IC600CB536
Series S i x
Programmable Controller
Communications Control Module Type 2 and Type 3
GFK-0238A
November 1988
IC600CB536
IC600CB537
General Description
The Communications Control Module Type 2
(CCM2) and Type 3 (CCM3) are modules for the
Series S i x PLC containing two communications
ports, two switches, and four indicator Light Emitting
Diodes (LEDs) for connection, control, and status of
the module.
The primary purpose of these modules is to provide a
serial interface between the Series Six Central
Processing Unit (CPU) and any intelligent device
which can initiate communications based on CCM2
and/or CCM3 supported protocols and electrical interface requirements. Examples of intelligent devices
which can be interfaced are:
CCM2, CCM3,
0 Host computer
Process control
e Color-graphics
The Series Six Plus PLC with expanded microcode
increases the number of user addressable I/O points.
This feature allows addressing of channeled I/O
points with the Series Six expanded instruction set.
The I/O points can be accessed by both the CCM and
the Remote Terminal Unit (RTU) protocol for CCM3,
and the CCM protocol only for CCM2. CCM also
supports addressing of the Auxiliary I/O Override
table.
Expanded user memory reference allows memory
addressing up to 64k of the user logic memory. The
expanded user logic memory is supported by both the
CCM and the RTU protocol.
or I/O CCM Series Six modules
or microprocessor based device
system
terminal
Table 1. FEATURES AND BENEFITS
FEATURES
Contains
two programmable communications interfaces.
BENEFITS
Permits a data link between Series Six and host
computer, programmable terminals, and other intelligent
devices.
Accepts requests for Serial Communications from CPU
user program. (If peer or master mode is selected.)
Allow CPU logic to initiate and control the
communication and data flow.
On-board diagnostics and board fault indicator lights.
Simplifies troubleshooting arid indicates correct data
transfer.
Direct interface with Operator Interface Unit (OIU).
Allows for simplified operator inputs into process under
control.
QAB (Quick Access 1024 byte general purpose Buffer)
Buffer data to minimize access time from an external
device.
Expanded
Permits addressing of channeled I/O points, up to 64K
user logic memory.
memory
Communications Control Module Type 2 and Type 3
2
GFK-023 8A
CCM2/CCM3 System Configurations
The CCM2/CCM3 supports two types of system configurations, point-to-point and multidrop.
In the point-to-point configuration only two devices
can be connected to the same communication line.
The communication line can be directly connected
using RS-232 (50 feet, 15 meters maximum) or
RS-422 (4000 feet, 1200 meters maximum). Modems
can be used for longer distances.
In the multidrop configuration more than two devices
can be connected to the same communication line.
One CCM2 or host device is configured as the master
and one or more CCM2s/CCM3s are configured as
slaves. A master is capable of initiating communications; a slave is not. There are three ways to connect
CCM2s/CCM3s in the multidrop configuration:
RS-422 direct, RS-232 using modems, and RS-232
using modems and microwave or radio transmitters.
slave does not exceed 4000 feet (1200 meters). This
distance assumes good quality cables and a moder-
ately “noisy” environment. A maximum of eight
slaves can be connected using RS-422 in a daisy chain
or multidrop configuration. The RS-422 line may be
of the 2-wire or 4-wire type.
RS-232 Using Modems: This configuration is used
for long distance communications, primarily over
telephone lines. The number of slaves possible is
determined by the modem capabilities.
RS-232 Using Modems and Microwave or Radio
Transmitters:
This configuration is used where
RS-422 Direct: This method can be used when the
cables cannot be used between modems. The FCC
normally requires the use of single frequency transmitters with short transmitter-on times. Therefore, a
warm-up delay for the radio transmitter must be
added before each transmission. The CCM2/CCM3
keys the radio transmitter to warm-up and wait a short
time before actually transmitting the data. The various time-out values for the communication protocol
maximum distance between the master and the last
are increased to include the added delay.
Table 2. RS232C/RS-422 CABLE SPECIFICATIONS
Length, Maximum - 50 feet (15 meters) for RS-232C; 4000 ft. (1.2Km) for RS-422
Overall Shield
24 AWG, Minimum
Connector to CCM Port J 1 - D-Subminiature Type, Cannon DB25P (solder pot) with DB 110963-3 Hood or
Equivalent (Standard RS-232C Connector)
Connector to CCM Port J2 - D-Subminiature Type, Cannon DE9P (solder pot) with DE110963-1
Equivalent
Hood or
Connector to Intelligent Device (Determined by intelligent device)
RS-422 Cable Selection
The following cables provide acceptable operation at data rates up to I9.2K BPS and distances up to 4000
feet.
Belden
-9184
Belden
-9302
NEC
-222PISLCBT
At shorter distances, almost any twisted pair or shielded twisted pair cable will work. It should be noted that
RS-422 requires that the transmitter and receiver ground be within a few volts of each other or damage to the
transmitter and receiver may result.
It is also noted that the twisted pairs should be matched so that both transmit signals make up one twisted pair
and both receive signals make up the other twisted pair, If this is ignored, then cross-talk can result from the
mis-matching which will affect the performance of the communication system.
3
Communications Control Module Type 2 and Type 3
GFK-0238A
Module Function Options
The options listed below for the CCM2/CCM3 are hardware selectable using switches and jumpers, or software
selectable using configuration registers.
300, 600, 1200,2400,4800,
Data Rate (bits per second)
Protocol
9600, 19.2K 38.4K
Peer-to-peer
Master, slave
RTU slave (CCM3 only)
Line Interface
RS-232C
RS-422
RS-422 with clocks (CCM2
Turn-Around Delay
only
Oms, lOms, 5OOms, 5OOms with time-outs disabled
8 data bits
Character Format
1 stop bit
Optional parity bit
Odd
None
Even CCM3
Parity
Operator Interface Unit (OIU)
RTU mode, (Port 32 only)
Enable
Disable
Connect, disconnect power to OIU from CCM
+ Terminating Resistors (RS-422)
Resistors IN receiver circuit if module is at the end of an RS-422 multidrop
or point-to-point link. Removed from receiver circuit if module is in an
intermediate drop in a multidrop link.
Table 3. SPECIFICATION AND SERIAL DATA FORMAT
Serial Data Format
1 BIT0
BIT 1
BIT2
BIT3
BIT4
Em5
I
BIT6
LSB
START
0
* Parity can be disabled on either port.
ACTIVE
DATA
BITS
1
or
0
BIT 7
BIT 8
BIT 9
MSB
*
PARITY
BIT10
STOP
1
1
Communications Control Module Type 2 and Type 3
5
GF’K-0238A
Description of User Items
Jumper JP2: Always set in l-2 position.
A
Single Pole/Double Throw/Center Off switch
(momentary contact)
B
Single Pole/Double Throw/Center Off switch
(momentary contact)
Jumper JP3: Always set in 1-2 position.
Jumper JP5: Always set in l-2 position.
Jumper JP4: 1-2 position, OIU
Both switches (A and B) perform the same
function in either the Up or DOWN position.
DISABLE.
Jumper JP4: 2-3 position, OIU ENABLE.
Jumper JP6: 1-2 position disconnects
+5V from pin 20 of Port Jl.
Switches A and B are used for CCM error
diagnostics.
2-3 position, connects +5V
to pin 20 of port Jl.
LED Indicators 1 to 4 (see below).
Jl Connector: 25pin “D” type female
connector for RS-232 and RS-422.
J2 Connector: 9-pin “D” type female
connector for RS-422 and RS-232.
10
Jumper JP8: Always set in 1-2 position.
11
Jumper JP7: Always set in l-2 position.
12
See installation of RS-422 interfaces for
terminating resistor configuration.
DIP Switches 9 to 16: Configuration selection
for port Jl (see Table 5).
Jumper T2: J2, RS-422 receiver circuit
DIP Switches 1 to 8: Configuration selection
for port J2 (see Table 6).
Jumper T4: RS-422 clock input
Jumper T6: Jl, RS-422 receiver circuit
DIP Switches 18 to 20: Miscellaneous
selection for both ports (see Table 5).
Jumper T8: Always set in storage position
Jumper JPI: Always set in 1-2 position,
Table 4. LED INDICATORS POWERUP ERROR CODES
I
CAUSE OF ERROR (” Light on,
LIGHT
1
2
3
4
BOARD OK
DIAG 1
DATA OK
DIAG 2
CCM POWER-UP
RAM TEST
FAILED
CCM USART
FAILED TO
INITIALIZE
??
Light off)
I
CCM PROM
TEST FAILED
CPU/CCM
COMMUNICATIONS
FAILED
a
0
a
b
b
0
0
0
0
0
?
0
0
0
0
0
Communications Control Module Type 2 and Type 3
6
GFK-0238A
LED Descriptions
BOARD OK (Module Status)
STATUS
DESCRIPTION
ON:
Board has passed the self-check test and is operating properly.
FLASHING:
Invalid configuration or invalid CPU number, 0 or greater than 90 for CCM slave mode, 0 or
greater than 247 for RTU mode (CCM3 only). The configuration or the CPU ID must be changed
and the module powered up again to recover.
OFF:
Board has failed power-up test indicating a hardware failure or the CCM failed to communicate
with the Series Six CPU. I f the BOARD OK LED goes off as a result of a major CCM error,
further information about the specific cause of the error can be obtained by toggling the front panel
switch. When this is done, the 4 indicator lights will create one of the patterns shown in Table 3.
- If it is a hardware failure then the CCM is
successful completion of the power-up test.
s If at some time after a successful power-up
BOARD OK and the DATA OK LED will
front panel LEDs cannot be obtained. Both
communications with the CPU.
inoperable and the LED will turn on again only after
there is a CCM/CPU communications failure, both the
turn off. In this case additional information from the
LEDs will turn on again upon successful
DIAG 1
STATUS
DESCRIPTION
ON:
Passed powerup
diagnostics. ON during normal operation.
Cycles on and off during powerup then remains on.
OFF:
May change states when toggling Switch A or B.
DATA OK (Serial Data Transmission Link)
STATUS
DESCRIPTION
ON:
Data transmission normal.
FLASHING:
The LED will flash as serial data is actually transmitted.
Data transmission is incorrect for one or more of the following reasons.
OFF:
- Parity, overrun or framing errors.
- Invalid header, data block, control character, or checksum.
In these cases the LED will turn on again after a successful session has been completed between
the Series Six and the external device, or if the module power is cycled.
A CCM./CPU
communications failure will cause this LED and the BOARD OK LED to turn OFF.
DIAG 2
STATUS
DESCRIPTION
ON:
Passed powerup diagnostics. ON during normal operation.
Cycles on and off during powerup then remains on.
OFF:
May change states when toggling Switch A or B.
7
Communications Control Module Type 2 and Type 3
GFK-0238A
Installation
is made; then secure the faceplate to the rack using
the thumbscrews at the top and bottom.
General
Before instaIling the CCM2/CCM3 in a CPU rack
verify the position of the factory set jumpers (see
Figures 1 and 2). Select the appropriate module function options by setting the on-board DIP switches (as
required) per the coding shown in Tables 5, 6, 7 and
8.
The CCM2/CCM3 module can be installed in a model
Six Plus, 60, 600, or 6000 PLC.
- In the Series Six 60,600, or 6000 PLC the second
slot to the left of the CPU power supply is
reserved for this module, and is the only position
where the CCM2/CCM3 can be installed.
- In the Series Six Plus PLC, slot 5 or 6 is reserved
for the CCM2/CCM3 module. When slot 6 is
used, set the backplane DIP switch package to all
positions OPEN.
NOTE
The normal powerup operation with all backplane DIP switch positions set to OPEN is: All
four LEDS powerup ON, next a BLINKING
sequence, then all LEDS remain ON.
An unpredictable LED powerup sequence results
when the backplane DIP switch package is set
otherwise. The ALU Module LEDS remain
OFF. And, if a Workmaster is connected, a
message “No communications with the Series
Six” is displayed.
The CCM2/CCM3 module obtains its ID Number
from the Series Six PLC. Use the L o g i c m a s t e r
software to set the correct ID Number in the Series
Six CPU scratchpad.
Since there are many combinations of devices this
module can interface with and many ways to wire up
these combinations only a few of the more common
wiring connections are shown as follows:
The pinout definitions for ports Jl and J2 are shown
in Figure 3.
Direct connect from one CCM2 module to another
CCM2 is shown in Figures 4 and 6.
Direct connect from a CCM2/CCM3 module to a
computer or process control system is shown in
Figure 5.
Wiring from a CCM2/CCM3 to a GEnet Factory
LAN BIU is shown in Figures 8 and 9.
Wiring for CCM 4-wire multidrop network is
shown in Figure 10.
Wiring for a CCM 2-wire multidrop network is
shown in Figure 1 I.
Wiring from a CCM2/CCM3 to an Operator Interface Unit (OIU) is shown in Figure 7.
Troubleshooting Checklist:
- Verify CPU Id Number
Use the extraction/insertion tool furnished with the
Series Six CPU to install or remove the circuit board.
With the circuit board in place in the rack, guide the
faceplate over the circuit board so that proper contact
- Verify CCM configuration setup
- Verify wiring
- Verify SCREQ commands (if used)
Communications Control Module Type 2 and Type 3
12
GFK-0238A
Faceplate Connections
The pinouts for the 25 pin (Jl) and 9 pin (52) ports (both female connectors) are shown below.
a41523
25
PIN 1
0
w
Figure 3. PORT CHARACTERISTICS (J1, J2)
Table 9. PORTS (Jl, J2) PIN-OUT DEFINITIONS
J2 Port
Jl Port
Pin No.
Description
1
*
2
3
4
RS-232
RS-232
RS-232
send
RS-232
*
signal
*
5
6
7
8
Description
15
16
17
RS-422
*
*
RS-422 data out (-)
1
2
3
4
RS-422
RS-232
RS-232
RS-232
clear to send
18
RS-422 data out (t,
5
19
20
21
22
23
24
25
OIU ground
6
7
8
9
RS-232 clear to send
RS-422 data out (-)
signal ground
RS-422 data in (+)
RS-422 data in (-)
14
ground
9
*
*
keyout I/O
13
*
Pin No.
Description
data out
data in
request to
10
II
12
Pin No.
+12 volts
O I U +5 volts (fused at 5 A)
RS-422 clock in (+)
-12 volts resistive
RS-422 clock in (-)
RS-422 clock out (+)
RS-422 clock out f-)
data out (+)
data out
data in
request to send
RS-422 data in (+)
Do not connect
Grounding
Both RS-232 and RS-422 require that the transmitter
and receiver circuits be at the same ground potential
(within a few hundred millivolts). On the CCM2 or
CCM3, none of the circuits are isolated from the
Series Six chassis ground, which is also the “local”
power company ground. In many cases this is not a
problem. However, the user should insure that the
ground voltages are within a few hundred millivolts
of each other before connecting the devices together.
A problem will exist only if the local power ground is
exceptionally noisy, or if the Series Six PLC rack or
other device is floating with respect to this ground
(which indicates an incorrect or very unusual configuration). If the user’s configuration is such that the
grounds do not meet the above condition, then isolating modems will be required instead of a direct
twisted pair hookup.
13
Communications Control Module Type 2 and Type 3
GFK-0238A
Installation of RS-422 Interfaces
The maximum number of slaves on a multidrop line
may be between 4 and 8, depending on the local
electrical noise, the type of cable, distance between
devices on the line, and the overall length of the
cable.
The maximum distance between the farthest 2
points in a multidrop system with 8 slave units on
the line that has been tested is 10,000 feet. However, this may not represent a worst case in terms of
noisy environments.
- 4000 feet seems to be a good rule of thumb for
maximum cable length. This assumes a twisted
pair cable of AWG 24 copper with a shunt capacitance of 16 pf/foot. (Refer to the RS-422 specification).
- In general, distance may be increased by using
cables which have less resistance and capacitance
per foot, than the 24 AWG cable illustrated
above.
get more than one (1) wire on the D connectors,
this is the only way to insure that the network
will function properly.
- For a multidrop network, the layout of the cable
between devices should be as a daisy chain bus;
NOT AS A STAR. Even if the physical proximity of the communicating devices is such that a
radial star would be nice, it will not work.
- Pairing of twisted pairs within the cable: It is
critical that the two transmit signals remain physically paired, and the two receive signals remain
physically paired in the twisted pair cable.
- It is not enough that electrically there is continuity between the correct points. If a transmit
wire gets paired with a receive wire (twisted
together) there may be crosstalk which will limit
the maximum dependable distance to about 3 feet
instead of 4000.
- In the case of a 2-wire network where the transmit and receive signals are connected together;
this is not a problem.
- For example: If a cable with half the resistance
per foot and only 8 pf/foot were used, operation
at 8000 feet is probably attainable.
Cable Configuration
Terminating resistors: The CCM2/CCM3 is supplied with 150 ohm terminating resistors in each
RS-422 receiver circuit. (These resistors have no
effect on RS-232 operation.)
The CCM2/CCM3 module can interface many
devices and there are many ways to wire these combinations. A few of the more common applications are
shown in the following figures.
- These resistors should be left in the circuit if the
CCM is at either end of a multidrop or
point-to-point link.
General guidelines for cable construction is provided
below:
- If the module is used as an intermediate device in
a multidrop network, the resistor should be
removed by placing Jumper T6 for the Jl port
and T2 for the J2 port in the storage position as
shown in Table 2.
I At short distances (under 1000 feet) almost any
twisted shielded pair will work. The specified
cables will provide reliable operation at data rates
up to 19.2 Kbps and distances up to 4000 feet.
Good wiring practices must be observed.
Twisted pairs must be matched.
- Jumper T8 must be in the storage position.
Physical layout: The following rules should be
followed:
- All connections on the multidrop bus should be
made inside the CCM serial port connectors. No
intervening terminal strips, splices, or other
devices should be used. Although it is difficult to
- When routing communication cables outdoors,
transient suppression devices should be used to
reduce the possibility of damage due to lightning
or static discharge. Best results have been
obtained with General Semiconductor Industries
Transzorb SA series wired from each signal line
to earth ground at both ends of the cable.
Communications Control Module Type 2 and Type 3
19
GFK-0238A
Table 10. MODULE SPECIFICATIONS
Dimensions - Circuit Board:
8.15 x 11.0 (inches), 208 x 280 (mm)
Dimensions - Faceplate:
12.46 x 1.175 (inches), 317 x 30 (mm)
Power Requirements:
(Supplied by CPU Power Supply)
+5 Vdc +12 Vdc -12 Vdc
Units of Load (CCM2)
17
4
4
Units of Load (CCM3)
17
4
4
Storage Temperature:
~ 0 to 70
Operating
~ 0” to 60” C (outside of rack)
Humidity:
Temperature:
C
~ 5% - 95% (non-condensing)
Table 11. ORDERING INFORMATION
Circuit Board & Faceplate (CCM2)
Circuit Board & Faceplate (CCM3)
Faceplate (CCM2/CCM3)
IC600CB536
IC60OCB537
IC6OOFP536
For further information, contact your local GE Fanuc - NA sales representative.
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