller

2-21

Genius I/O blocks 1-13

Genius I/O diagnostics 4-28 bus controller diagnostic storage

4-29 bus controller input and output addresses 4-29 bus controller input status definitions 4-29 to 4-33 bus controller output data 4 - 3 6 bus controller output data definitions 4-36 to 4-37 bus status/control byte 4-39 fault table 4-28 fault table pointer 4-28 fault table registers 4-34 point status bit map 4-38 register memory size 4-28

Genius I/O system general description 1-6 typical communications I ink 1 - 6

GEnet Factory LAN 1-18, 1-19

Global data service 1-21

Glossary of terms,

Grounding procedures, system 3-15 ground conductors 3-16 safety ground 3-16 signal ground 3-17 programming device grounding 3-16

H

How to enable expanded functions 4-12

I

I/O C C M 2 - 2 6

I/O Control Module description of 2-10 illustration of

2-11 jumpers, configurable 2-11


Index

GEK-96602 l/O Link Local module 2-27 illustration of

2-28

I/O Receiver module 2-43

I/O chain signal continuation or termination 2-44 illustration of 2-43

I/O Transmitter module 2-49 illustration of 2-50 status indicators

2-51 l/O addressing 2-31 expanded mode

2-33 normal mode 2-33 l/O blocks, Genius I / O 1-13

I/O cable catalog numbers 2-64

I/O channels 4-3 l/O circuitry, function of

1-12

I/O interface modules

Advanced l/O Receiver 2-46

I/O Receiver 2-43

I/O Transmitter 2-49

Remote l/O Driver 2-55

Remote I/O Receiver 2-58 list of 2-42

I/O module load 3-28

I/O modules 1-12

I/O modules, table of 1-12

I/O point DIP switch settings 2-32

I/O point address switches, illustration of 2-31

I/O point selection 3-27 l/O power supply 3-20 ac power source connections 3-20 dc power source connections 3-21 specifications 2-30

I/O rack, description of 2-29 interconnections 2-36 specifications

2-30 typical, 2-29 3-19

I/O references, expanded mode, table o f 2 - 3 5

I/O station 2-36

C P U 2 - 3 7

L o c a l 2 - 3 9

Remote 2-40 definition of 2-36

I/O structure 2-29

I/O system cables, parallel 3-24, 3-25

I/O system cables, serial link 3-26

I/O system configuration 2-36, 3-19

INDEX

I/O system interface module installation 3-21

I/O Receiver 3-22 l/O Transmitter 2-49, 3-22, 4-2

Remote I/O Driver 3-23

Remote I/O Receiver 3-24 l/O system troubleshooting 5-20

I/O rack power supply 5-20, 5-21 l/O indicator chart 5-22 to 5-27

I/O rack connections 5-27 to 5-30 intermittent fault conditions 5-37 suggested sequence of

5-31

CHAIN OK light 5-31

CHAIN PARITY light 5-32

FAULT ENABLE light 5-34

ISOLATED POWER light 5-33

LINK OK light 5-35

LOCAL OK light 5-34

LOCAL PARITY light 5-32

POWER light 5-33

REMOTE OK light 5-36

REMOTE PARITY light 5-37 check at CPU 5-31 input not recognized 5-38 no outputs function 5-38 only 1 output fails

5-38 with the Advanced I/O Receiver

5-39 to 5-49

Input/Output circuitry, function of

1-12

Inserting a printed circuit board 3-5 lnstal lation instructions for

Series Six Plus 3-1

Installing a battery 3-8

Internal discrete reference memory al locat ion 2-34

Internal discrete reference mapping

4-5

Internal memory, function of 2-17

Interrupt Input module location in system 4-2

Introduction to Series Six Plus 1 - 1

L

LAN interface module 1-20

List of figures xviii to xvix

List of tables xx to xxi

Local area network, GEnet 1-19 l - 3


l-4

Index

GEK-96602

Local l/O station 2-39

Local I/O station, illustration of 2-39

Logic Control module description of 2-12 illustration of 2-13

Logic Control to Arithmetic Control cable 3-11

Logic memory, function of

2-16

Logicmaster 6 serial version 2-65

Logicmaster 6 software 1-7, 4-12

Loop Management Module 1-16

M

Maintenance of the Series Six Plus

PC 5-1

Manuals, related

Memory mapping 4-6, 4-7

Memory protection key switch 2-19

Memory types of 1-11, 2-18

Memory, CMOS RAM 1-11

Module installation, CPU 3-6

Module replacement concept 5-2

Modules, Communications 1-13

Modules, I/O 1-12

Modules, Intelligent 1 - 1 3

Modules, System lnterface 1-1 3

N

Network interface 1-20

Normal mode I/O addressing 2-33, 4-3

Normal mode of operation 4 - 1

0

Operator Interface Unit 1-15

Operator lnterface Terminal 1-15

Optional devices 1 - 1 4

Operator Interface Unit 1-15

Operator Interface Terminal 1-15

ProLoop Process Controllers 1 - 1 6

Redundant Processor Unit 1 -14

Override Detect ion, Active 2-17

P

PC compatibility guide 1-22

PC terminology 1-21

Parallel bus I/O cables 2-64, 3-24

Physical equipment configuration 2-1

INDEX

Planning, system 1-20

Power supply 2-4 auxiliary circuit board 2-8 block diagram 2-8 dc voltage outputs 2-8 specifications 2-7 terminal block connections 2-6 user items 2-5

Product structure 2-1

Preface iii

ProLoop Process Controllers 1 - 1 6

Programmable Controllers

Series Six Plus 1-2 advantages of 1-2 block diagram 1-1 concepts 1-11 definition of 1-1 terminology 1-21

Programming functional groups 1-9,

1 - 1 0

Programming language 1-9

Programming requirements 1-7

Programming the Series Six Plus, general information 1-7 with a Cimstar I computer

2-64 with an IBM PC

2-65 with a Workmaster computer

2-62

R

RPU addressing 2-65

RS-232 to RS-422 Adaptor 1-21

Rack configuration 2-2

Rack mounting brackets 2-3

Real I/O mapping 4-5

Real I/O memory allocation 2-34

Real-time clock 4-27

Redundant Processor Unit 1-14

Register memory size 4-5

Related publications iv

Remote I/O Driver 2-55 addressing

2-56 illustration of

2-55 opt ion jumpers 2-57 status byte 2-56

Remote l/O Receiver 2-58 illustration of 2-58 option jumpers 2-60

Remote l/O station 2-40 illustration of 2-41


Index

GEK-96602

Remote I/O system 2-52 configuration jumpers 2-54 remote l/O addressing 2-53 system response time 2-53 typical connections 2-52

Removing a printed circuit board

3-6

Required references, summary of

4-9

I/O references 4-9

Register references 4-19

S

Scan rate 1-5

Scratch pad 2-17

Series Six Plus features of 1-4

I/O diagnost ics 4-2

I/O structure 2-29 instal lat ion 3-1

Arithmetic Control module 3-11

Auxiliary I/O module 3-13

CPU module installation 3-7

CPU power supply connections

3-14

CPU rack installation 3-2

Combined memory module 3-8

Communications Control modules,

3-13

I/O Control module 3-12

Logic Control module 3-11 extract ion/insertion tool 3 - 4 instruct ions 3-1 mounting, illustration of 3-3

Software packages 1-8

Specifications, General 1-5

Start-up CPU 3-31

I N D E X

System grounding procedures 3-15 ground conductors 3-76 safety ground 3-16 signal ground 3-17 programming device grounding 3-16

System planning 1-20

T

Table of contents vii to xvii

Tables, list of xviii to xix

Terminology, PC 1-21

Troubleshooting and repair 5 - 1

Troubleshooting, general information

5-2

Troubleshooting sequences 5-31

Troubleshooting with the Advanced l/O Receiver 5-39 to 5-49

U - W

Units of load, 3-28, 3-29

Window function 4-24

Window function, entering a 4-25

Workmaster computer general description of 1 - 7 , 1 - 8 connection to Series Six Plus

2-62 illustration of 2-64 to Series Six Plus adapter boards

2 - 6 2 to Series Six Plus connections

2-63 system grounding procedures

3-15 to Workmaster connections 2-63 l - 5

GE FANUC AUTOMATION NORTH AMERICA, INC., CHARLOTTESVILLE, VIRGINIA




GfK-96602A


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GE Fanuc Series Six Plus Manual

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Programmable Control Products

Archive

Document

This electronic manual was created by scanning a printed document, then processing the file using character-recognition software.

Please be aware that this process may have introduced minor errors. For critical applications, use of a printed manual is recommended.

Series Six Plus

Programmable Logic Controller

User’s Manual

Warnings, Cautions, and Notes as Used in this Publication

Preface

. . .

iii

PREFACE

Chapter 1. Introduction to

Series Six Plus PLC.

Chapter 2. Physicaf Equipment Configuration.

Chapter 3. Installation Instructions.

Chapter 4.

CPU

of

Chapter 5. Troubleshooting and Repair.

Appendix A. Glossary of Terms.

Series Six Installation and Maintenance Manual,

Application Guide for the Series Six Programmable Controller,

Series Six Data Communications Manual,

Series Six Data Sheet Manual,

Series Six Axis Positioning Module Type 1 Manual,

Series Six ASCII/BASIC Module Manual,

WORKMASTER G u i d e t o O p e r a t i o n ,

Logicmaster 6 User’s Manual,

G enius l/O System User’s Manual,

Series Six Axis Positioning Module Type II User’s Manual,

ProLoop Process Controllers,

Series Six Operator interface Terminal User’s Manual,

V u M a s t e r Co/or G r a p h i c s T e r m i n a l ,

Series Six PC l/O link Local Module User’s Manual,

Ground

Load

Series Six

Contents

FIGURES

Figure 5.4

5.9

Table 1

TABLES

Contents

TABLES

Table 2.20

Cable

xix

and

r ---v-- -I

L

-l

c-w

Introduction To The Series Six Plus PLC 1 - 3

Industrial

and

Introduction To The Series Six Pius PLC

II

1-12 Introduction To The Series Six

PLC

Function of the Input/Output Circuitry

Inputs

ac

ac,

Series

Table 1.5

GENIUS I/O BLOCKS

V dc Source

12-bit

ac

ac, 2A

115 V ac/125 V

1.6 OTHER MODULES

Remote

One

Those PLCs.