MicroMod 53MC5000 PLC and Printer Interface Owner's Manual

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MicroMod 53MC5000 PLC and Printer Interface Owner's Manual | Manualzz

INSTRUCTION MANUAL

MICRO-DCI

53MC5000 PLC AND PRINTER INTERFACES

PN24627A

Rev. 1

MicroMod Automation, Inc.

The Company

MicroMod Automation is dedicated to improving customer efficiency by providing the most ost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation.

We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support.

The quality, accuracy and performance of the Company's products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology.

Use of Instructions

Ì Warning. An instruction that draws attention to the risk of injury or death.

Note. Clarification of an instruction or additional information.

Caution. An instruction that draws attention to the risk of the product, process or surroundings. i

Information. Further reference for more detailed information or technical details.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of MicroMod

Automation, Inc.

Licensing, Trademarks and Copyrights

MOD 30 and MOD 30ML are trademarks of MicroMod Automation, Inc.

MODBUS is a trademark of Modicon Inc.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

The relevant sections of these instructions must be read carefully before proceeding.

1. Warning Labels on containers and packages must be observed.

2. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given or injury or death could result.

3. Normal safety procedures must be taken to avoid the possibility of an accident occurring when operating in conditions of high

4. pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used.

6. When disposing of chemicals, ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual may be obtained from the Company address on the back cover, together with servicing and spares information.

All software, including des ign, appearance, algorithms and source co des, is copyrighted by MicroMod Automation, inc. and is owned by MicroMod Automation or its suppliers.

Contents

Table of Contents

PREFACE Preface-i

1.0 INTRODUCTION 1-1

1.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 DDI-A/B HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 FIELD UPGRADE INFORMATION FOR EXISTING PCS UNITS . . . . . . . . . . . . 1-1

1.4 RS-232/485 ITB SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 MODEL NUMBER BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2.0 INSTALLATION 2-1

2.1 53MC5000 PROCESS CONTROL STATION INSTALLATION . . . . . . . . . . . . . 2-1

2.2 MOUNTING THE RS-232/485 ITB . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 RS-232/485 ITB CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 ITB SIGNAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.5 RS-232/485 ITB POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . 2-3

3.0 PRODUCT DESCRIPTION 3-1

3.1 DDI-A AND DDI-B MEMORY MAPS . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 TYPICAL PCS-PLC INFORMATION TRANSFERS . . . . . . . . . . . . . . . . . 3-1

3.2.1 CALCULATING STARTING ADDRESSES FOR WRITES . . . . . . . . . . 3-2

3.3 PCS - PLC MEMORY MAP AGREEMENT . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 PLC MEMORY ADDRESSING SCHEME . . . . . . . . . . . . . . . . . . . . . 3-2

3.5 PCS FLOATING POINT-TO-INTEGER CONVERSION . . . . . . . . . . . . . . . . 3-3

3.6 DDI-A AND DDI-B CHANNEL SETUP . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.6.1 APB SETUP BYTES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.6.2 PLC CONTROL AND STATUS BYTES . . . . . . . . . . . . . . . . . . 3-7

3.6.3 PLC READ CONTROL BYTES . . . . . . . . . . . . . . . . . . . . . 3-7

3.6.4 PLC WRITE CONTROL BYTES . . . . . . . . . . . . . . . . . . . . . 3-7

3.6.5 OPTOMUX DIGITAL AND ANALOG I/O CONTROL BYTES . . . . . . . . . 3-7

3.7 SCAN TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4.0 ALLEN-BRADLEY MODE 4-1

4.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 DATA TABLE ADDRESSING . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 INSTALLATION CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.4 RS-232/485 ITB-PLC CABLES . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.5 ALLEN-BRADLEY COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.6 CONTROL BYTES FOR ALLEN-BRADLEY . . . . . . . . . . . . . . . . . . . . 4-4

4.7 SET-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.7.1 ALLEN-BRADLEY KF3 SETUP SELECTIONS . . . . . . . . . . . . . . . 4-8

4.7.2 ALLEN-BRADLEY KF2 COMMUNICATION OPTION SWITCHES . . . . . . . 4-9

4.8 FAULT ISOLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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53MC9015 53MC5000 PLC and Printer Interfaces

5.0 OPTO 22 MODE 5-1

5.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 PCS DATABASE MAP FOR OPTO 22 MODE . . . . . . . . . . . . . . . . . . . 5-1

5.2.1 PCS DATABASE MAP DIGITAL LOCATIONS . . . . . . . . . . . . . . 5-4

5.2.2 PCS DATABASE MAP ANALOG LOCATIONS . . . . . . . . . . . . . . 5-6

5.3 CONTROL BYTES FOR OPTO 22 . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.4 OPTOMUX COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.5 ANALOG I/O NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.5.1 READ ANALOG COMMAND . . . . . . . . . . . . . . . . . . . . . . 5-12

5.5.2 READ ANALOG INPUTS COMMAND . . . . . . . . . . . . . . . . . . 5-12

5.6 SUPPORTED OPTOMUX CONFIGURATIONS . . . . . . . . . . . . . . . . . . 5-13

5.7 RS-232/485 ITB-PLC CONNECTION . . . . . . . . . . . . . . . . . . . . . . 5-13

5.8 SCALING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.9 SET-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.10 FAULT ISOLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

6.0 MODBUS RTU MODE 6-1

6.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 INSTALLATION CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 RS-232/485 ITB-PLC CABLES . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4 PCS MODBUS MASTER OPERATION . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 PCS MODBUS MASTER MEMORY MAP . . . . . . . . . . . . . . . . 6-3

6.4.2 WRITING A SINGLE L-VALUE . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.3 READING A SINGLE L-BYTE . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.4 WRITING A SINGLE L-BYTE . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.5 READING MULTIPLE L-VALUES . . . . . . . . . . . . . . . . . . . . 6-3

6.4.6 WRITING MULTIPLE L-VALUES . . . . . . . . . . . . . . . . . . . . 6-3

6.4.7 READING C-VALUES . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.8 WRITING C-VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.9 WRITING A SINGLE C-VALUE . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.10 READING L- AND C-VALUES TOGETHER . . . . . . . . . . . . . . . 6-4

6.4.11 WRITING L- AND C-VALUES TOGETHER . . . . . . . . . . . . . . . 6-5

6.4.12 PCS MODBUS MASTER COMMANDS . . . . . . . . . . . . . . . . . 6-6

6.4.13 PCS MODBUS MASTER DIAGNOSTIC COMMAND . . . . . . . . . . . 6-7

6.4.14 PCS MODBUS MASTER CONTROL BYTES . . . . . . . . . . . . . . 6-8

6.4.15 PCS MODBUS MASTER SET-UP PROCEDURE . . . . . . . . . . . . . 6-12

6.4.16 PCS MODBUS MASTER FAULT ISOLATION AIDS . . . . . . . . . . . 6-13

6.5 PCS MODBUS SLAVE OPERATION . . . . . . . . . . . . . . . . . . . . . . 6-14

6.5.1 PCS MODBUS SLAVE MEMORY MAP . . . . . . . . . . . . . . . . . 6-14

6.5.2 PCS MODBUS SLAVE COMMANDS . . . . . . . . . . . . . . . . . . 6-15

6.5.3 PCS MODBUS SLAVE CONTROL BYTES . . . . . . . . . . . . . . . . 6-16

6.5.4 PCS MODBUS SLAVE SET-UP PROCEDURE . . . . . . . . . . . . . . 6-18

6.5.5 PCS MODBUS SLAVE FAULT ISOLATION AIDS . . . . . . . . . . . . . 6-19

7.0 SIEMENS S5 MODE 7-1

7.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 INSTALLATION CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3 RS-232/485 ITB-PLC CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.4 CONTROL BYTES FOR SIEMENS . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.5 SET-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Contents-ii

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Contents

7.6 FAULT ISOLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

8.0 KOYO MODE 8-1

8.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 INSTALLATION CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.3 RS-232/485 ITB-PLC CABLES . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.4 PCS MEMORY MAP FOR KOYO OPERATING MODE . . . . . . . . . . . . . . . . 8-2

8.5 KOYO HEADER BLOCK COMMAND BYTE . . . . . . . . . . . . . . . . . . . . 8-3

8.6 CONTROL BYTES FOR KOYO . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.7 SET-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.8 FAULT ISOLATION AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

9.0 PRINTER INTERFACE 9-1

9.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 CABLE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.3 DDI CHANNEL SETUP BYTES . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.4 STANDARD DATALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.4.1 STANDARD DATALOG DISPLAY . . . . . . . . . . . . . . . . . . . . 9-6

9.5 RUNNING DATALOGS IN THE BACKGROUND . . . . . . . . . . . . . . . . . . 9-6

9.5.1 TRIGGERING BACKGROUND DATALOGS FROM FCS . . . . . . . . . . . 9-7

9.5.2 TRIGGERING BACKGROUND DATALOGS FROM F-CIM . . . . . . . . . . 9-7

9.5.3 TRIGGERING BACKGROUND DATALOGS FROM F-TRAN . . . . . . . . . 9-7

9.6 FREE FORMAT DATALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9.6.1 FREE FORMAT DATALOG EXAMPLE 1 . . . . . . . . . . . . . . . . . 9-9

9.6.2 FREE FORMAT DATALOG EXAMPLE 2 . . . . . . . . . . . . . . . . 9-12

10.0 PARTS REPLACEMENT 10-1

10.1 PARTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.3 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

APPENDIX A: BASE 2/8/10/16 TABLE A-1

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53MC9015 53MC5000 PLC and Printer Interfaces

List of Tables

Table 1-1. RS-232/485 ITB (686B720) Specifications . . . . . . . . . . . . . . . . . 1-3

Table 4-1. Allen-Bradley Commands Used . . . . . . . . . . . . . . . . . . . . . 4-3

Table 4-2. APB Setup Bytes for Allen-Bradley . . . . . . . . . . . . . . . . . . . . 4-4

Table 4-3. PLC Control and Status Bytes for Allen-Bradley . . . . . . . . . . . . . . . 4-4

Table 4-4. Allen-Bradley PLC Read Control Bytes . . . . . . . . . . . . . . . . . . 4-5

Table 4-5. Allen-Bradley PLC Write Control Bytes . . . . . . . . . . . . . . . . . . 4-6

Table 4-6. KF3 Setup Selections . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Table 4-7. Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Table 5-1. APB Setup Bytes for OPTOMUX . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-2. OPTOMUX PLC Control and Status Bytes . . . . . . . . . . . . . . . . . 5-9

Table 5-3. OPTOMUX Digital I/O Control Bytes . . . . . . . . . . . . . . . . . . . 5-10

Table 5-4. OPTOMUX Analog I/O Control Bytes . . . . . . . . . . . . . . . . . . . 5-11

Table 5-5. Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Table 6-1. PCS Modbus Master Commands . . . . . . . . . . . . . . . . . . . . . 6-6

Table 6-2. APB Setup Bytes for PCS Modbus Master . . . . . . . . . . . . . . . . . 6-8

Table 6-3. Control and Status Bytes for PCS Modbus Master . . . . . . . . . . . . . . 6-9

Table 6-4. Read Control Bytes for PCS Modbus Master . . . . . . . . . . . . . . . . 6-9

Table 6-5. Write Control Bytes for PCS Modbus Master . . . . . . . . . . . . . . . . 6-11

Table 6-6. PCS Modbus Master Fault Isolation Aids . . . . . . . . . . . . . . . . . . 6-13

Table 6-7. PCS Modbus Slave Commands . . . . . . . . . . . . . . . . . . . . . 6-15

Table 6-8. APB Setup Bytes for PCS Modbus Slave . . . . . . . . . . . . . . . . . 6-16

Table 6-9. Control and Status Bytes for PCS Modbus Slave . . . . . . . . . . . . . . 6-16

Table 6-10. Error Code Bytes for PCS Modbus Slave . . . . . . . . . . . . . . . . . 6-17

Table 6-11. Modbus Slave Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . 6-19

Table 7-1. APB Setup Bytes for Siemens . . . . . . . . . . . . . . . . . . . . . . 7-3

Table 7-2. PLC Control and Status Bytes for Siemens . . . . . . . . . . . . . . . . . 7-3

Table 7-3. Siemens PLC Read (Fetch) Control Bytes . . . . . . . . . . . . . . . . . 7-4

Table 7-4. Siemens PLC Write (Send) Control Bytes . . . . . . . . . . . . . . . . . 7-5

Table 7-5. Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Table 8-1. APB Setup Bytes for Koyo . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Table 8-2. PLC Control and Status Bytes for Koyo . . . . . . . . . . . . . . . . . . 8-3

Table 8-3. Koyo PLC Read Control Bytes . . . . . . . . . . . . . . . . . . . . . . 8-4

Table 8-4. Koyo PLC Write Control Bytes . . . . . . . . . . . . . . . . . . . . . . 8-5

Table 8-5. Fault Isolation Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Table 9-1. DDI Setup Bytes for Datalog . . . . . . . . . . . . . . . . . . . . . . . 9-1

Table 10-1. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Table 10-2. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Table A-1. Base 2/8/10/16 Conversion Table . . . . . . . . . . . . . . . . . . . . A-2

Contents-iv

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List of Figures

Figure 1-1. DDI-A and DDI-B Channels . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 1-2. 53MC5000 Standard Rear Terminal Board ITB Configurations . . . . . . . . . 1-6

Figure 1-3. 53MC5000 Cord Set Connector Board ITB Configurations . . . . . . . . . . . 1-7

Figure 2-1. ITB Snap-Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure 2-2. Signal and Power Connections . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 3-1. PCS DDI-A Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-2. PCS DDI-B Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-3. PCS-PLC Data Transfers . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3-4. Control Bytes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 4-1. Typical Point-to-Point Installation (SLC-5/02 Shown) . . . . . . . . . . . . . 4-2

Figure 4-2. Typical Allen-Bradley Data Highway Installation . . . . . . . . . . . . . . . 4-2

Figure 4-3. Typical Allen-Bradley DH-485 Network Installation . . . . . . . . . . . . . . 4-2

Figure 4-4. RS-232/485 ITB J1 to Allen-Bradley PLC Cable . . . . . . . . . . . . . . . 4-3

Figure 4-5. Allen-Bradley KF2 Communication Option Switches . . . . . . . . . . . . 4-10

Figure 5-1. PCS DDI-A OPTO 22 Database Map . . . . . . . . . . . . . . . . . . . . 5-2

Figure 5-2. PCS DDI-B OPTO 22 Database Map . . . . . . . . . . . . . . . . . . . . 5-3

Figure 5-3. OPTO 22 Digital Boards . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Figure 5-4. OPTO 22 Analog Boards . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Figure 5-5. Typical Installation Configurations . . . . . . . . . . . . . . . . . . . . 5-13

Figure 5-6. RS-232/485 ITB TB2 to OPTOMUX Board Connections . . . . . . . . . . . 5-13

Figure 6-1. Typical Modbus Point-to-Point Installations . . . . . . . . . . . . . . . . . 6-1

Figure 6-2. Typical Modbus Master Multidrop Installation . . . . . . . . . . . . . . . . 6-1

Figure 6-3. RS-232/485 ITB J1 to Modbus PLC Cable . . . . . . . . . . . . . . . . . 6-2

Figure 6-4. RS-232/485 ITB TB2 to Modbus PLC Cable . . . . . . . . . . . . . . . . . 6-2

Figure 6-5. Reading L- and C-Values . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 6-6. Writing L- and C-Values . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Figure 7-1. Point-to-Point Installation Configuration . . . . . . . . . . . . . . . . . . 7-1

Figure 7-2. RS-232/485 ITB J1 to Siemens PLC Cable . . . . . . . . . . . . . . . . . 7-2

Figure 8-1. Installation Configurations . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Figure 8-2. RS-232/485 ITB J1 to Koyo PLC Cable . . . . . . . . . . . . . . . . . . . 8-2

Figure 8-3. RS-232/485 ITB TB2 to Koyo PLC Cable . . . . . . . . . . . . . . . . . . 8-2

Figure 9-1. DDI-A and DDI-B Printer Connections . . . . . . . . . . . . . . . . . . . 9-2

Figure 9-2. Standard Datalog Datapoint Parameters . . . . . . . . . . . . . . . . . . 9-4

Figure 9-3. Standard Datalog Example . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Figure 9-4. Standard Datalog Display (Display 33) . . . . . . . . . . . . . . . . . . . 9-6

Figure 9-5. Free Format Datalog Example 1 . . . . . . . . . . . . . . . . . . . . . 9-11

Figure 9-6. Free Format Datalog Example 2 . . . . . . . . . . . . . . . . . . . . . 9-13

Figure 10-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . 10-3

Figure 10-2. Auxiliary Processor Board (APB) . . . . . . . . . . . . . . . . . . . . 10-4

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Contents-vi

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Preface

PREFACE

This manual should be used in conjunction with Instruction Bulletin 53MC5000, MICRO-DCI Process Control Station, Revision 2 (formerly titled Instruction Bulletin 53MC5000, MICRO-DCI Modular

Controller, Revision 1). It is assumed the reader is familiar with the information presented in that document to install and operate the 53MC5000 Process Control Station.

BOOK OVERVIEW

Section 1, Introduction - This section provides preliminary information to acquaint the user with the product. Also provided is the 53MC5000 Process Control Station (PCS) Model Number Breakdown.

Section 2, Installation - This section provides mounting instructions for the RS-232/485 ITB, information to cable an RS-232/485 ITB to the 53MC5000 Process Control Station, and information to connect power to the RS-232/485 ITB.

Section 3, Product Description - This section provides general information about the product functionality. More specific functional information is provided, as applicable, in each of the following Sections 4 through 9.

Section 4, Allen-Bradley Mode - This section defines the datapoints that must be configured for

Allen-Bradley operating mode. It provides information to fabricate the RS-232/485 ITB-to-PLC cable and lists the Allen-Bradley commands used.

Section 5, OPTO 22 Mode - This section defines the datapoints that must be configured for

OPTO 22 operating mode. It provides information to fabricate the RS-232/485 ITB-to-OPTOMUX station cable and lists the OPTOMUX commands used.

Section 6, MODBUS RTU Mode - This section defines the datapoints that must be configured for

MODBUS RTU master and slave operating modes. It provides information to fabricate the

RS-232/485 ITB-to-PLC cable and lists the MODBUS RTU commands used for both modes.

Section 7, Siemens S5 Mode - This section defines the datapoints that must be configured for Siemens S5 operating mode. It provides information to fabricate the RS-232/485 ITB-to-PLC cable and lists the Siemens S5 commands used.

Section 8, Koyo Mode - This section defines the datapoints that must be configured for Koyo operating mode. It provides information to fabricate the RS-232/485 ITB-to-PLC cable and lists the

Koyo commands used.

Section 9, Printer Interface - This section provides information to print-out the standard datalog from the datalog display, or with FCS, F-CIM, or F-TRAN. It also provides two free format F-TRAN datalog programs with print-out examples.

Section 10, Parts Replacement - This section provides the procedure to remove and replace the

DDI-A and DDI-B Auxiliary Processor Boards (APBs)

Appendix A, Base 2/8/10/16 Table - Binary/Octal/Decimal/Hexadecimal conversion table.

Preface-i

PREFACE

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

Preface-ii

PREFACE

Section 1. Introduction

1.0 INTRODUCTION

1.1 OVERVIEW

The 53MC5000 Process Control Station (PCS) DDI-A

1

Printer/PLC option and the DDI-B

2

Printer/PLC option each provide the capability to transfer logical bit indicators and floating point variables to or from a Programmable Logic Controller (PLC). The DDI-A/B Printer/PLC options also provide the capability to send serial output PCS datalog information to a printer.

PLC types that the PCS can communicate with are Allen-Bradley, Modbus RTU, Siemens S5, and

Koyo. In Modbus RTU mode, the PCS can be configured to function as a Modbus master or as a slave. The PCS can also communicate with OPTO 22 digital and analog brain boards.

All data transfers (with the exception of Modbus slave operation) are initiated by the PCS and are with respect to the PCS: writing means that data is output from the PCS option to an addressed

PLC and reading means that requested data is input to the PCS from the PLC. Additional PCS

DDI-A/B information is provided in Section 3, Product Description.

1.2 DDI-A/B HARDWARE DESCRIPTION

As shown in Figure 1-1, hardware elements of the DDI-A/B options include the DDI-A and DDI-B

Auxiliary Processor Boards (APBs) and the RS-232/485 Interconnection Terminal Boards (ITBs).

The APBs are installed in Expansion Board slots 3 and 1 respectively for DDI-A and DDI-B. There is an RS-232/485 ITB mounted external to the PCS on 2.9 inch (74 mm) wide PVC track for each

DDI option. Each ITB is cable connected to the rear of the PCS. An ITB cable can be ordered with the option. Also required for each option, is a custom fabricated cable that connects from the ITB to the PLC or printer serial/parallel converter. The custom fabricated cable is supplied by the user; cable diagrams are provided in the PLC and printer interface sections of this book.

1.3 FIELD UPGRADE INFORMATION FOR EXISTING PCS UNITS

This information only pertains to existing 53MC5000 PCS controllers that will be field upgraded with one or both PLC DDI options (DDI-A/B). Continue to Section 1.4, RS-232/485 ITB

Specifications, if the PCS came with the PLC DDI-A/B options preinstalled.

The Printer/PLC DDI-A and DDI-B options require the following:

• A PCS that has an Exapansion board.

• A Main board firmware level of 4 (datapoints B382 = 4 and B383 = 29 or higher). Figure 1-1 shows the PROM chip location on the Main board.

• A firmware level of 1 for each APB (DDI-A datapoint B297 = 27 or higher and DDI-B datapoint B463 = 27 or higher).

(1)

(2)

DDI-A = Digital Device Interface - A

DDI-B = Digital Device Interface - B

1-1

INTRO

53MC9015 53MC5000 PLC and Printer Interfaces

MAIN

BOARD

POWER

SUPPLY

FIRMWARE IS REV. 4 OR HIGHER

FOR DDI PLC/PRINTER OPTION

SLOTS

5 4 3 2 1

+

EXPANSION

BOARD

DDI-A DDI-B

DDI-A AND DDI-B AUXILIARY

PROCESSOR BOARDS (APBs)

FIRMWARE IS REV 1 OR

HIGHER. (SEE SECTION 9,

TABLE 9-1, TO REMOVE AND

INSTALL AN APB.)

ALL POWER AND GROUNDING

CONNECTIONS NOT SHOWN

RS-232/485

ITB

686B720

DDI-A

TO PLC/PRINTER

RS-232

OR

RS-485

■ ■ ■ ■

RS-232/485

ITB

686B720

DDI-B

TO PLC/PRINTER

RS-232

OR

RS-485

NOTE:

EITHER THE ITB RS-232 OR RS-485 SERIAL PORT CAN BE CONNECTED TO A REMOTE DEVICE (PLC OR PRINTER).

THE RS-232 SERIAL PORT HAS AN IDEAL DATA TRANSFER RANGE OF APPROXIMATELY 50 FT. (15.2 M),

WHEREAS THE RS-485 SERIAL PORT DATA TRANSFER RANGE IS MUCH GREATER (E.G., 4000 FT. [1219 M]).

THEREFORE, AN RS-422/232 ADAPTER CAN BE USED FOR AN RS-232 REMOTE DEVICE TO INTERFACE IT TO THE

RS-485 SERIAL PORT IF LONGER COMMUNICATION DISTANCES ARE REQUIRED. (THE RS-422 AND RS-485 SE-

RIAL INTERFACES HAVE COMPATIBLE SIGNALS FOR THIS APPLICATION.)

Figure 1-1. DDI-A and DDI-B Channels

1-2

INTRO

Section 1. Introduction

• An available Expansion board slot for the DDI-A APB (slot 3) and/or the DDI-B APB (slot 1).

To determine the Expansion board option card complement, display slot location datapoints

B095 through B099 (for slots 1 through 5 respectively). Option card codes are 128 = MicroLink, 129 = APB, 1 = 6DI/4DO, 2 = Single Channel Analog Input, 3 = Multi-Channel Analog I/O, 4 = 16DI/DO, and 5 = HART Modem. One exception is the 6DI/4DO option card code (1), which may not appear in the displayed datapoint even if the card occupies a slot location. (Instructions to remove and install hardware in the PCS are provided in Table 10-1,

Parts Replacement.)

• An RS-232/485 ITB with ITB-to-PCS cable for each DDI-A/B option. (Instructions to install an ITB are provided in Section 2.)

• A custom fabricated ITB-to-PLC cable or ITB-to-serial/parallel converter cable for the printer.

These cables are described in the applicable PLC/printer section (Sections 4 through 9) that follows.

It should be noted that an APB at the proper firmware level in slot 3 can be bridged with a Connector board to a HART Option Modem card in slot 5 for DDI-A Printer or PLC operation and for HART

Multi-Channel Analog operation.

1.4 RS-232/485 ITB SPECIFICATIONS

Specifications for the RS-232/485 ITB are provided in Table 1-1 as follows:

Table 1-1. RS-232/485 ITB (686B720) Specifications

Characteristic

Operating Temperature Range

Relative Humidity

Shock and Vibration

Input Power Requirements

Specification

Environmental Characteristics

4 ° - 52°C (40° - 125°F)

10% to 90% maximum

0.5 G (Gravity - 32 ft/sec/sec)

Input Power

12 to 26 V dc at 100 mA maximum

INTRO

1-3

53MC9015 53MC5000 PLC and Printer Interfaces

1.5 MODEL NUMBER BREAKDOWN

A model number breakdown with supporting Figures 1-2 and 1-3 is provided in the pages that follow:

TYPE NO. 53MC

SERIES NO. 53MC5000

MODULAR CONTROLLER

53 MC 5 0 0 0 A 2

Engineering File Reference:

Controllers, Regulators and Accessories

MICRO-DCI Controller

Design Designation: Fixed Data

53

MC

5

Number of Control Loops

One Loop

Two Loops

Four Loops

Power Requirements

AC (120/240)

DC (24)

1

2

4

1

2

Functional Requirements

Standard

Extended

Standard with Factory Configuration

Extended with Factory Programming

Standard with Configuration by Subsidiary or Field

Integration

Extended with Programming by Subsidiary or Field

Integration

Design Level

Enclosure Type

DIN 72 x 144 mm Bezel

1

2

3

4

5

6

A

Main Rear Terminal Requirement

Standard Rear Term. Board

Std. Rear Term. w/Valve Holder Connector

Cord Set Connector Board Only

Cord Set Connector Board, Standard ITB

Cord Set Connector Board, Cable, Standard ITB

Cord Set Connector Board w/Valve Holder Connector

Cord Set Connector Board w/Valve Holder Connector, Standard

ITB

Cord Set Connector Board w/Valve Holder Connector, Cable,

Standard ITB

2

6

7

4

5

1

2

3

8

Chassis

Standard

Expansion Ready

Safety Classification

General Purpose

FM Approved: Nonincendive for Class I, Div. 2, Groups A,B,C, & D

A

B

A

B

1-4

MODNUML

Section 1. Introduction

Discrete I/O Option #1

Not Implemented

6DI/4DO Board Only

6DI/4DO Board, DI/DO ITB

6DI/4DO Board, Cable, DI/DO ITB

16DI/DO Board Only

53 MC 5 0 0 0 A 2

16DI/DO Board, ITB

16DI/DO Board, Cable, ITB

DDI-A HART Auxiliary Processor Board (APB) Only

DDI-A HART APB, HART Modem ITB

DDI-A HART APB, HART Modem ITB, 5 Foot Cable

DDI-A Printer/PLC Auxiliary Processor Board (APB) Only

DDI-A Printer/PLC APB, RS-232/485 ITB

DDI-A Printer/PLC APB, RS-232/485 ITB, 5 Foot Cable

Dual Relay ITB

Not Implemented

One ITB

Two ITBs

Three ITBs

Analog I/O Option

Not Implemented

Single Channel Analog Input Board Only

Multi-Channel Analog I/O Board

Multi-Channel Analog I/O Board, Analog ITB

Multi-Channel Analog I/O Board, Cable, Analog ITB

Multi-Channel Analog/HART Option

Multi-Channel Analog/HART Option, HART ITB

Multi-Channel Analog/HART Option, HART ITB, 5 Foot Cable

Analog Conditioning Module

Not Implemented

0-20 mA

0-5 V

RTD 100 ohm, -100 ° C to +100° C

Type J, 0 to +760 ° C

Type T, 0 to +200 ° C

Communications Option #1

Not Implemented

Cable Only

Communication ITB Only

Communication ITB, Cable

MicroLink A Communication Board Only

MicroLink A Communication Board, Cable

MicroLink A Communication Board, Cable, Communication ITB

Communications B Option

Not Implemented

MicroLink B

MicroLink B, Cable

MicroLink B, Cable, ITB

DDI-B HART APB Only

DDI-B HART APB, HART Modem ITB

DDI-B HART APB, HART Modem ITB, 5 Foot Cable

DDI-B Printer/PLC Auxiliary Processor Board (APB) Only

DDI-B Printer/PLC APB, RS-232/485 ITB

DDI-B Printer/PLC APB, RS-232/485 ITB, 5 Foot Cable

Conformal Coating

Not Required

Required

E

F

G

H

J

X

A

B

C

D

K

L

M

2

3

X

1

X

A

B

C

D

E

F

G

X

A

B

C

D

E

E

F

X

A

B

C

D

C

D

E

X

A

B

F

G

H

J

X

A

MODNUML

1-5

53MC9015 53MC5000 PLC and Printer Interfaces

1-6

MODNUML

Section 1. Introduction

MODNUML

5

1-7

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

1-8

MODNUML

Section 2. Installation

2.0 INSTALLATION

2.1 53MC5000 PROCESS CONTROL STATION INSTALLATION

The PCS instruction bulletin described in the Preface of this book should be referenced for the installation procedure.

2.2 MOUNTING THE RS-232/485 ITB

The RS-232/485 ITB is designed for snap-mounting into non-conductive, 2.9 inch (74 mm) wide

PVC track that is either surface direct mounted (wall mounted) or mounted on DIN rail (32 or 35 mm) with adapters.

This ITB is not provided with an enclosure. It may be mounted within a user provided enclosure as protection against environmental hazards and mechanical damage, and to provide operating personnel with suitable protection from electric shock.

WARNING

The RS-232/485 ITB when properly installed in the non-conductive,

2.9 inch (74 mm) wide PVC track snap-mount channel, complies with

ANSI/ISA, UL, CSA, and IEC safety requirements with respect to accessibility to a potential shock hazard when installed in a service

access area that can only be accessed, by use of tool, by qualified service personnel. It is the user’s responsibility to provide supplementary protection against accidental contact with these ITBs mounted in an operator access area where access can be gained without the use of a tool.

The 2.9 inch (74 mm) wide PVC track is available in 4 foot (1.2 m) lengths as part number 129A003U03 for wall mounting and for DIN rail mounting. To mount the PVC track on either the 32 mm or 35 mm DIN rails, order kit part number 614B958U01, which contains 24 DIN Adapters. DIN rails are NOT available from MicroMod Automation Inc. and must be purchased locally.

As shown in Figure 2-1, the elongated mounting holes for the PVC track are centered 2 inches

(50.8 mm) apart, as well as the two parallel rows of adapter holes. The track can be mounted directly to the wall with screws through the elongated holes or it can be mounted on 32 mm or 35 mm DIN rail with DIN Adapters that are inserted into the adapter holes. It is not necessary to snap all 24 adapters into a single 4 foot PVC track section.

General considerations when snap-mounting the RS-232/485 ITB to the PVC track are as follows:

• The ITB can be mounted horizontally or vertically.

• Minimum above board clearance is 3 inches (76.2 mm) for connector cable bends, but 7 inches (177.8 mm) is more desirable to allow access space above the track surface for installation of wires and connectors to the ITB.

2-1

INSTALL

53MC9015 53MC5000 PLC and Printer Interfaces

2-2

INSTALL

Section 2. Installation

2.3 RS-232/485 ITB CABLE CONNECTIONS

An RS-232/485 ITB can be connected to either the DDI-A channel (Process Control Station J5) or the DDI-B channel (Process Control Station J9), but not both. As shown in Figure 2-2, the

DDI-A cable with 20 pin connectors is installed in J5 of the RS-232/485 ITB and J5 of the

53MC5000 Process Control Station. The DDI-B cable with modular connectors is installed in J4 of the RS-232/485 ITB and J9 of the 53MC5000 Process Control Station.

2.4 ITB SIGNAL CONNECTIONS

An RS-232/485 ITB can be connected either from J1 to an RS-232 device or from TB2 to an RS-

485 device, but not both. The signal layout for J1, which has nine pins, is provided in a table in Figure 2-2. Although J1 is a standard nine pin RS-232 jack, a cable is not provided for this jack because of the various device types that can be connected to it. The cable from J1 to the device must therefore be fabricated. Illustrations of typical cables are provided in each of the PLC sections.

A signal layout for the five lugs of TB2 is also provided in a table in Figure 2-2. As shown in the illustration, TB2 is dedicated to RS-485 devices. The RS-232/485 ITB transmits from the TB2 T+ and T- lugs, and receives at the R+ and R- lugs. The cable shield should be connected to the SH lug of TB2.

2.5 RS-232/485 ITB POWER CONNECTIONS

Assigned power input terminals for the RS-232/485 ITB are illustrated in Figure 2-2. Input power requirements for the RS-232/485 ITB are 12 to 26 V dc at 100 mA maximum. As shown in Figure

2-2, the positive power supply terminal is connected to the ITB TB1 +24 V lug and the negative power supply terminal is connected to TB1 ground lug. The ITB power supply should not be connected to other loads that may cause noise and signal degradation. All wiring is supplied by the customer.

A Process Control Station can operate with +24 V dc input, with ac inputs of 110/120 V, or with ac inputs of 220/240 V. Procedures to connect the controller to +24 V dc, 110/120 V ac, and

220/240 V ac, are provided in the Process Controller Station book which is given in the Preface of this document.

WARNING

Instruments (e.g, Process Control Station) that are powered from an ac line service constitute a potential electric shock hazard to the user.

Make certain that these system ac power lines are disconnected from the operating branch circuit before attempting electrical connections.

INSTALL

2-3

53MC9015 53MC5000 PLC and Printer Interfaces

GROUNDING

Installations are expected to have access to a high quality, noise-free point of earth reference. Connection should be through a low resistance (less than one ohm) lead wire directly to the installation’s point of earth reference which can be an independent grounding rod or ground grid mesh that penetrates the permanent moisture level below the frost line in accordance with Article 250 of ANSI/NFPA 70, the

National Electrical Code, or other code(s) acceptable to the authority having jurisdiction over the installation.

COMMON BUS BAR

Use of a common bus bar that is connected to the earth ground through a low resistance (less than one ohm) lead wire is recommended to minimize potential voltage differences that may occur as a result of ground loops, e.g., potential differences between separate power grounds, signal grounds, etc.

METAL CONDUIT

In noisy locations, the power wiring should be enclosed in metal electrical conduit and not routed in close proximity to signal wiring.

2-4

INSTALL

Section 2. Installation

INSTALL

2-5

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

2-6

INSTALL

Section 3. Product Description

3.0 PRODUCT DESCRIPTION

3.1 DDI-A AND DDI-B MEMORY MAPS

As shown in Figures 3-1 and 3-2, there are two identical memory maps in the 53MC5000 PCS, one for the DDI-A option and one for the DDI-B option. Each memory map has a set of contiguous Ltype datapoints and a set of contiguous C-type datapoints. There are 512 L-type datapoints (32 words or 64 bytes) and 64 C-type datapoints (64 words). In operations involving both L and C

data, the L data is transferred first.

The datapoint locations for the PCS memory maps can be summarized as follows:

Channel Type

DDI-A

DDI-B L

C

L

C

Datapoint

Range

L1536 - L2047

C704 - C767

L1024 - L1535

C640 - C703

3.2 TYPICAL PCS-PLC INFORMATION TRANSFERS

Figure 3-3 illustrates how information is read from a PLC to the PCS and entered into a memory map (DDI-A is used here), and how information is written from the PCS to the PLC.

• 320 L-type contiguous datapoints (20 words) are read from PLC memory locations L000 through L319 and sent to PCS contiguous datapoint locations L1536 through L1855.

• 8 C-type datapoints (8 words) are read from PLC memory locations C00 through C07 and sent to PCS contiguous datapoint locations C704 through C711.

• 64 L-type datapoints (4 words) are to be written from the PCS to the PLC. Four words are counted up from the bottom to find the starting address of the datapoint information to be transferred. The information transfer starts at location L1984. Datapoints L1984 through

L2047 are transferred to PLC contiguous locations L320 to L383.

• 3 C-type datapoints (3 words) are to be written from the PCS to the PLC. Three words are counted up from the bottom to find the starting address of the datapoint information to be transferred. The information transfer starts at location C765. Datapoints C765 through

C767 are transferred to PLC contiguous locations C08 to C10.

• Depending upon the PLC, the minimum transfer quantity of L-type datapoints is 8 or 16, even if only a single L-type datapoint is to be transferred.

• The user is completely free to dedicate the L- and C-type datapoints to the reads and writes as required; however, the total number of L-locations (512) and the total number of C-words

(64) must not exceed the maximums.

3-1

DESCRP

53MC9015 53MC5000 PLC and Printer Interfaces

3.2.1 CALCULATING STARTING ADDRESSES FOR WRITES

Methods to calculate L and C starting datapoint locations from the bottom of memory for write operations are as follows:

DDI-A L-Type Starting Location (Words) = L(2048) - (Number of Output Words X 16)

If four words are to be output from the L-Stack, then the starting datapoint location is as follows:

L-Stack Starting Location = L(2048) - (4 X 16) = L(2048) - (64) = L1984

DDI-B L-Type Starting Location (Bytes) = L(1536) - (Number of Output Bytes X 8)

If six bytes are to be output from the L-Stack, then the starting datapoint location is as follows:

L-Stack Starting Location = L(1536) - (6 X 8) = L(1536) - (48) = L1488

DDI-A C-Type Starting Location (Words) = C(768 - Number of Output Words)

If three words are to be output from the C-Stack, then the starting datapoint location is as follows:

C-Stack Starting Location = C(768 - 3) = C765

DDI-B C-Type Starting Location (Words) = C(704 - Number of Output Words)

If three words are to be output from the C-Stack, then the starting datapoint location is as follows:

C-Stack Starting Location = C(704 - 3) = C701

3.3 PCS - PLC MEMORY MAP AGREEMENT

It is important to remember that data is stored in contiguous locations in the PCS and PLC memory maps; therefore, there must be agreement in the data assignments between these two (PCS output identifiers must match PLC input identifiers and PCS input identifiers must match the PLC output identifiers).

When defining the number of PLC L and C memory locations, the user should allow room for possible future expansion of both memory areas. This is advised because expanding the L and C PLC memory areas causes the established memory locations to move down.

3.4 PLC MEMORY ADDRESSING SCHEME

Starting PLC Memory Address High and Low Bytes are part of the Read and Write Control Bytes sent from the PCS to a PLC for read and write operations. The high and low bytes are two bytes that form the starting PLC memory location to be addressed for the operation. These two bytes contain byte-decimal data; therefore, if the PLC uses a memory addressing scheme that is not bytedecimal, then decimal values must be entered into these bytes that represent the starting memory address being accessed by the operation. This conversion is not performed by the PCS. For example, if the PLC starting memory address is a word-octal 300

8

or a word-hexadecimal C0

16

, then the decimal values that must be entered in the two byte starting memory address are 1 for the

Starting PLC Memory Address High Byte and 128 for the Starting PLC Memory Address Low Byte.

These numbers are derived as follows:

C0

16

= 300

8

= 192

10

(See Appendix A for data conversion procedures)

192

10

X 2 = 384

10

(there are two bytes per word)

384/256 = 1 with 128 remainder; therefore the High byte value is 1, and the Low byte value is 128.

3-2

DESCRP

Section 3. Product Description

3.5 PCS FLOATING POINT-TO-INTEGER CONVERSION

In the PCS, floating point numbers are converted to 16 bit unsigned integers before being written to the PLC. When converted from a floating point number to a 16 bit unsigned integer by the PCS, the following rounding procedure applies:

PCS Range

−∞ to <1

1 to <32,769

32,769 to <65,536

65,536 to + ∞

Conversion to PLC Integer Value

0

Rounded down to nearest integer

Rounded down to nearest even integer

All values are stored as 65,535

Data read from the PLC (with the exception of OPTO 22) is considered to be 16 bit unsigned integers and is converted to floating point numbers by the PCS as follows:

PLC Integer

0 to 32,768

32,769 to 65,535

PCS Floating Point Conversion

Unchanged

Rounded down to nearest even integer

It should be noted that a process measurement range (e.g., temperature) with negative numbers is possible using an algorithm in the PLC that converts the range to all positive numbers; an F-TRAN routine can be written to perform the same task in the PCS.

DESCRP

3-3

53MC9015 53MC5000 PLC and Printer Interfaces

W B

O Y

R T

D E

S

0

LSB

1 2 3 4

DDI-A L-TYPE CONTIGUOUS DATAPOINTS

5 6 7

(MSB)

8

(LSB)

9 10 11 12 13 14 15

MSB

(0) (1) (2) (3) (4) (5) (6) (7)

0 0,1 L1536 L1537 L1538 L1539 L1540 L1541 L1542 L1543 L1544 L1545 L1546 L1547 L1548 L1549 L1550 L1551

1 2,3 L1552 L1553 L1554 L1555 L1556 L1557 L1558 L1559 L1560 L1561 L1562 L1563 L1564 L1565 L1566 L1567

2 4,5 L1568 L1569 L1570 L1571 L1572 L1573 L1574 L1575 L1576 L1577 L1578 L1579 L1580 L1581 L1582 L1583

3 6,7 L1584 L1585 L1586 L1587 L1588 L1589 L1590 L1591 L1592 L1593 L1594 L1595 L1596 L1597 L1598 L1599

4 8,9 L1600 L1601 L1602 L1603 L1604 L1605 L1606 L1607 L1608 L1609 L1610 L1611 L1612 L1613 L1614 L1615

5 10,11 L1616 L1617 L1618 L1619 L1620 L1621 L1622 L1623 L1624 L1625 L1626 L1627 L1628 L1629 L1630 L1631

6 12,13 L1632 L1633 L1634 L1635 L1636 L1637 L1638 L1639 L1640 L1641 L1642 L1643 L1644 L1645 L1646 L1647

7 14,15 L1648 L1649 L1650 L1651 L1652 L1653 L1654 L1655 L1656 L1657 L1658 L1659 L1660 L1661 L1662 L1663

8 16,17 L1664 L1665 L1666 L1667 L1668 L1669 L1670 L1671 L1672 L1673 L1674 L1675 L1676 L1677 L1678 L1679

9 18,19 L1680 L1681 L1682 L1683 L1684 L1685 L1686 L1687 L1688 L1689 L1690 L1691 L1692 L1693 L1694 L1695

10 20,21 L1696 L1697 L1698 L1699 L1700 L1701 L1702 L1703 L1704 L1705 L1706 L1707 L1708 L1709 L1710 L1711

11 22,23 L1712 L1713 L1714 L1715 L1716 L1717 L1718 L1719 L1720 L1721 L1722 L1723 L1724 L1725 L1726 L1727

12 24,25 L1728 L1729 L1730 L1731 L1732 L1733 L1734 L1735 L1736 L1737 L1738 L1739 L1740 L1741 L1742 L1743

13 26,27 L1744 L1745 L1746 L1747 L1748 L1749 L1750 L1751 L1752 L1753 L1754 L1755 L1756 L1757 L1758 L1759

14 28,29 L1760 L1761 L1762 L1763 L1764 L1765 L1766 L1767 L1768 L1769 L1770 L1771 L1772 L1773 L1774 L1775

15 30,31 L1776 L1777 L1778 L1779 L1780 L1781 L1782 L1783 L1784 L1785 L1786 L1787 L1788 L1789 L1790 L1791

16 32,33 L1792 L1793 L1794 L1795 L1796 L1797 L1798 L1799 L1800 L1801 L1802 L1803 L1804 L1805 L1806 L1807

17 34,35 L1808 L1809 L1810 L1811 L1812 L1813 L1814 L1815 L1816 L1817 L1818 L1819 L1820 L1821 L1822 L1823

18 36,37 L1824 L1825 L1826 L1827 L1828 L1829 L1830 L1831 L1832 L1833 L1834 L1835 L1836 L1837 L1838 L1839

19 38,39 L1840 L1841 L1842 L1843 L1844 L1845 L1846 L1847 L1848 L1849 L1850 L1851 L1852 L1853 L1854 L1855

20 40,41 L1856 L1857 L1858 L1859 L1860 L1861 L1862 L1863 L1864 L1865 L1866 L1867 L1868 L1869 L1870 L1871

21 42,43 L1872 L1873 L1874 L1875 L1876 L1877 L1878 L1879 L1880 L1881 L1882 L1883 L1884 L1885 L1886 L1887

22 44,45 L1888 L1889 L1890 L1891 L1892 L1893 L1894 L1895 L1896 L1897 L1898 L1899 L1900 L1901 L1902 L1903

23 46,47 L1904 L1905 L1906 L1907 L1908 L1909 L1910 L1911 L1912 L1913 L1914 L1915 L1916 L1917 L1918 L1919

24 48,49 L1920 L1921 L1922 L1923 L1924 L1925 L1926 L1927 L1928 L1929 L1930 L1931 L1932 L1933 L1934 L1935

25 50,51 L1936 L1937 L1938 L1939 L1940 L1941 L1942 L1943 L1944 L1945 L1946 L1947 L1948 L1949 L1950 L1951

26 52,53 L1952 L1953 L1954 L1955 L1956 L1957 L1958 L1959 L1960 L1961 L1962 L1963 L1964 L1965 L1966 L1967

27 54,55 L1968 L1969 L1970 L1971 L1972 L1973 L1974 L1975 L1976 L1977 L1978 L1979 L1980 L1981 L1982 L1983

28 56,57 L1984 L1985 L1986 L1987 L1988 L1989 L1990 L1991 L1992 L1993 L1994 L1995 L1996 L1997 L1998 L1999

29 58,59 L2000 L2001 L2002 L2003 L2004 L2005 L2006 L2007 L2008 L2009 L2010 L2011 L2012 L2013 L2014 L2015

30 60,61 L2016 L2017 L2018 L2019 L2020 L2021 L2022 L2023 L2024 L2025 L2026 L2027 L2028 L2029 L2030 L2031

31 62,63 L2032 L2033 L2034 L2035 L2036 L2037 L2038 L2039 L2040 L2041 L2042 L2043 L2044 L2045 L2046 L2047

WORDS

0 - 15

WORDS

DDI-A C-TYPE CONTIGUOUS DATAPOINTS

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

C704 C705 C706 C707 C708 C709 C710 C711 C712 C713 C714 C715 C716 C717 C718 C719

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

16 - 31 C720 C721 C722 C723 C724 C725 C726 C727 C728 C729 C730 C731 C732 C733 C734 C735

WORDS 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

32 - 47 C736 C737 C738 C739 C740 C741 C742 C743 C744 C745 C746 C747 C748 C749 C750 C751

WORDS 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

48 - 63 C752 C753 C754 C755 C756 C757 C758 C759 C760 C761 C762 C763 C764 C765 C766 C767

Notes: Depending upon the PLC memory architecture, the PCS L-type datapoint memory area can be visualized as having 32 words, with each word a 16 bit unsigned integer or as having 64 bytes, with each byte an 8 bit unsigned integer. If the L-type memory is word-oriented, then the Least Significant Bit (LSB) is 0 and the Most Significant Bit is (15). If the L-type memory is byte oriented, then the LSB for each byte is 0 and the MSB for each byte is 7. The PCS C-type memory area always has 64 words maximum.

Figure 3-1. PCS DDI-A Memory Map

3-4

DESCRP

Section 3. Product Description

W B

O Y

R T

D E

S

0

LSB

1 2 3 4

DDI-B L-TYPE CONTIGUOUS DATAPOINTS

5 6 7

(MSB)

8

(LSB)

9 10 11 12 13 14 15

MSB

(0) (1) (2) (3) (4) (5) (6) (7)

0 0,1

1 2,3

2 4,5

3 6,7

4 8,9

L1024 L1025 L1026 L1027 L1028 L1029 L1030 L1031 L1032 L1033 L1034 L1035 L1036 L1037 L1038 L1039

L1040 L1041 L1042 L1043 L1044 L1045 L1046 L1047 L1048 L1049 L1050 L1051 L1052 L1053 L1054 L1055

L1056 L1057 L1058 L1059 L1060 L1061 L1062 L1063 L1064 L1065 L1066 L1067 L1068 L1069 L1070 L1071

L1072 L1073 L1074 L1075 L1076 L1077 L1078 L1079 L1080 L1081 L1082 L1083 L1084 L1085 L1086 L1087

L1088 L1089 L1090 L1091 L1092 L1093 L1094 L1095 L1096 L1097 L1098 L1099 L1100 L1101 L1102 L1103

5 10,11 L1104 L1105 L1106 L1107 L1108 L1109 L1110 L1111 L1112 L1113 L1114 L1115 L1116 L1117 L1118 L1119

6 12,13 L1120 L1121 L1122 L1123 L1124 L1125 L1126 L1127 L1128 L1129 L1130 L1131 L1132 L1133 L1134 L1135

7 14,15 L1136 L1137 L1138 L1139 L1140 L1141 L1142 L1143 L1144 L1145 L1146 L1147 L1148 L1149 L1150 L1151

8 16,17 L1152 L1153 L1154 L1155 L1156 L1157 L1158 L1159 L1160 L1161 L1162 L1163 L1164 L1165 L1166 L1167

9 18,19 L1168 L1169 L1170 L1171 L1172 L1173 L1174 L1175 L1176 L1177 L1178 L1179 L1180 L1181 L1182 L1183

10 20,21 L1184 L1185 L1186 L1187 L1188 L1189 L1190 L1191 L1192 L1193 L1194 L1195 L1196 L1197 L1198 L1199

11 22,23 L1200 L1201 L1202 L1203 L1204 L1205 L1206 L1207 L1208 L1209 L1210 L1211 L1212 L1213 L1214 L1215

12 24,25 L1216 L1217 L1218 L1219 L1220 L1221 L1222 L1223 L1224 L1225 L1226 L1227 L1228 L1229 L1230 L1231

13 26,27 L1232 L1233 L1234 L1235 L1236 L1237 L1238 L1239 L1240 L1241 L1242 L1243 L1244 L1245 L1246 L1247

14 28,29 L1248 L1249 L1250 L1251 L1252 L1253 L1254 L1255 L1256 L1257 L1258 L1259 L1260 L1261 L1262 L1263

15 30,31 L1264 L1265 L1266 L1267 L1268 L1269 L1270 L1271 L1272 L1273 L1274 L1275 L1276 L1277 L1278 L1279

16 32,33 L1280 L1281 L1282 L1283 L1284 L1285 L1286 L1287 L1288 L1289 L1290 L1291 L1292 L1293 L1294 L1295

17 34,35 L1296 L1297 L1298 L1299 L1300 L1301 L1302 L1303 L1304 L1305 L1306 L1307 L1308 L1309 L1310 L1311

18 36,37 L1312 L1313 L1314 L1315 L1316 L1317 L1318 L1319 L1320 L1321 L1322 L1323 L1324 L1325 L1326 L1327

19 38,39 L1328 L1329 L1330 L1331 L1332 L1333 L1334 L1335 L1336 L1337 L1338 L1339 L1340 L1341 L1342 L1343

20 40,41 L1344 L1345 L1346 L1347 L1348 L1349 L1350 L1351 L1352 L1353 L1354 L1355 L1356 L1357 L1358 L1359

21 42,43 L1360 L1361 L1362 L1363 L1364 L1365 L1366 L1367 L1368 L1369 L1370 L1371 L1372 L1373 L1374 L1375

22 44,45 L1376 L1377 L1378 L1379 L1380 L1381 L1382 L1383 L1384 L1385 L1386 L1387 L1388 L1389 L1390 L1391

23 46,47 L1392 L1393 L1394 L1395 L1396 L1397 L1398 L1399 L1400 L1401 L1402 L1403 L1404 L1405 L1406 L1407

24 48,49 L1408 L1409 L1410 L1411 L1412 L1413 L1414 L1415 L1416 L1417 L1418 L1419 L1420 L1421 L1422 L1423

25 50,51 L1424 L1425 L1426 L1427 L1428 L1429 L1430 L1431 L1432 L1433 L1434 L1435 L1436 L1437 L1438 L1439

26 52,53 L1440 L1441 L1442 L1443 L1444 L1445 L1446 L1447 L1448 L1449 L1450 L1451 L1452 L1453 L1454 L1455

27 54,55 L1456 L1457 L1458 L1459 L1460 L1461 L1462 L1463 L1464 L1465 L1466 L1467 L1468 L1469 L1470 L1471

28 56,57 L1472 L1473 L1474 L1475 L1476 L1477 L1478 L1479 L1480 L1481 L1482 L1483 L1484 L1485 L1486 L1487

29 58,59 L1488 L1489 L1490 L1491 L1492 L1493 L1494 L1495 L1496 L1497 L1498 L1499 L1500 L1501 L1502 L1503

30 60,61 L1504 L1505 L1506 L1507 L1508 L1509 L1510 L1511 L1512 L1513 L1514 L1515 L1516 L1517 L1518 L1519

31 62,63 L1520 L1521 L1522 L1523 L1524 L1525 L1526 L1527 L1528 L1529 L1530 L1531 L1532 L1533 L1534 L1535

WORDS

0 - 15

WORDS

0 1 2 3

DDI-B C-TYPE CONTIGUOUS DATAPOINTS

4 5 6 7 8 9 10 11 12 13 14 15

C640 C641 C642 C643 C644 C645 C646 C647 C648 C649 C650 C651 C652 C653 C654 C655

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

16 - 31 C656 C657 C658 C659 C660 C661 C662 C663 C664 C665 C666 C667 C668 C669 C670 C671

WORDS 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

32 - 47 C672 C673 C674 C675 C676 C677 C678 C679 C680 C681 C682 C683 C684 C685 C686 C687

WORDS 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

48 - 63 C688 C689 C690 C691 C692 C693 C694 C695 C696 C697 C698 C699 C700 C701 C702 C703

Notes: Depending upon the PLC memory architecture, the PCS L-type datapoint memory area can be visualized as having 32 words, with each word a 16 bit unsigned integer or as having 64 bytes, with each byte an 8 bit unsigned integer. If the L-type memory is word-oriented, then the Least Significant Bit (LSB) is 0 and the Most Significant Bit is (15). If the L-type memory is byte oriented, then the LSB for each byte is 0 and the MSB for each byte is 7. The PCS C-type memory area always has 64 words maximum.

Figure 3-2. PCS DDI-B Memory Map

DESCRP

3-5

53MC9015 53MC5000 PLC and Printer Interfaces

3-6

Figure 3-3. PCS-PLC Data Transfers

DESCRP

Section 3. Product Description

3.6 DDI-A AND DDI-B CHANNEL SETUP

The DDI-A/B channels each have up to 25 B-type control datapoints that are used for communications setup, read/write operations, and status. Seventeen of these B-type datapoints are configured for each DDI channel by the user to define the PCS-PLC data transfer operations, e.g., starting PLC high/low memory addresses, data quantity transferred each transaction, communications baud rate, etc. The datapoints are described in detail in each PLC section of the book under four catagories, which are APB Setup Bytes, PLC Control and Status Bytes, Read Control Bytes, and Write Control Bytes. There is one exception, OPTO 22, which uses Digital I/O Control Bytes and Analog I/O Control Bytes instead of the Read/Write Control Bytes. The remaining OPTO 22 bytes are similar to the other PLCs.

3.6.1 APB SETUP BYTES

The APB Setup Bytes contain communications control information such as baud rate and the selected data format protocol. Also included in this catagory is the mode byte, which is used to identify the required PLC interface functionality. These bytes are applicable to all of the PLC operating modes; they are illustrated in Figure 3-4.

3.6.2 PLC CONTROL AND STATUS BYTES

The PLC Control and Status Bytes contain information needed for both the read and write operations. This includes the scan time and, as applicable, the self address (Modbus slave mode) or network interface address (Allen-Bradley mode). Also included is the setup error code, which is not configured by the user but is a channel error code. In general, these bytes are applicable to all of the PLC operating modes with some slight variations by PLC type; they are illustrated in Figure 3-4.

3.6.3 PLC READ CONTROL BYTES

The PLC Read Control Bytes contain information needed to transfer the data from the PLC to the

PCS. This information includes the PLC address, PLC starting memory address, the number of Ltype datapoints to be transferred, and the number of C-type datapoints to be transferred. Also included are the PLC error code, communications error code, and error count, which are not configured by the user but are status indicators for the read transaction. These bytes are not applicable to the OPTO 22. They are applicable to all of the other PLC operating modes with some slight variations. The PLC Read Control Bytes are illustrated in Figure 3-4.

3.6.4 PLC WRITE CONTROL BYTES

The PLC Write Control Bytes contain information needed to transfer information from the PCS to the PLC. This information includes the PLC address, PLC starting memory address, the number of

L-type datapoints to be transferred, and the number of C-type datapoints to be transferred. Also included are the PLC error code, communications error code, and error count, which are not configured by the user but are status indicators for the write transaction. These bytes are not applicable to the OPTO 22. They are applicable to all of the other PLC operating modes with some slight variations. The PLC Write Control Bytes are illustrated in Figure 3-4.

3.6.5 OPTOMUX DIGITAL AND ANALOG I/O CONTROL BYTES

The OPTOMUX Digital I/O Control Bytes and Analog I/O Control Bytes are applicable only to the

OPTO 22. These bytes are configured by the user; they are described in detail in Section 5,

OPTO 22 Mode.

DESCRP

3-7

53MC9015 53MC5000 PLC and Printer Interfaces

APB Setup Bytes

Title

Mode

Baud Rate

Set-Up

DDI-A

B290

B292

B293

DDI-B

B456

B458

B459

PLC Control and Status Bytes

Title

Self Address

Setup Error

Scan Time

DDI-A DDI-B

B670

B684

B685

B646

B660

B661

Scan Overruns Counter B686 B662

PLC Read Control Bytes

Title

PLC Address

Starting PLC Memory

Address Low

Starting PLC Memory

Address High

Number of L Locations to Read

Number of C Locations to Read

Command Code

DDI-A DDI-B

B664

B665

B666

B667

B668

B640

B641

B642

B643

B644

PLC Error Code* or

PLC Reply Status*

Communications

Error*

B669 B645

B671

B672

B647

B648

Error Count* B673 B649

*Can be reset by the user by writing a 0

into the datapoints.

Figure 3-4. Control Bytes

PLC Write Control Bytes

Title

PLC Address

Starting PLC Memory

Address Low

Starting PLC Memory

Address High

Number of L Locations to Write

Number of C Locations to Write

Command Code

DDI-A DDI-B

B674

B675

B676

B677

B678

B650

B651

B652

B653

B654

PLC Error Code* or

PLC Reply Status*

Communications

Error*

B679 B655

B681

B682

B657

B658

Error Count* B683 B659

*Can be reset by the user by writing a 0

into the datapoints.

3-8

DESCRP

Section 3. Product Description

3.7 SCAN TIME

The Scan Time is a time period from 100 to 25,500 ms that the user selects by entering a value from 1 to 255 into datapoints B685 (DDI-A) and B661 (DDI-B). The read and write data exchanges occur between the PCS and PLC during this time interval; therefore, the purpose of the Scan Time is to set the data update rate for the PCS. The PLC scan cycle runs asynchronously to the internal

F-TRAN scan cycle. Because of this, an F-TRAN program that uses data in the PLC L- or C-database modules might read adjacent datapoint locations that are a scan update apart. A typical

Scan Time that is properly set can be depicted as follows:

Read

Phase

Scan Time n

Write

Phase

Read

Phase

Scan Time n+1

Write

Phase

Read

Phase

Scan Time

Notice, all of the read and write phases are completed within the Scan Time cycle.

n+2

Write

Phase

If the read and write phases exceed the specified Scan Time, then a Scan Overrun occurs and the

Scan Overruns Counter (B686 for DDI-A and B662 for DDI-B) is incremented. The Scan Time itself should be increased or the data being exchanged during the read or write phases should be reduced. A Scan Time that is improperly set can be depicted as follows:

Read

Phase

Scan Time n

Write

Phase

Scan Time n+1

(Dead Time) Read

Phase

Scan Time n+2

Write

Phase

Notice that the write phase is overlapping into the Scan Time n+1

window because the Scan Time is improperly set. The Scan Time n+1

window now has a large dead time of inactivity until Scan Time n+2

starts again with a new read phase. An improper Scan Time therefore can actually reduce

PCS throughput.

As shown below, the read and write phases are data exchanges that have three minimal time intervals: the command from the PCS, which requires 13 characters minimum; the PLC turnaround time, which is assumed as 20 ms minimum; and the PLC response, which also requires 13 characters minimum.

Read L and C

Words Command

(13 Characters minimum)

Read Phase

960 ms

PCS-PLC

Turnaround

Time

PLC Response

(13

Characters minimum)

Write L and C

Words Command

(13 Characters minimum)

Write Phase

960 ms

PCS-PLC

Turnaround

Time

PLC Response

(13 Characters minimum)

As shown above, there is a minimum 52 character overhead and a minimum 1920 ms time overhead. The time for each phase is extended depending on the quantity of data exchanged and the baud rate at which it is exchanged. Generally, the read phase is longer, as a greater quantity of data is usually transferred from the PLC to the PCS. During the write phase, the PLC response is an echo message of the write command without the data.

DESCRP

3-9

53MC9015 53MC5000 PLC and Printer Interfaces

Each character has 11 bits (start, 8 data bits, parity, and stop bit) and at 9600 baud, 1 character time is 1.15 ms (9600/11 = 872 characters; 1 second/872 = 1.15 ms per character). It is true that the 1.15 ms character time used in the overhead calculation is also affected by the baud rate; however, for conservative calculations this number should remain constant for all baud rates at 9600 or above. Baud rates lower than 9600 should double the 1.15 ms character time for each half reduction in the baud rate (e.g., 9600/2 = 4800 baud = 2 x 1.15 = 2.3 ms per character time, etc.).

Given the information above, a formula that can be used to calculated Scan Time intervals for baud rates at 9600 or higher is as follows:

Scan Time =

( [ 2 (L rd

+ C rd

+ L wrt

+ C wrt

) + 52 ] × 11 × 1.15 ) + 1920

Baud

Formula constants:

2 = 2 eleven bit characters per word (should not be used if L rd

, etc., are already given in bytes)

52 = 52 minimum character overhead

11 = 11 bits per character

1.15 = character time in ms

1920 = minimum PCS-PLC turnaround time in ms

Example: Using the data transfers of Figure 1-2, the read phase has 20 L-words and 8 C-words; the write phase has 4 L-words and 3 C-words. At 9600 baud, the Scan Time would be calculated as follows:

Scan Time = ( [2 (20 + 8 + 4 + 3) + 52] x 11 x 1.15 ) + 1920/ 9600

= ( [2 (35) + 52] x 11 x 1.15 ) + 1920/ 9600

= (122 x 11 x 1.15 ) + 1920 / 9600

= 3463/9600 = 0.361 seconds or 361 ms

= 4 for 400 ms (361 ms is rounded to next higher increment of 100)

The applicable DDI port datapoint, B294 [DDI-A] or B460 [DDI-B] is configured with a 4.

NOTE

When specifying low scan times for large data transfers with some PLC types, persistent timeout errors (error code 255) or command errors

(e.g. checksum error, etc.) may occur because the PLC may not always be able to respond within the allowed time period. If this happens, the scan time should be increased until the errors stop.

3-10

DESCRP

Section 4. Allen-Bradley Mode

4.0 ALLEN-BRADLEY MODE

4.1 PURPOSE

The Allen-Bradley interface application permits data transfers between the Process Control Station

(PCS) and an addressed Allen-Bradley Programmable Logic Controller (PLC). Allen-Bradley DF-1

Protocol with Data Table and Allen-Bradley PLC-2 Data Table Addressing modes are supported.

4.2 DATA TABLE ADDRESSING

Data Table Addressing is the oldest Allen-Bradley addressing mode supported by the PCS Allen-

Bradley PLC Interface. Data Table Addressing was introduced by Allen-Bradley with the PLC-2, which stored data in a common memory file called the Data Table. The PCS Allen-Bradley interface reads and writes the data table as unsigned 16 bit integers.

Because of the large PLC-2 installed base, many support products (e.g., configuration tools, operator stations, etc.), which relied on the Data Table Addressing scheme, were offered by Allen-

Bradley and other third party vendors. Allen-Bradley, therefore, has traditionally provided some form of Data Table Addressing in subsequent PLC family introductions, such as the PLC-5. For this reason, the Allen-Bradley PLC-2 Data Table Addressing mode is supported by the PCS.

Data is written to and read from contiguous locations in the Allen-Bradley PLC Data Table. (A typical PLC memory data table is illustrated in Figure 3-3.) The boundary between the L and C data types in the PLC should therefore be properly positioned.

4.3 INSTALLATION CONFIGURATIONS

As shown in Figures 4-1 through 4-3, typical Allen-Bradley installation configurations that are supported by the PCS are Point-to-Point, Data Highway, and DH-485 Network. It should be noted that communication with network PLCs is bidirectional with one node; however, the read and write functions can be separated across two PLCs if necessary. If more than one PLC must be accessed, a suggested network application approach is to dedicate one PLC as the data source and destination for the other PLCs on the network.

4.4 RS-232/485 ITB-PLC CABLES

A custom RS-232 cable is required for connection from the RS-232/485 ITB J1 to the PLC. The recommended cable for this PLC application is illustrated in Figure 4-4. In the figure, one end of the cable has a nine pin male plug that connects to J1 of the RS-232/485 ITB and the other end has a 25 pin or 15 pin male or female plug as required by the PLC. The pin call-outs for the 15 pin plug are shown in brackets in the figure.

The RS-485 TB2 lug connections for the RS-232/485 ITB are the standard five wire bundle:

T+ (out), T- (out), R+ (in), R- (in), and SH (shield).

Typical maximum cable lengths are 50 feet (15.2 m) for RS-232 and 4000 feet (1219 m) for RS-485.

4-1

ALLEN

4-2

53MC9015 53MC5000 PLC and Printer Interfaces

53MC5000

PCS

RS-232/485

ITB

1747-KE SLC-5/02

Figure 4-1. Typical Point-to-Point Installation (SLC-5/02 Shown)

53MC5000

PCS

RS-232/485

ITB

1770-KF2

PLC-5

(TO BE READ)

ALLEN-BRADLEY

DATA HIGHWAY

PLC-5

(TO BE WRITTEN)

Figure 4-2. Typical Allen-Bradley Data Highway Installation

53MC5000

PCS

RS-232/485

ITB

1770-KF3

ALLEN-BRADLEY

DH-485 NETWORK

1747-KA SLC-5/02

(TO BE

READ)

1747-KA SLC-5/02

(TO BE

WRITTEN)

Figure 4-3. Typical Allen-Bradley DH-485 Network Installation

ALLEN

Section 4. Allen-Bradley Mode

RS-232/485 ITB, J1

(FEMALE DB-9

CABLE END)

RxD (IN)

TxD (OUT)

GND

2

7

8

3

5

ALLEN-BRADLEY

(MALE/FEMALE, DB-25/15

CABLE END)

2 TxD

3 RxD

7 GND

4 RTS

5 CTS

Figure 4-4. RS-232/485 ITB J1 to Allen-Bradley PLC Cable

4.5 ALLEN-BRADLEY COMMANDS

The Allen-Bradley commands used by the PCS interface application are summarized in Table 4-1 as follows:

Table 4-1. Allen-Bradley Commands Used

Function

Read

Write

Initialization (Sets maximum

ENQS, NAKS, and timeout of network interface.)

Command

Code

01

00

08

06

Title

Unprotected Read

Protected Write

Unprotected Write

Set Variables

ALLEN

4-3

53MC9015 53MC5000 PLC and Printer Interfaces

4.6 CONTROL BYTES FOR ALLEN-BRADLEY

The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write

Control Bytes are presented in Tables 4-2 through 4-5. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.)

Table 4-2. APB Setup Bytes for Allen-Bradley

Title Definition

Mode

Baud

Rate

It indicates the APB communications functionality as follows:

0 = Off, 1 = Allen-Bradley

This datapoint should be left at 0 and configured to a 1 after all of the other control bytes are configured because setting this datapoint causes the Allen-Bradley PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400, 9 = 28800, 8 = 14400, 7 = 19200,

6 = 9600, 5 = 4800, 4 = 2400, 3 = 1200, 2 = 600,

1 = 300, 0 = 110

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

Set

By

DDI-A DDI-B

User B290 B456

Default

0

User B292 B458

User B293 B459

0

0

Table 4-3. PLC Control and Status Bytes for Allen-Bradley

Title Definition DDI-A DDI-B Set

By

Default

B670 B646 User 0 Self

Address

It is the PCS source address used in all messages to the Allen-Bradley PLC.

Setup

Error

Scan

Time

It indicates the following: 0 = No Error, 1 = L-words to read > 32, 2 = C-words to read > 64, 3 = L-words to write > 32, 4 = C-words to write > 64, 5 = The write command is not 0 or 8 (0 is Protected Write and 8 is

Unprotected Write), 10 = Scan Time at 0. These error codes cause DDI channel operation to halt.

It is the PCS time period for the read and write phases of a PCS-PLC transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms. (See

Section 3.7.)

Scan

Overruns

Counter*

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Scan Time should be increased. (See Section 3.7.)

*User can reset by writing zeros into the datapoints.

B684 B660 Software

B685 B661 User

B686 B662 Software

0

0

0

4-4

ALLEN

Section 4. Allen-Bradley Mode

Table 4-4. Allen-Bradley PLC Read Control Bytes

Title

PLC Address

Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B664 B640 User

The two byte PLC memory starting address.

Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer, e.g., the PLC octal address 2764

8

= 00000101 11110100

2

=

05F4

16

(0000 0101 1111 0100). 5

16

= 5

10

, therefore 5 is entered as the high byte B666

[or B642]. F4

16

= 244

10

therefore 244 is entered as the low byte B665 [or B641]. If the PLC address is a hexadecimal 4180

16

,

41

16

= 65

10

and 80

16

= 128

10

; therefore,

65

10

would be entered as the high byte

B666 [or B642] and 128

10

would be entered as the low byte B665 [or B641]. (See

Appendix A for decimal conversions.) This value may have to be doubled and must be an even number for some byte address oriented Allen-Bradley PLC’s.

Reference the appropriate Allen-Bradley

documentation.)

B665 B641 User

B666 B642 User

B667 B643 User Number of L-Words to Read

Number of C-Words to Read

The number of L-words that are to be accessed from the PLC.

The number of C-words that are to be accessed from the PLC.

PLC Error Code*

(Reply Status)

Communications

Error Code*

The status codes are reported in decimal; however, they are listed in hexadecimal in the PLC manual. 255 = no reply; 00 =

Success - No Error. See the PLC book for the Remote STS (Status) Error Codes.

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

Error Count* This byte is a running total of PLC Error

Code responses that are not 00 (Success -

No Error) and non-zero Communications

Error Codes.

*User can reset by writing zeros into the datapoints.

B668

B671

B672

B673

B644

B647

B648

B649

User

Software

Software

Software

Default

0

0

0

0

0

0

0

0

ALLEN

4-5

53MC9015 53MC5000 PLC and Printer Interfaces

Table 4-5. Allen-Bradley PLC Write Control Bytes

Title

PLC Address

Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B674 B650 User

The two byte PLC memory address that states where to start writing data into the

PLC memory. Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer

(see Allen-Bradley Read Control Bytes for example. The value provided in the example may have to be doubled and must be an even number for some byte address oriented Allen-Bradley PLC’s.

Generally, the SLC500 is word address oriented and other Allen-Bradley models are byte address oriented. Reference the appropriate Allen-Bradley

documentation.)

B675 B651 User

B676 B652 User

B677 B653 User Number of L-Words to Write

Number of C-Words to Write

Write Command

The number of L-words that are to be written to the PLC.

The number of C-words that are to be written to the PLC.

Only 0 (Protected Write) or 8 (Unprotected

Write) are acceptable entries.

PLC Error Code*

(Reply Status)

Communications

Error*

The status codes are reported in decimal; however, they are listed in hexadecimal in the PLC manual. 255 = no reply; 00 =

Success - No Error. See the PLC book for the Remote STS (Status) Error Codes.

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

Error Count* This byte is a running total of PLC Error

Code responses that are not 00 (Success -

No Error) and non-zero Communications

Error Codes.

*User can reset by writing zeros into the datapoints.

B678

B679

B681

B682

B683

B654

B655

B657

B658

B659

User

User

Software

Software

Software

Default

0

0

0

0

0

0

0

0

0

4-6

ALLEN

Section 4. Allen-Bradley Mode

4.7 SET-UP PROCEDURE

The PLC documentation must be referenced to install and configure the PLC; however, examples are given in this section of KF2 communication switch selections, initialization command selections for the KF2, and KF3 initialization switch selections.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. This section provides an illustration of the required custom RS-232 cable if J1 of the ITB is to be connected to the PLC; otherwise, the standard RS-485 four wire bundle can be used if TB2 is to be connected to the PLC. (PLC means the device in the PLC complex that is cable connected to the PCS.)

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the PLC memory map as determined from the quantity of L-words and C-words to be transferred between the PCS and PLC. The size and address locations of the PCS L- and Cmemory areas are defined in Section 3.1.

6. At the PCS and PLC, enter the appropriate configuration values as follows:

If PLC Network Connection to a KF2 or KF3

If there is a network connection to a KF3, see Table 4-6 for KF3 setup selections.

If there is a network connection to a KF2, see Figure 4-5 for KF2 Communication Option Switch Selections.

DF1 Protocol Selections

Typical DF1 protocol selections for the Initialization Set Variables command or DF1 protocol switch settings are as follows:

ACK Timeout - 01

Maximum number of NAKS - 01

Maximum number of ENQS - 00

DF1 protocol selections may require trial settings until operation is refined; for example, two configurations (an SLC500 with a 1747-KE Communication Module and an SLC500 with a 1770-KF3 DH-485 Communication Module and 1747-AK Link Coupler) each required the following DF1 protocol settings:

Embedded Response Detect - ADER

ACK Timeout - 10

ENQuiry Retries - 00

NAK Received Retries - 00

PCS APB Setup Bytes (Table 4-2)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the PLC.

Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC.

Self Address (B295, B461) - Use the assigned PCS address.

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4-7

53MC9015 53MC5000 PLC and Printer Interfaces

PLC Control and Status Bytes (Table 4-3)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

PLC Read Control Bytes (Table 4-4)

PLC Address (B664, B640) - This is a decimal value of the PLC address.

Starting PLC Memory Address High and Low Bytes (B665, B641, B666, B642) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-Words to Read (B667, B643) - Can not exceed 32.

Number of C-Words to Read (B668, B644) - Can not exceed 64.

Destination Address (B669, B645) - For PLC networks; it is the network interface address used by the initialization message.

PLC Write Control Bytes (Table 4-5)

PLC Address (B674, B650) - This is a decimal value of the PLC address.

Starting PLC Memory Address High and Low Bytes (B675, B651, B676, B652) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-Words to Write (B677, B653) - Can not exceed 32.

Number of C-Words to Write (B678, B654) - Can not exceed 64.

Write Command (B679, B655) - 0 for Protected Writes, 8 for Unprotected Writes.

APB Setup Bytes (Table 4-2)

Mode (B290, B456) - 1 to start Allen-Bradley PLC interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-PLC activity.

4.7.1 ALLEN-BRADLEY KF3 SETUP SELECTIONS

The selections for a typical KF3 unit are summarized in Table 4-6. It is recommended these same selections be used whenever possible. Reference the Allen-Bradley KF3 documentation for information regarding the setup selections.

Table 4-6. KF3 Setup Selections

Option

0

1

2

Description

Node Address (Choose an address number that is not already dedicated to another network device.)

DH-485 Baud Rate

300

1200

2400

4800

9600

19200

Diagnostic Command Execution

No

Yes

1 of 2

Range Set Value

0-31 Any valid address 0-31

96

03

12

24

48

96

19

00

00

01

4-8

ALLEN

Option

3

4

5

6

7

8

9

Section 4. Allen-Bradley Mode

Table 4-6. KF3 Setup Selections

Description

RS-232 Baud Rate

300

600

1200

2400

4800

9600

19200

Parity

No Parity

Even Parity

DF1 Protocol

Full-Duplex

Half-Duplex Local

Half-Duplex Remote

Error Detection

BCC

CRC

Modem Handshake

Disabled

Enabled

Duplicate Message Detection

Disabled

Enabled

Sub-Menu Selections:

0 - Maximum Token Holder Address

1 - Token Hold Factor

2 - DF1 Retries

3 - DF1 ACK Timeout

4 - CTS-to-Transmit Delay

5 - End of Message-to-RTS Off

6 - Half-Duplex Master Address

7 - Group Number

01-31

01-10

00-10

01-50

00-99

00-99

00-77

00-77

2 of 2

Range Set Value

96

03

06

12

24

48

96

19

00

00

01

00

00

01

02

00

00

01

00

00

01

00

00

01

00

00

10

00

31

01

00

01

4.7.2 ALLEN-BRADLEY KF2 COMMUNICATION OPTION SWITCHES

The Allen-Bradley KF2 communications option switch selections are provided in Figure 4-5. It is recommended these same settings be used whenever possible.

ALLEN

4-9

53MC9015 53MC5000 PLC and Printer Interfaces

STATION NUMBER

ASYNCHRONOUS LINK NETWORK LINK

FEATURES COMMUNICATION RATE

RS-232-C/RS-422-A ASYNCHRONOUS LINK

COMMUNICATION

RATE

NETWORK

LINK

SELECTION

SW8 SW1 SW2 SW3 SW4 SW5 SW6 SW7

ON

OFF

RS-232C FULL DUPLEX STATION NUMBER 015 9600

BCC ERROR

CHECKING

BAUD

57,600 PEER

BITS PER COMM

SECOND LINK

EVEN PARITY (KF2 MODULE’S

NETWORK LINK)

NO EMBEDDED

RESPONSES PASS ANY RECEIVED

DETECT AND IGNORE

DUPLICATE MESSAGES

DIAGNOSTIC COMMANDS

TO THE ATTACHED

ASYNCHRONOUS DEVICE

IGNORE HANDSHAKING

SIGNALS

NOTES: POWER UNIT OFF; SELECT SWITCH SETTINGS; THEN POWER UNIT UP, BECAUSE

THE STATUS OF THE COMMUNICATION OPTION SWITCHES IS ONLY READ AT

POWER-UP.

THE SWITCH SETTINGS ILLUSTRATED WERE THE ACTUAL KF2 COMMUNICATION

SELECTIONS FOR A TEST UNIT. IT IS RECOMMENDED THAT

THESE SAME SETTINGS BE USED WHENEVER POSSIBLE.

Figure 4-5. Allen-Bradley KF2 Communication Option Switches

4-10

ALLEN

Section 4. Allen-Bradley Mode

4.8 FAULT ISOLATION AIDS

Table 4-7 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 4-7. Fault Isolation Aids

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

Setup Errors 1 through 4 (Table 4-3) - Violating memory map restrictions. Setup Error 5 = Bad

Write Command. Setup Error 10 - Scan Time at 0. PCS APB Setup bytes (Table 4-2) - Should agree with the communication setup of the PLC system.

Scan Overrun Counter (Table 4-3 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Proper cable fabrication between the RS-232/485 ITB and the PLC (Figure 4-4).

Communication Error Code and Error Count (Tables 4-4 and 4-5) - For checksum (Block Check

Character [BCC]) and bad message errors, the PCS does not use the data but will try again, for example: if a checksum error occurs during the read, the PCS will perform the write in that Scan

Time and attempt another read the next Scan Time. If there are five consecutive read errors or five consecutive write errors, the PCS causes a re-initialize sequence.

Network Problems

Ensure KF2 (Figure 4-5) or KF3 (Table 4-6) are properly setup.

Some network problems can be isolated by reconfiguring to a smaller system.

Possible PLC Problems

PLC Error Code and Error Count (Tables 4-4 and 4-5) - Convert decimal PLC Error Code (Reply

Status) to hexadecimal using Appendix A and reference the Allen-Bradley PLC documentation for possible explanation.

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. (Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-PLC transactions attempted with timeout errors.)

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4-11

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

4-12

ALLEN

Section 5. OPTO 22 Mode

5.0 OPTO 22 MODE

5.1 PURPOSE

The OPTO 22 interface application performs data transfers between the Process Control Station

(PCS) and a system of OPTOMUX boards (stations) over the OPTO 22 serial I/O communication system.

5.2 PCS DATABASE MAP FOR OPTO 22 MODE

The PCS database map for the OPTO 22 mode depicts the way the data from the actual boards of the OPTO 22 serial I/O communication system is stored in the PCS memory. Unlike all other PLC modes, the OPTO 22 database map is determined by the specific configuration of OPTO 22 hardware.

As shown in Figures 5-1 and 5-2, the PCS database map is divided into three spaces as it follows the OPTO 22 hardware:

1. Digital Boards 0 - 15

2. Digital Boards 16 - 31

3. Analog Boards 32 - 39

The user must follow certain rules as the database is defined:

• Board addresses must be contiguous and start with the lowest address of the group.

• The maximum combination of digital and analog boards for each DDI-A/B channel is 40

(addresses 0 - 39). This number cannot be exceeded and addresses above 39 should not be used.

• Outputs on a board must be contiguous and start with module 0.

• Inputs must be contiguous and adjacent to the last output on a board.

It should be noted that the digital sections are fixed in the PCS database and that the analog section varies according to the number of analog boards and modules per board. Also, that there are no single, contiguous write and read spaces. Data to be read or written is gathered and deposited from inputs and outputs stored all over the database map.

5-1

OPTO

53MC9015 53MC5000 PLC and Printer Interfaces

BOARD

NUMBER

0

1

2

6

7

8

3

4

5

9

10

11

12

13

14

15

0 1 2 3

CONTIGUOUS DIGITAL BOARDS 0 - 15

MODULE NUMBER

4 5 6 7 8 9 10 11 12 13 14 15

L1536 L1537 L1538 L1539 L1540 L1541 L1542 L1543 L1544 L1545 L1546 L1547 L1548 L1549 L1550 L1551

L1552 L1553 L1554 L1555 L1556 L1557 L1558 L1559 L1560 L1561 L1562 L1563 L1564 L1565 L1566 L1567

L1568 L1569 L1570 L1571 L1572 L1573 L1574 L1575 L1576 L1577 L1578 L1579 L1580 L1581 L1582 L1583

L1584 L1585 L1586 L1587 L1588 L1589 L1590 L1591 L1592 L1593 L1594 L1595 L1596 L1597 L1598 L1599

L1600 L1601 L1602 L1603 L1604 L1605 L1606 L1607 L1608 L1609 L1610 L1611 L1612 L1613 L1614 L1615

L1616 L1617 L1618 L1619 L1620 L1621 L1622 L1623 L1624 L1625 L1626 L1627 L1628 L1629 L1630 L1631

L1632 L1633 L1634 L1635 L1636 L1637 L1638 L1639 L1640 L1641 L1642 L1643 L1644 L1645 L1646 L1647

L1648 L1649 L1650 L1651 L1652 L1653 L1654 L1655 L1656 L1657 L1658 L1659 L1660 L1661 L1662 L1663

L1664 L1665 L1666 L1667 L1668 L1669 L1670 L1671 L1672 L1673 L1674 L1675 L1676 L1677 L1678 L1679

L1680 L1681 L1682 L1683 L1684 L1685 L1686 L1687 L1688 L1689 L1690 L1691 L1692 L1693 L1694 L1695

L1696 L1697 L1698 L1699 L1700 L1701 L1702 L1703 L1704 L1705 L1706 L1707 L1708 L1709 L1710 L1711

L1712 L1713 L1714 L1715 L1716 L1717 L1718 L1719 L1720 L1721 L1722 L1723 L1724 L1725 L1726 L1727

L1728 L1729 L1730 L1731 L1732 L1733 L1734 L1735 L1736 L1737 L1738 L1739 L1740 L1741 L1742 L1743

L1744 L1745 L1746 L1747 L1748 L1749 L1750 L1751 L1752 L1753 L1754 L1755 L1756 L1757 L1758 L1759

L1760 L1761 L1762 L1763 L1764 L1765 L1766 L1767 L1768 L1769 L1770 L1771 L1772 L1773 L1774 L1775

L1776 L1777 L1778 L1779 L1780 L1781 L1782 L1783 L1784 L1785 L1786 L1787 L1788 L1789 L1790 L1791

BOARD

NUMBER

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

CONTIGUOUS DIGITAL BOARDS 16 - 31

MODULE NUMBER

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

L1792 L1793 L1794 L1795 L1796 L1797 L1798 L1799 L1800 L1801 L1802 L1803 L1804 L1805 L1806 L1807

L1808 L1809 L1810 L1811 L1812 L1813 L1814 L1815 L1816 L1817 L1818 L1819 L1820 L1821 L1822 L1823

L1824 L1825 L1826 L1827 L1828 L1829 L1830 L1831 L1832 L1833 L1834 L1835 L1836 L1837 L1838 L1839

L1840 L1841 L1842 L1843 L1844 L1845 L1846 L1847 L1848 L1849 L1850 L1851 L1852 L1853 L1854 L1855

L1856 L1857 L1858 L1859 L1860 L1861 L1862 L1863 L1864 L1865 L1866 L1867 L1868 L1869 L1870 L1871

L1872 L1873 L1874 L1875 L1876 L1877 L1878 L1879 L1880 L1881 L1882 L1883 L1884 L1885 L1886 L1887

L1888 L1889 L1890 L1891 L1892 L1893 L1894 L1895 L1896 L1897 L1898 L1899 L1900 L1901 L1902 L1903

L1904 L1905 L1906 L1907 L1908 L1909 L1910 L1911 L1912 L1913 L1914 L1915 L1916 L1917 L1918 L1919

L1920 L1921 L1922 L1923 L1924 L1925 L1926 L1927 L1928 L1929 L1930 L1931 L1932 L1933 L1934 L1935

L1936 L1937 L1938 L1939 L1940 L1941 L1942 L1943 L1944 L1945 L1946 L1947 L1948 L1949 L1950 L1951

L1952 L1953 L1954 L1955 L1956 L1957 L1958 L1959 L1960 L1961 L1962 L1963 L1964 L1965 L1966 L1967

L1968 L1969 L1970 L1971 L1972 L1973 L1974 L1975 L1976 L1977 L1978 L1979 L1980 L1981 L1982 L1983

L1984 L1985 L1986 L1987 L1988 L1989 L1990 L1991 L1992 L1993 L1994 L1995 L1996 L1997 L1998 L1999

L2000 L2001 L2002 L2003 L2004 L2005 L2006 L2007 L2008 L2009 L2010 L2011 L2012 L2013 L2014 L2015

L2016 L2017 L2018 L2019 L2020 L2021 L2022 L2023 L2024 L2025 L2026 L2027 L2028 L2029 L2030 L2031

L2032 L2033 L2034 L2035 L2036 L2037 L2038 L2039 L2040 L2041 L2042 L2043 L2044 L2045 L2046 L2047

CONTIGUOUS ANALOG BOARDS 32 - 39 (MAXIMUM FULLY POPULATED ANALOG BOARD CONFIGURATION)

BOARD

NUMBER

32

33

0 1 2 3 4 5 6

MODULE NUMBER

7

C704 C705 C706 C707 C708 C709 C710 C711

C712 C713 C714 C715 C716 C717 C718 C719

8 9 10 11 12 13 14 15

34

35

36

C720 C721 C722 C723 C724 C725 C726 C727

C728 C729 C730 C731 C732 C733 C734 C735

C736 C737 C738 C739 C740 C741 C742 C743

37

38

39

C744 C745 C746 C747 C748 C749 C750 C751

C752 C753 C754 C755 C756 C757 C758 C759

C760 C761 C762 C763 C764 C765 C766 C767

OR OTHER ANALOG BOARD AND MODULE CONFIGURATIONS

(BOARDS X MODULES MUST BE ≤ 64)

CONTIGUOUS ANALOG BOARDS 32 - 35 (MINIMUM FULLY POPULATED ANALOG BOARD CONFIGURATION)

BOARD MODULE NUMBER

NUMBER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

32

33

34

35

C704 C705 C706 C707 C708 C709 C710 C711 C712 C713 C714 C715 C716 C717 C718 C719

C720 C721 C722 C723 C724 C725 C726 C727 C728 C729 C730 C731 C732 C733 C734 C735

C736 C737 C738 C739 C740 C741 C742 C743 C744 C745 C746 C747 C748 C749 C750 C751

C752 C753 C754 C755 C756 C757 C758 C759 C760 C761 C762 C763 C764 C765 C766 C767

Figure 5-1. PCS DDI-A OPTO 22 Database Map

5-2

OPTO

Section 5. OPTO 22 Mode

9

10

11

12

6

7

8

13

14

15

BOARD

NUMBER 0

0

1

2

1 2 3

CONTIGUOUS DIGITAL BOARDS 0 - 15

4 5 6

MODULE NUMBER

7 8 9 10 11 12 13 14 15

L1024 L1025 L1026 L1027 L1028 L1029 L1030 L1031 L1032 L1033 L1034 L1035 L1036 L1037 L1038 L1039

L1040 L1041 L1042 L1043 L1044 L1045 L1046 L1047 L1048 L1049 L1050 L1051 L1052 L1053 L1054 L1055

L1056 L1057 L1058 L1059 L1060 L1061 L1062 L1063 L1064 L1065 L1066 L1067 L1068 L1069 L1070 L1071

3

4

5

L1072 L1073 L1074 L1075 L1076 L1077 L1078 L1079 L1080 L1081 L1082 L1083 L1084 L1085 L1086 L1087

L1088 L1089 L1090 L1091 L1092 L1093 L1094 L1095 L1096 L1097 L1098 L1099 L1100 L1101 L1102 L1103

L1104 L1105 L1106 L1107 L1108 L1109 L1110 L1111 L1112 L1113 L1114 L1115 L1116 L1117 L1118 L1119

L1120 L1121 L1122 L1123 L1124 L1125 L1126 L1127 L1128 L1129 L1130 L1131 L1132 L1133 L1134 L1135

L1136 L1137 L1138 L1139 L1140 L1141 L1142 L1143 L1144 L1145 L1146 L1147 L1148 L1149 L1150 L1151

L1152 L1153 L1154 L1155 L1156 L1157 L1158 L1159 L1160 L1161 L1162 L1163 L1164 L1165 L1166 L1167

L1168 L1169 L1170 L1171 L1172 L1173 L1174 L1175 L1176 L1177 L1178 L1179 L1180 L1181 L1182 L1183

L1184 L1185 L1186 L1187 L1188 L1189 L1190 L1191 L1192 L1193 L1194 L1195 L1196 L1197 L1198 L1199

L1200 L1201 L1202 L1203 L1204 L1205 L1206 L1207 L1208 L1209 L1210 L1211 L1212 L1213 L1214 L1215

L1216 L1217 L1218 L1219 L1220 L1221 L1222 L1223 L1224 L1225 L1226 L1227 L1228 L1229 L1230 L1231

L1232 L1233 L1234 L1235 L1236 L1237 L1238 L1239 L1240 L1241 L1242 L1243 L1244 L1245 L1246 L1247

L1248 L1249 L1250 L1251 L1252 L1253 L1254 L1255 L1256 L1257 L1258 L1259 L1260 L1261 L1262 L1263

L1264 L1265 L1266 L1267 L1268 L1269 L1270 L1271 L1272 L1273 L1274 L1275 L1276 L1277 L1278 L1279

BOARD

CONTIGUOUS DIGITAL BOARDS 16 - 31

MODULE NUMBER

NUMBER 0

16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

L1280 L1281 L1282 L1283 L1284 L1285 L1286 L1287 L1288 L1289 L1290 L1291 L1292 L1293 L1294 L1295

17 L1296 L1297 L1298 L1299 L1300 L1301 L1302 L1303 L1304 L1305 L1306 L1307 L1308 L1309 L1310 L1311

18

19

20

L1312 L1313 L1314 L1315 L1316 L1317 L1318 L1319 L1320 L1321 L1322 L1323 L1324 L1325 L1326 L1327

L1328 L1329 L1330 L1331 L1332 L1333 L1334 L1335 L1336 L1337 L1338 L1339 L1340 L1341 L1342 L1343

L1344 L1345 L1346 L1347 L1348 L1349 L1350 L1351 L1352 L1353 L1354 L1355 L1356 L1357 L1358 L1359

21

22

23

24

25

26

27

28

29

30

31

L1360 L1361 L1362 L1363 L1364 L1365 L1366 L1367 L1368 L1369 L1370 L1371 L1372 L1373 L1374 L1375

L1376 L1377 L1378 L1379 L1380 L1381 L1382 L1383 L1384 L1385 L1386 L1387 L1388 L1389 L1390 L1391

L1392 L1393 L1394 L1395 L1396 L1397 L1398 L1399 L1400 L1401 L1402 L1403 L1404 L1405 L1406 L1407

L1408 L1409 L1410 L1411 L1412 L1413 L1414 L1415 L1416 L1417 L1418 L1419 L1420 L1421 L1422 L1423

L1424 L1425 L1426 L1427 L1428 L1429 L1430 L1431 L1432 L1433 L1434 L1435 L1436 L1437 L1438 L1439

L1440 L1441 L1442 L1443 L1444 L1445 L1446 L1447 L1448 L1449 L1450 L1451 L1452 L1453 L1454 L1455

L1456 L1457 L1458 L1459 L1460 L1461 L1462 L1463 L1464 L1465 L1466 L1467 L1468 L1469 L1470 L1471

L1472 L1473 L1474 L1475 L1476 L1477 L1478 L1479 L1480 L1481 L1482 L1483 L1484 L1485 L1486 L1487

L1488 L1489 L1490 L1491 L1492 L1493 L1494 L1495 L1496 L1497 L1498 L1499 L1500 L1501 L1502 L1503

L1504 L1505 L1506 L1507 L1508 L1509 L1510 L1511 L1512 L1513 L1514 L1515 L1516 L1517 L1518 L1519

L1520 L1521 L1522 L1523 L1524 L1525 L1526 L1527 L1528 L1529 L1530 L1531 L1532 L1533 L1534 L1535

CONTIGUOUS ANALOG BOARDS 32 - 39 (MAXIMUM FULLY POPULATED ANALOG BOARD CONFIGURATION)

BOARD

NUMBER

32

33

0 1 2 3 4 5 6

MODULE NUMBER

7

C640 C641 C642 C643 C644 C645 C646 C647

C648 C649 C650 C651 C652 C653 C654 C655

8 9 10 11 12 13 14 15

34

35

36

C656 C657 C658 C659 C660 C661 C662 C663

C664 C665 C666 C667 C668 C669 C670 C671

C672 C673 C674 C675 C676 C677 C678 C679

37

38

39

C680 C681 C682 C683 C684 C685 C686 C687

C688 C689 C690 C691 C692 C693 C694 C695

C696 C697 C698 C6 99 C700 C701 C702 C703

OR OTHER ANALOG BOARD AND MODULE CONFIGURATIONS

(BOARDS X MODULES MUST BE ≤ 64)

CONTIGUOUS ANALOG BOARDS 32 - 35 (MINIMUM FULLY POPULATED ANALOG BOARD CONFIGURATION)

BOARD MODULE NUMBER

NUMBER 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

32

33

34

35

C640 C641 C642 C643 C644 C645 C646 C647 C648 C649 C650 C651 C652 C653 C654 C655

C656 C657 C658 C659 C660 C661 C662 C663 C664 C665 C666 C667 C668 C669 C670 C671

C672 C673 C674 C675 C676 C677 C678 C679 C680 C681 C682 C683 C684 C685 C686 C687

C688 C689 C690 C691 C692 C693 C694 C695 C696 C697 C698 C699 C700 C701 C702 C703

Figure 5-2. PCS DDI-B OPTO 22 Database Map

OPTO

5-3

53MC9015 53MC5000 PLC and Printer Interfaces

5.2.1 PCS DATABASE MAP DIGITAL LOCATIONS

In Figures 5-1 and 5-2, each of the board’s 16 digital modules map into 16 L-datapoints as shown.

In addition to the rules given in Section 5.2, the user must specify the same number of PLC modules for every even and odd board for digital board addresses 0-15 and 16-31. Control bytes are dedicated to this function as shown in Figure 5-3.

In Figure 5-3, the PCS memory map L-datapoints are listed vertically in each module, e.g., L1536

(DDI-A) and L1024 (DDI-B) appear side-by-side in module 0 of board 0. Figure 5-3 therefore shows how either DDI option can be mapped into the physical OPTO 22 board modules. Figure 5-

3 also illustrates the values that would be entered into the Digital I/O Control Bytes for the installed

OPTO 22 configuration shown. The DDI-A datapoints are shown first, followed by the DDI-B datapoints which are in brackets, e.g., DDI-A B667 [DDI-B B643].

If it is assumed that board addresses 0, 1, 16, and 17 are installed with the module complements shown, then the DDI-A Digital I/O Control Bytes listed in Table 5-3 would have the following values:

Title

Number of Active Boards 00-15

Number of Active Boards 16-31

Number of Output Modules for Even Board

Addresses 00-15

Number of Output Modules for Odd Board

Addresses 00-15

Number of Output Modules for Even Board

Addresses 16-31

Number of Output Modules for Odd Board

Addresses 16-31

Output Watchdog Delay Boards 00-15

Output Watchdog Delay Boards 16-31

DDI-A

Datapoint

B665

B666

B667

B668

B669

B670

B671

B672

Value Entered and Comments

2, Boards 0 and 1.

2, Boards 16 and 17.

10, for Board 0, Modules 0 through 9

(datapoints L1536 through L1545).

12, for Board 1, Modules 0 through 11

(datapoints L1552 through L1563).

6, for Board 16, Modules 0 through 5

(datapoints L1792 through L1797).

3, for Board 17, Modules 0 through 2

(datapoints L1808 through L1810).

2, if a i minute Watchdog delay time is desired for Boards 0 and 1.

3, if a 10 minute Watchdog delay time is desired for Boards 16 and 17.

It should be noted that whenever OPTOMUX PB4MD boards are used, then the last 12 of the 16 Lvalues for each board must be skipped in the PCS memory map because these boards have only four modules each.

5-4

OPTO

OPTO

Section 5. OPTO 22 Mode

BOARD

ADDRESS

0

1

2

15

0 1 2 3 4

CONTIGUOUS DIGITAL BOARDS 0 - 15

5

MODULE NUMBER

6 7 8 9 10 11 12 13 14 15

L L

1 1

5 0

3 2

L L

(DDI-A AND DDI-B DATAPOINTS ARE SHOWN VERTICALLY BELOW)

L L L L L L L L L L L L L L L L L L L L L L L L L L

1 1

5 0

3 2

1 1

5 0

3 2

1 1

5 0

3 2

1 1

5 0

4 2

1 1

5 0

4 2

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

4 3

1 1

5 0

5 3

L L

1 1

5 0

5 3

6 4 7 5 8 6 9 7 0 8 1 9 2 0 3 1 4 2 5 3 6 4 7 5 8 6 9 7 0 8 1 9

DDI-A B667 [DDI-B B643] = EVEN BOARD MODULE OUTPUTS (E.G., IF B667 [OR

B643] = 10, THEN L1536 [L1024] TO L1545 [L1033] ARE OUTPUT MODULE

SLOTS AND L1546 [L1034] TO L1551 [L1039] ARE INPUT MODULE SLOTS).

L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

5 4

1 1

5 0

6 4

1 1

5 0

6 4

1 1

5 0

6 5

1 1

5 0

6 5

1 1

5 0

6 5

1 1

5 0

6 5

1 1

5 0

6 5

1 1

5 0

6 5

2 0 3 1 4 2 5 3 6 4 7 5 8 6 9 7 0 8 1 9 2 0 3 1 4 2 5 3 6 4 7 5

DDI-A B668 [DDI-B B644] = ODD BOARD MODULE OUTPUTS (E.G., IF B668 [OR

B644] = 12, THEN L1552 [L1040] TO L1563 [L1051] ARE OUTPUT MODULE

SLOTS AND L1564 [L1052] TO L1567 [L1055] ARE INPUT MODULE SLOTS).

IN MODULE SLOTS L1568 [L1056] THROUGH L1791 [L1279] FOR BOARDS 2-15:

DDI-A B667 [DDI-B B643] SELECTIONS APPLY TO EVEN BOARD ADDRESSES,

DDI-A B668 [DDI-B] B644 SELECTIONS APPLY TO ODD BOARD ADDRESSES,

WATCHDOG DELAY DDI-A B671 [DDI-B B647] APPLIES TO ALL BOARD OUTPUT

MODULES.

NUMBER OF

ACTIVE

CONTIGUOUS

BOARDS

B665/B641

1

2

3

16

BOARD

ADDRESS

16

17

18

31

0 1 2 3 4

CONTIGUOUS DIGITAL BOARDS 16 - 31

5

MODULE NUMBER

6 7 8 9 10 11 12 13 14 15

L L

1 1

7 2

L L

1 1

7 2

(DDI-A AND DDI-B DATAPOINTS ARE SHOWN VERTICALLY BELOW)

L L

1 1

7 2

L L

1 1

7 2

L L

1 1

7 2

L L

1 1

7 2

L L

1 1

7 2

L L

1 1

7 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

L L

1 1

8 2

9 8

2 0

9 8

3 1

9 8

4 2

9 8

5 3

9 8

6 4

9 8

7 5

9 8

8 6

9 8

9 7

0 8

0 8

0 8

1 9

0 9

2 0

0 9

3 1

0 9

4 2

0 9

5 3

0 9

6 4

0 9

7 5

DDI-A B669 [DDI-B B645] = EVEN BOARD MODULE OUTPUTS (E.G., IF B669 [OR

B645] = 6, THEN L1792 [L1280] TO L1797 [L1285] ARE OUTPUT MODULE SLOTS

AND L1798 [L1286] TO L1807 [L1295] ARE INPUT MODULE SLOTS).

L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L L

1 1

8 2

0 9

8 6

1 1

8 2

0 9

9 7

1 1

8 2

1 9

0 8

1 1

8 2

1 9

1 9

1 1

8 3

1 0

2 0

1 1

8 3

1 0

3 1

1 1

8 3

1 0

4 2

1 1

8 3

1 0

5 3

1 1

8 3

1 0

6 4

1 1

8 3

1 0

7 5

1 1

8 3

1 0

8 6

1 1

8 3

1 0

9 7

1 1

8 3

2 0

0 8

1 1

8 3

2 0

1 9

1 1

8 3

2 1

2 0

1 1

8 3

2 1

3 1

DDI-A B670 [DDI-B B646] = ODD BOARD MODULE OUTPUTS (E.G., IF B670 [OR

B646] = 3, THEN L1808 [L1296] TO L1810 [L1298] ARE OUTPUT MODULE SLOTS

AND L1811 [L1299]TO L1823 [L1311] ARE INPUT MODULE SLOTS).

IN MODULE SLOTS L1824 [L1312] THROUGH L2047 [L1535] FOR BOARDS 18-31:

DDI-A B669 [DDI-B B645] SELECTIONS APPLY TO EVEN BOARD ADDRESSES,

DDI-A B670 [DDI-B B646] SELECTIONS APPLY TO ODD BOARD ADDRESSES,

WATCHDOG DELAY DDI-A B672 [DDI-B B648] APPLIES TO ALL BOARD OUTPUT

MODULES.

NUMBER OF

ACTIVE

CONTIGUOUS

BOARDS

B666/B642

1

2

3

16

Figure 5-3. OPTO 22 Digital Boards

5-5

53MC9015 53MC5000 PLC and Printer Interfaces

5.2.2 PCS DATABASE MAP ANALOG LOCATIONS

As shown in Figures 5-1 and 5-2, the PCS can accomodate 64 C-values on eight contiguous analog boards (32 through 39) maximum. Any combination of contiguous boards and modules can be used, providing boards x modules does not exceed 64. It should be noted that even though there may be unused modules on an analog board, there are no unused corresponding C-locations in the PCS database. The PCS database expands to the module configuration as required. In addition to the rules given in Section 5.2, the user must specify the same number of PLC modules for every board for analog board addresses 32-39. Control bytes are dedicated to this function as shown in Figure 5-4.

In Figure 5-4, the PCS memory map C-datapoints are listed vertically in each module, e.g., C704

(DDI-A) and C640 (DDI-B) appear side-by-side in module 0 of board 32. Figure 5-4 therefore shows how either DDI option can be mapped into the physical OPTO 22 board modules. Figure 5-

4 also illustrates the values that would be entered into the Analog I/O Control Bytes for the installed OPTO 22 configuration shown. The DDI-A datapoints are shown first, followed by the

DDI-B datapoints which are in brackets, e.g., DDI-A B677 [DDI-B B653].

If it is assumed that board addresses 32 and 33 are installed with the module complements shown, and a Read Input Average Data command is selected, then the DDI-A Digital I/O Control Bytes listed in Table 5-4 would have the following values:

Output Watchdog Delay Boards 32-39

Number of Active Boards 32-39

Number of Analog Modules on Boards

Number of Analog Outputs

Analog Input Type for Board Addresses 33 and 37, 32 and 36

Title

Analog Input Type for Board Addresses 35 and 39, 34 and 38

Samples to Average

DDI-A

Datapoint

B673

B675

B676

B677

B679

B680

Value Entered and Comments

1, if a 10 second Watchdog delay time is desired for Boards 32 and 33.

2, Boards 32 and 33.

12, Boards 32 and 33.

8, for Boards 32 and 33, Modules 0 through 7.

132, for Type 8 probe on Board 33 and

Type 4 probe on Board 32. 84

16

=

132

10

. As shown in Figure 5-4, Type 8

Probe is a Type T Thermocouple and

Type 4 Probe is a Type J

Thermocouple.

0, for No Temperature Probe

B681 3, for Read Input Average Data command if selected, to indicate three

100 ms samples should be taken for the average figure.

5-6

OPTO

OPTO

Section 5. OPTO 22 Mode

BOARD

ADDRESS 0 1 2 3

CONTIGUOUS ANALOG BOARDS 32 - 39

4 5

MODULE NUMBER

6 7 8 9 10 11 12 13 14 15

NUMBER OF

ACTIVE

CONTIGUOUS

BOARDS

B675/B651

NUMBER OF ANALOG MODULES PER BOARD DDI-A B676 [DDI-B B652]. (E.G., IF B676 [OR B652] = 12,

THEN 12 MODULES PER BOARD AND MAXIMUM POPULATION OF 60 MODULES ON 5 BOARDS

[BOARDS X MODULES CAN NEVER EXCEED 64].)

(DDI-A AND DDI-B DATAPOINTS ARE SHOWN VERTICALLY BELOW)

32 1 C C

7 6

0 4

4 0

C C

7 6

0 4

5 1

C C

7 6

0 4

6 2

C C

7 6

0 4

7 3

C C

7 6

0 4

8 4

C C

7 6

0 4

9 5

C C

7 6

1 4

0 6

C C

7 6

1 4

1 7

C C

7 6

1 4

2 8

C C

7 6

1 4

3 9

C C

7 6

1 5

4 0

C C

7 6

1 5

5 1

E

M

P

T

Y

E

M

P

T

Y

E

M

P

T

Y

E

M

P

T

Y

33

DDI-A B677 [DDI-B B653] = BOARD MODULE OUTPUTS (E.G., IF B677 [OR

B653] = 8, THEN C704 [C640] TO C711 [C647] ARE OUTPUT MODULE SLOTS

AND C712 [C648] TO C715 [C651] ARE INPUT MODULE SLOTS.

C C

7 6

1 5

6 2

C C

7 6

1 5

7 3

C C

7 6

1 5

8 4

C C

7 6

1 5

9 5

C C

7 6

2 5

0 6

C C

7 6

2 5

1 7

C C

7 6

2 5

2 8

C C

7 6

2 5

3 9

C C

7 6

2 6

4 0

C C

7 6

2 6

5 1

C C

7 6

2 6

6 2

C C

7 6

2 6

7 3

E

M

P

T

Y

E

M

P

T

Y

E

M

P

T

Y

E

M

P

T

Y

SLOT ADDRESSING CONTINUES FROM PREVIOUS BOARD.

DDI-A B677 [DDI-B B653] = 8; THEREFORE, C716 [C652] TO C723 [C659] ARE

OUTPUT MODULE SLOTS AND C724 [C660] TO C727 [C663] ARE INPUT

MODULE SLOTS.

2

34

39

(IF 5 BOARDS ARE USED WITH 12 MODULES EACH, THEN BOARD

ADDRESSES ARE 32 TO 36. ALSO, SLOT ADDRESSING ALWAYS CONTINUES

FROM PREVIOUS BOARD.)

3

8

TYPE

0

16

1

16

2

16

3

16

4

16

5

16

INPUT PROBE TYPES

PROBE

NO TEMPERATURE PROBE

ICTD PROBE (AD4 MODULE)

10 OHM RTD PROBE (AD14T)

100 OHM RTD PROBE (AD10T)

TYPE J THERMOCOUPLE (AD5/AD5T)

TYPE K THERMOCOUPLE (AD8/AD8T)

TYPE

6

16

7

16

8

16

9

16

A to

F

16

PROBE

TYPE R THERMOCOUPLE (AD17T)

TYPE S THERMOCOUPLE (AD17T)

TYPE T THERMOCOUPLE (AD18T)

TYPE E THERMOCOUPLE (AD19T)

RESERVED

PROBE TYPE SELECTION (A MAXIMUM OF 4 TYPES CAN BE SELECTED FOR THE INPUT MODULES OF

THE 8 ANALOG BOARDS)

CHANNEL DATAPOINT LEFT DIGIT RIGHT DIGIT

DDI-A

DDI-B

B679

B655

PROBE TYPE FOR BOARDS 33 AND 37 PROBE TYPE FOR BOARDS 32 AND 36

PROBE TYPE FOR BOARDS 33 AND 37 PROBE TYPE FOR BOARDS 32 AND 36

DDI-A

DDI-B

B680

B656

PROBE TYPE FOR BOARDS 35 AND 39

PROBE TYPE FOR BOARDS 35 AND 39

PROBE TYPE FOR BOARDS 34 AND 38

PROBE TYPE FOR BOARDS 34 AND 38

EXAMPLES: TYPE 8 PROBE FOR BOARDS 33 AND 37 AND TYPE 4 PROBE FOR BOARDS 32 AND 36 =

84

16

. SEE APPENDIX A; 84

16

= 132

10

. ENTER 132 IN B679 [OR B655].

TYPE 5 PROBE FOR BOARDS 35 AND 39 AND TYPE 6 PROBE FOR BOARDS 34 AND 38 = 56

16

SEE APPENDIX A; 56

16

= 86

10

. ENTER 86 IN B680 [OR B656].

.

USE PROBE TYPE 0 FOR ALL ANALOG INPUTS OTHER THAN THERMOCOUPLES OR IF THERMOCOUPLE

INPUT PROBE TYPES GIVEN ABOVE ARE MIXED ON A SINGLE BOARD. IF INPUT PROBE TYPES ARE

MIXED ON A SINGLE BOARD, THE READ ANALOG INPUTS (76 [L]) COMMAND MUST BE USED AND THE

INPUT VALUES ARE RANGED BY THE PCS AS -819 TO 3276, REPRESENTING 0 TO 100% OF INPUT.

Figure 5-4. OPTO 22 Analog Boards

5-7

53MC9015 53MC5000 PLC and Printer Interfaces

5.3 CONTROL BYTES FOR OPTO 22

The OPTOMUX APB Setup Bytes, PLC Control and Status Bytes, Digital I/O Control Bytes, and

OPTOMUX Analog I/O Control Bytes are presented in Tables 5-1 through 5-4. If any Control

Byte is changed during operation, it takes up to 10 seconds to become effective (there is a

10 second interval between PCS checks for setup changes.)

Table 5-1. APB Setup Bytes for OPTOMUX

Title Definition

Mode

Baud

Rate

It indicates the APB communications functionality as follows: 0 = Off, 2 = OPTO 22 Mode

This datapoint should be left at 0 and configured to a 2 after all of the other control bytes are configured because setting this datapoint causes the OPTO-22 PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400 4 = 2400

9 = 28800 3 = 1200

8 = 14400 2 = 600

7 = 19200 1 = 300

6 = 9600 0 = 110

5 = 4800

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

3 = 7 bits, 1 stop bit, even parity

4 = 7 bits, 1 stop bit, odd parity

5 = 7 bits, 2 stop bits, no parity

Set

By

DDI-A DDI-B

User B290 B456

Default

0

User B292 B458

User B293 B459

0

0

5-8

OPTO

Section 5. OPTO 22 Mode

Table 5-2. OPTOMUX PLC Control and Status Bytes

Title Definition

Communic Communications Error Codes are as follows: ations

Error

Code*

255 = Timeout

254 = Checksum Error

253 = Bad Message

252 and 251= PCS Hardware Malfunction

240-247 = OPTO 22 Error Codes 00-07 (See the appropriate OPTO 22 documentation for complete definitions.)

00 = Power-Up Clear Expected - Command Ignored

01 = Undefined Command - Illegal Command

Character

02 = Checksum Error

03 = Input Buffer Overrun

04 = Non-Printable ASCII Character Received

05 = Data Field Error

06 = Communications Link Watchdog Time-Out Error

07 = Specified Limits Invalid

Communic ations

Error

Count*

It is a running total of all timeouts, checksum errors, and bad messages, etc. The Communications Error Counts can be reset during operation by writing a 0 into B683 and B659.

Setup

Error

Scan

Time

It indicates the following: 0 = No Error, 2 = Bad B

Value, 4 = Initialization Routine Running, 10 = Scan

Time at 0.

It is the PCS time period for the read and write phases of a PCS-OPTOMUX transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms. (See Section 3.7.)

Scan

Overruns

Counter*

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Scan Time should be increased. (See Section 3.7.)

First Bad

Board

Address*

Contains the address (0 - 39) of the first board returning communication errors (e.g., 255 = Timeout, 254 = Bad

Checksum, 253 = Bad Message, 252 and 251 = PCS hardware malfunction, and 240 - 247 = OPTOMUX PLC

Error Codes 00 - 07. See Communications Error Code above.) Every time a board is accessed, it is checked for a communications error. Boards are accessed in descending order by group: the analog group (39 to

32), digital group 2 (31 to 16), then digital group 1 (15 to

0).

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B682 B658 Software

B683 B659 Software

B684 B660 Software

B685 B661 User

B686 B662 Software

B687 B663 Software

Default

0

0

0

0

0

0

OPTO

5-9

53MC9015 53MC5000 PLC and Printer Interfaces

Table 5-3. OPTOMUX Digital I/O Control Bytes

Title

Communication Mode - A minimum of one word (16 Lvalues) is transferred even if only one L-value is used as an active indicator of a process event.

0 = No data exchange

1 = Reads only - (PCS ⇐ board).

2 = Reads and writes - (PCS ⇔ board)

3 = Writes only - (PCS ⇒ board)

Number of Contiguous Active Boards 00-15

Number of Contiguous Active Boards 16-31

Number of Contiguous Output Modules for Even Board

Addresses 00-15

Number of Contiguous Output Modules for Odd Board

Addresses 00-15

Number of Contiguous Output Modules for Even Board

Addresses 16-31

Number of Contiguous Output Modules for Odd Board

Addresses 16-31

Watchdog Delay on Outputs (PCS ⇒ board) of Each Board

Address 00-15:

0 - Watchdog disabled

1 - After 10 seconds, turn-off all outputs.

2 - After 1 minute turn-off all outputs.

3 - After 10 minutes turn-off all outputs.

4 - Watchdog timer disabled.

5 - After 10 seconds turn-on output 0, turn-off all other outputs.

6 - After 1 minute turn-on output 0, turn-off all other

outputs.

7 - After 10 minutes turn-on output 0, turn-off all other outputs.

Watchdog Delay on Outputs (PCS ⇒ board) of Each Board

Address 16-31 - the description is the same as

Addresses 00 - 15.

DDI-A DDI-B Set By Default

B664 B640 User 0

B665 B641 User

B666 B642 User

B667 B643 User

B668 B644 User

B669 B645 User

B670 B646 User

B671 B647 User

B672 B648 User

0

0

0

0

0

0

0

0

5-10

OPTO

Section 5. OPTO 22 Mode

Table 5-4. OPTOMUX Analog I/O Control Bytes

Title

Watchdog Delay on Outputs (PCS ⇒ board) of Each Board

Address 32-39:

0 - Watchdog timer disabled

1 - After 10 seconds, write zero scale.

2 - After 1 minute, write zero scale.

3 - After 10 minutes, write zero scale.

4 - Watchdog timer disabled.

5 - After 10 seconds, write full scale.

6 - After 1 minute, write full scale.

7 - After 10 minutes, write full scale.

Communication Mode

0 = No data exchange

1 = Reads only - (PCS ⇐ board).

2 = Reads and writes - (PCS ⇔ board)

3 = Writes only - (PCS ⇒ board)

Number of Contiguous Active Boards 32-39

Number of Analog Modules on Analog Boards

Number of Contiguous Analog Outputs (in ascending order, starts with 0)

Read Analog Command - Uses ASCII code of the letter that is the command (e.g., 76 for Read Analog Inputs L Positions,

ASCII 76 = L):

76, L, Read Analog Inputs

85, U, Read Input Average Data

108, l, Read Temperature Inputs

97, a, Read Lowest Values

98, b, Clear Lowest Values

99, c, Read and Clear Lowest Values

100, d, Read Peak Values

101, e, Clear Peak Values

102, f, Read and Clear Peak Values

Analog Input Type for Board Addresses 33 and 37, 32 and 36.

(Enter decimal value.)

Analog Input Type for Board Addresses 35 and 39, 34 and 38.

(Enter decimal value.)

Samples to Average (U Command) - Specifies the number of

100 ms samples to be taken. It affects all analog inputs.

DDI-A DDI-B Set By Default

B673 B649 User 0

B674 B650 User

B675 B651 User

B676 B652 User

B677 B653 User

B678 B654 User

B679 B655 User

B680 B656 User

B681 B657 User

0

0

0

0

0

0

0

0

OPTO

5-11

53MC9015 53MC5000 PLC and Printer Interfaces

5.4 OPTOMUX COMMANDS

The PCS OPTO 22 interface application uses three command sequences: Initialization, Read, and

Write, to communicate with the OPTOMUX boards. During the Initialization sequence the PCS sends to the OPTOMUX boards a Reset; control byte values (e.g., B667/B643, which contain the number of even board output modules); watchdog times (e.g., Watchdog Delay, B671/B647); and analog input probe type identifiers (e.g., B655, B656, B679, and B680, which are the probe identifier datapoints). The Read I/O sequence causes data to be sent from the OPTOMUX boards to the

PCS and the Write I/O sequence causes data to be sent from the PCS to the OPTOMUX boards.

After the Initialization sequence is complete, it is not repeated unless a datapoint is changed or a power-up condition occurs. If a datapoint is changed, an Initialization sequence will occur within

10 seconds. After the Initialization sequence is completed, the Read and Write sequences alternately operate to transfer data between the PCS and the OPTOMUX boards.

5.5 ANALOG I/O NUMBERS

All analog writes from the PCS must have values between 0 and 4095. These limits will be imposed on all numbers outside this range. Analog read commands other than Read Temperature Inputs return numbers between -819 and 3276. The Read Temperature Input command returns a

-273 C ° to 2047 C°.

5.5.1 READ ANALOG COMMAND

The Read Analog Command control byte in Table 5-4 provides a suite of read commands that can be selected by the user. These commands can be categorized into five five groups that have the following analog I/O numbers:

1. Read Analog Inputs - reads and reports the analog data as a raw number between -819 and 3276.

2. Read Temperature Inputs - reads the analog data and reports it as a temperature according to the probe types connected to the board modules as described in the codes entered into the Analog Input Type control bytes of Table 5-4.

3. Read Input Average Data - reports the analog data as an average of n samples where

n is entered into control bytes B681 for DDI-A and B657 for DDI-B of Table 5-4. The averaged numeric value is between -819 to 3276.

4. Read Peak/Lowest Values - reads the peak or the lowest values between -819 and

3276, depending on the command used

5. Clear Peak/Lowest Values - clears the peak or the lowest values between -819 and

3276, depending on the command used

5.5.2 READ ANALOG INPUTS COMMAND

If module types are mixed on one board, the Read Analog Inputs command must be used. The data will be returned ranged as -819 to 3276 representing 0 to 100% of input and must be converted to whatever units are required in the PCS.

5-12

OPTO

Section 5. OPTO 22 Mode

5.6 SUPPORTED OPTOMUX CONFIGURATIONS

As shown in Figure 5-5, typical OPTOMUX installation configurations that are supported by the

PCS are multidrop connection and cascade (daisy chain) connection.

53MC5000

PCS

16 17 18

RS-232/485

ITB

00 01

Typical Multidrop Connection

02

• • •

53MC5000

PCS

RS-232/485

ITB

00 01 02

Typical Cascade (Daisy Chain) Connection

• • • 39

Figure 5-5. Typical Installation Configurations

5.7 RS-232/485 ITB-PLC CONNECTION

As illustrated in Figure 5-6, TB2 (RS-485) of the RS-232/485 ITB is connected to the OPTOMUX board. The lug connections for TB2 are for the standard four wire bundle: T+ (out), T- (out),

R+ (in), and R- (in).

The maximum cable length for RS-485 is 4000 feet (1219 m).

RS-232/485 ITB TB2

CONNECTION

RECEIVE (R-)

RECEIVE (R+)

TRANSMIT (T-) 3

1

2

TRANSMIT (T+) 4

SHIELD 5

OPTOMUX BOARD

CONNECTION

TO HOST (-)

TO HOST (+)

FROM HOST (-)

FROM HOST (+)

GROUND

Figure 5-6. RS-232/485 ITB TB2 to OPTOMUX Board Connections

OPTO

5-13

53MC9015 53MC5000 PLC and Printer Interfaces

5.8 SCALING

The minimum value from an OPTO 22 module will be interpreted by the PCS as a -819

10

or 0 and the maximum value will be interpreted by the PCS as a 3276

10

. The range of values from -819

10 to 3276

10

is equivalent to a range from 0 to 4095

10

. The values 0 to 3276 or -819 to 3276 must be scaled to a 0 - 100% process range. For thermocouple temperature inputs where the OPTOMUX boards have identical probe types as specified in Figure 5-4, the final temperature is written to the database and does not require scaling. For thermocouple temperature inputs where the OP-

TOMUX boards have mixed probe types, the full range from 0 to 100% is spanned with the values of -819 to 3276

10

. For analog outputs, the full range from 0 to 100% is spanned with the values of

0 to 4095

10

.

Three typical examples of input scaling are as follows:

Example 1: A 1-5 V sensing device is used to measure a signal that is 0 to 200 GPM (gallons per minute) and the input analog module is 0-5 V.

Sensor Module PCS Value

5 V max.

5 V max.

3276

1 V min.

1 V

0 V min.

0

-819

Comments

The PCS range 0 to 3276 is scaled with 3276/200 = 16.38.

Therefore, the PCS must be scaled with an F-TRAN algorithm that uses 16.38 to convert from the input value read to GPM. Every 16.38 value change at the PCS = 1

GPM flow. A PCS value of -819 = 0 V input, which means an error condition, e.g., sensor wires were cut.

Example 2: A 1-5 V sensing device is used to measure a signal that is 0 to 200 GPM (gallons per minute) and the input analog module is 1-5 V.

Sensor Module PCS Value

5 V max.

5 V max.

3276

1 V min.

1 V min.

0

Comments

The PCS range 0 to 3276 is scaled with 3276/200 = 16.38.

Therefore, the PCS must be scaled with an F-TRAN algorithm that uses 16.38 to convert from the input value read to GPM. Every 16.38 value change at the PCS = 1

GPM flow.

Example 3: A 0-5 V sensing device is used to measure a signal that is 0 to 200 GPM (gallons per minute) and the input analog module is 0-5 V.

Sensor Module PCS Value

5 V max.

5 V max.

3276

1 V 1 V

0 V min.

0 V min.

0

-819

Comments

The PCS range is -819 to 3276, which is equivalent to

0 to 4095. It is scaled with 4095/200 = 20.475. Therefore, the PCS must be scaled with an F-TRAN algorithm that uses 20.475 to convert from the input value read to GPM.

Every 20.475 value change at the PCS = 1 GPM flow.

5-14

OPTO

Section 5. OPTO 22 Mode

5.9 SET-UP PROCEDURE

The OPTOMUX documentation must be referenced to install and configure the OPTOMUX boards.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. Figure 5-6 provides an illustration of the RS-485 four wire-to-OPTOMUX board connection.

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the module assignments for the OPTOMUX board(s) according to the conventions described in Figures 5-3 and 5-4.

6. At the PCS configure all of the appropriate DDI channel datapoints set by the user as follows:

APB Setup Bytes for OPTOMUX (Table 5-1)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the OPTOMUX board(s).

Set-Up (B293, B459) - Data format transfer protocol is set to match the OPTOMUX boards.

OPTOMUX PLC Control and Status Bytes (Table 5-2)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

OPTOMUX Digital I/O Control Bytes (Table 5-3)

Communication Mode (B664, B640) - It is determined by the module population

(e.g, output modules and/or input modules).

Enter the quantity as determined from step 5 for the following datapoints:

Number of Contiguous Active Boards 00-15 (B665, B641).

Number of Contiguous Active Boards 16-31 (B666, B642).

Number of Contiguous Output Modules for Even Board Addresses 00-15

(B667, B643).

Number of Contiguous Output Modules for Odd Board Addresses 00-15

(B668, B644).

Number of Contiguous Output Modules for Even Board Addresses 16-31

(B669, B645).

Number of Contiguous Output Modules for Odd Board Addresses 16-31

(B670, B646).

Watchdog Delay Board Addresses 00-15 (B671, B647) - Enter the appropriate code 0-7.

Watchdog Delay Board Addresses 16-31 (B672, B648) - Enter the appropriate code 0-7.

OPTOMUX Analog I/O Control Bytes (Table 5-4)

Watchdog Delay Board Addresses 32-39 (B671, B647) - Enter the appropriate code 0-7.

Communication Mode (B674, B650) - It is determined by the module population

(e.g, output modules and/or input modules).

Enter the quantity as determined from step 5 for the following datapoints:

Number of Contiguous Active Boards 32-39 (B675, B651).

Number of Analog Modules on Analog Boards (B676, B652).

Number of Contiguous Analog Outputs (B677, B653).

OPTO

5-15

53MC9015 53MC5000 PLC and Printer Interfaces

Read Analog Command (B678, B654) - Enter the ASCII code for the type of analog reads to be performed.

Enter the code as determined from step 5 for the following two datapoints:

Analog Input Type for Board Addresses 32, 33, 36, 37 (B679, B655).

Analog Input Type for Board Addresses 34, 35, 38, 39 (B680, B656).

Samples to Average (Read Input Average Data command) (B681, B657) - 0 disables sampling. It affects all analog inputs. Enter the appropriate number.

APB Setup Bytes for OPTOMUX (Table 5-1)

Mode (B290, B456) - Enter a 2 to start the OPTOMUX interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-station board activity.

OPTO 22 Brain Boards

The XMT and RCV LEDs flash on all of the selected OPTO brain boards.

5-16

OPTO

Section 5. OPTO 22 Mode

5.10 FAULT ISOLATION AIDS

Table 5-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 5-5. Fault Isolation Aids

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

PCS Setup Error 2 (Table 5-2) - Bad B Value. Setup Error 10 - Scan Time at 0. PCS APB Setup bytes (Table 5-1) - Baud Rate and Set-Up should agree with the communication setup of the

OPTOMUX board(s).

Scan Overrun Counter (Table 5-2 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Communications errors that occur during the Initialization sequence cause the PCS to cycle in the

Initialization sequence until the cause of the error is rectified. For checksum (Block Check

Character [BCC]) and bad message errors, the PCS does not use the data but will try again, for example: if a checksum error occurs during the read, the PCS will perform the write in that Scan

Time and attempt another read the next Scan Time. If there are five consecutive read errors or five consecutive write errors, the PCS will enter the Initialization sequence.

See Table 5-2, Communication Error Code (B682, B658) for error codes.

See Table 5-2, Communications Error Count (B683, B659) for the running total of communications errors.

See Table 5-2, First Bad Board Address (B687, B663) for the address of the first OPTOMUX board accessed when the error occurred.

Reconfigure to a smaller system to eliminate the suspect OPTOMUX board.

Check custom cable between the RS-232/485 ITB and the OPTOMUX board.

(See Figure 5-6).

Possible OPTO-22 Problems

See Table 5-2, Communications Error Code (B682, B658) for OPTOMUX error codes 240-247

(00-07 in OPTOMUX documentation). Ensure OPTOMUX brain board jumper settings are correct. Brain board may be mis-wired or failing. Verify with OPTOMUX documentation.

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. (Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-OPTOMUX board transactions attempted with timeout errors.)

OPTO

5-17

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

5-18

OPTO

Section 6. MODBUS RTU Mode

6.0 MODBUS RTU MODE

6.1 PURPOSE

The Modbus Remote Terminal Unit (RTU) interface application permits data transfers between the

Process Control Station (PCS) and an addressed Modbus Programmable Logic Controller (PLC).

The Modbus RTU binary protocol, with a given command set for initialization, write, read, and diagnostics is supported by the PCS. All of the Modbus command messages are followed by a Longitudinal Redundancy Check (LRC). The PCS can operate as a Modbus master or a slave. PCS

Modbus master operation is described first in this section followed by PCS Modbus slave operation.

6.2 INSTALLATION CONFIGURATIONS

Typical point-to-point and multidrop Modbus installation configurations are illustrated in Figures 6-1 and 6-2 respectively. In the multidrop configuration, communication is bidirectional with one node; however, the read and write functions can be separated across two PLCs if necessary.

53MC5000

PCS

MASTER

RS-232/485

ITB

MODBUS

PLC

PCS Modbus Master Point-to-Point Installation

53MC5000

PCS

SLAVE

RS-232/485

ITB

MODBUS

HOST

PCS Modbus Slave Point-to-Point Installation

Figure 6-1. Typical Modbus Point-to-Point Installations

MODBUS2

53MC5000

PCS

MASTER

RS-232/485

ITB

RS-485

MODBUS

PLC

(TO BE READ)

MODBUS

PLC

(TO BE WRITTEN)

Multidrop

Figure 6-2. Typical Modbus Master Multidrop Installation

6-1

53MC9015 53MC5000 PLC and Printer Interfaces

6.3 RS-232/485 ITB-PLC CABLES

A custom RS-232 cable is required for point-to-point connection from the RS-232/485 ITB J1 to the

PLC. The recommended cable for this PLC application is illustrated in Figure 6-3. In the figure, one end of the cable has a nine pin male plug that connects to J1 of the RS-232/485 ITB and the other end has a 25 pin male or female plug as required by the PLC.

RS-232/485 ITB, J1

(FEMALE DB-9

CABLE END)

MODBUS PLC

(MALE/FEMALE, DB-25

CABLE END)

(MODEL 884

MODBUS PLC)

RxD (IN)

TxD (OUT)

GND

2

3

5

7

8

2 TxD

3 RxD

7 GND

4 RTS

5 CTS

6 DSR

20 DTR

(USED WITH MODBUS POINT-TO-POINT INSTALLATIONS)

Figure 6-3. RS-232/485 ITB J1 to Modbus PLC Cable

For multidrop installations, the standard four wire bundle with shield is used to connect TB2 of the

RS-232/485 board to the Modbus PLC RS-422 input. The TB2 lug connections are illustrated in

Figure 6-4. The maximum cable length for RS-485 (422) is 4000 feet (1219 m).

RS-232/485 ITB TB2

CONNECTION

RECEIVE (R-)

RECEIVE (R+)

TRANSMIT (T-) 3

TRANSMIT (T+) 4

SHIELD 5

1

2

(USED WITH MODBUS MULTIDROP INSTALLATIONS)

MODBUS

CONNECTION

TRANSMIT (T-)

TRANSMIT (T+)

RECEIVE (R-)

RECEIVE (R+)

GROUND

Figure 6-4. RS-232/485 ITB TB2 to Modbus PLC Cable

6-2

MODBUS2

Section 6. MODBUS RTU Mode

6.4 PCS MODBUS MASTER OPERATION

In Modbus master operation, the PCS initiates the read and write commands to the PLC.

6.4.1 PCS MODBUS MASTER MEMORY MAP

The DDI-A and DDI-B PCS memory maps for Modbus master operation are laid out similar to those shown in Figures 3-1 and 3-2, except the L-values are stored on the byte boundary instead of a word boundary. The size of the memory is unchanged, but a minimum of one byte (8 L-values) is transferred even if only one L-value is used as an active indicator of a process event. Data transfers are similar to those shown in Figure 3-3 and described in Section 3.2. There is one exception and that is the last datapoint of the L-memory area (DDI-A - L2047, DDI-B - L1535), can be written as a single coil (bit) from the PCS to the PLC.

6.4.2 WRITING A SINGLE L-VALUE

Write Function Code 5 - Preset [Write] a Single Coil.

Writing a single L-value causes the last bit of the L-memory area (DDI-A - L2047, DDI-B - L1535) to be written to a single coil in the PLC.

6.4.3 READING A SINGLE L-BYTE

Read Function Code 1 - Read Coil Status, or Read Function Code 2 - Read Input Status.

A single byte of L-data read from the PLC appears at the top of the L-memory area (L1536 for DDI-

A; L1024 for DDI-B).

6.4.4 WRITING A SINGLE L-BYTE

Write Function Code 15 - Force [Write] Multiple Coils.

The last byte of the L-memory area is used to write to the PLC (L2040 of DDI-A; L1528 of DDI-B).

6.4.5 READING MULTIPLE L-VALUES

Read Function Code 1 - Read Coil Status, or Read Function Code 2 - Read Input Status.

When reading multiple L-values, whole bytes must be transferred from the PLC to the PCS. If the data must fall on byte boundaries in the PCS, then care should be taken in the choice of the PLC read memory address. The coil or status bit at this address will be the least significant bit of the first byte read into the PCS. All subsequent bytes will follow contiguously.

6.4.6 WRITING MULTIPLE L-VALUES

Write Function Code 15 - Force [Write] Multiple Coils.

When writing multiple L-values, data is sent from the PCS L-memory area to the PLC in whole bytes. If the data sent must be loaded into specific byte boundaries in the PLC, then care should be taken in the choice of the PLC write memory address. The coil or status bit at this address will be the least significant bit of the first byte written to the PLC. All subsequent bytes will follow contiguously.

6.4.7 READING C-VALUES

Read Function Code 3 - Read Holding Registers, or Read Function Code 4 - Read Input Registers.

Reading C-values causes the addressed information to be retrieved from the PLC memory at word boundaries. The requested information is sent to the PCS where the C-values are stored in the Cmemory area at word boundaries. Storage starts at the top of the PCS C-memory area and continues until the transfer is complete.

MODBUS2

6-3

53MC9015 53MC5000 PLC and Printer Interfaces

6.4.8 WRITING C-VALUES

Write Function Code 16 - Preset [Write] Multiple Holding Registers.)

Writing C-values causes the addressed information to be accessed from the PCS C-memory area at word boundaries. The information is accessed starting at n locations from the bottom of the Cstack, where n is the number of words to be transferred. The last word in the stack is the last word to be transferred. The accessed information is sent to the PLC where the C-values are stored in memory at word boundaries.

6.4.9 WRITING A SINGLE C-VALUE

Write Function Code 6 - Preset [Write] Single Holding Register.

A single C-value written from the PCS to the PLC causes information placed in the last word of the

C-memory area (C767 for DDI-A, C703 for DDI-B) to be sent to the PLC.

6.4.10 READING L- AND C-VALUES TOGETHER

Read Function Code 3 - Read Holding Registers, or Read Function Code 4 - Read Input Registers.

Because these commands are word oriented, only an even number of L-bytes can be transferred to the PCS. If an attempt is made to transfer an odd number of L-bytes, the next lower even number will be used. To facilitate transferring L- and C-values together, the requested L-bytes must first be moved by the user from the PLC L-value memory segment to the top of the C-value memory segment before all of data is sent to the PCS (see Figure 6-5). At the PCS the L-bytes are separated from the C-words before each data stream is stored into its respective memory area. The Lvalues are stored in the L-memory area on byte boundaries and the C-values are stored in the

C-memory area on word boundaries.

FUNCTION CODE 3 - READ HOLDING REGISTERS OR FUNCTION CODE 4 - READ INPUT REGISTERS

PCS DDI-A L-VALUES

LSB MSB LSB MSB

L1536

L1536+n

L2047

PCS DDI-A C-VALUES

C704

C704+n

C767

LSB MSB

4

3

EVEN NUMBER OF L-BYTES

PLC L-VALUES

LSB MSB LSB MSB

L0

2

1

Ln

NOT USED NOT USED

NOT USED NOT USED

PLC C-VALUES

L0

Ln

C0

Cn

NOT USED

NOT USED

LSB MSB

1. AN EVEN NUMBER OF L-VALUES ARE MOVED BY THE USER

TO THE TOP OF THE PLC C-VALUE MEMORY SEGMENT.

(NEXT LOWEST EVEN NUMBER IS USED AT THE PCS IF AN

ODD NUMBER OF L-VALUES ARE SPECIFIED.)

2 REQUESTED L-VALUES, FOLLOWED BY C-VALUES, ARE SENT

TO THE PCS.

3. AT THE PCS, THE L-VALUES ARE STORED IN THE L-MEMORY AREA.

4. AT THE PCS, THE C-VALUES ARE STORED IN THE C-MEMORY AREA.

Figure 6-5. Reading L- and C-Values

6-4

MODBUS2

Section 6. MODBUS RTU Mode

6.4.11 WRITING L- AND C-VALUES TOGETHER

Write Function Code 16 - Preset [Write] Multiple Holding Registers.

Because this command is word oriented, only an even number of L-bytes can be transferred to the

PLC. If an attempt is made to transfer an odd number of L-bytes, the next lower even number will be used. To facilitate transferring L- and C-values together, the L-bytes and C-words are first moved from the PCS to the PLC C-value memory segment. The L-values, which are at the top of the PLC C-value memory segment, must then be moved by the user to the L-value memory segment (see Figure 6-6). The L-values are stored in the PLC L-value memory segment and the C-values are stored in the C-value memory segment.

PCS DDI-A L-VALUES

LSB MSB LSB MSB

L1536

L2000

L2047

PCS DDI-A C-VALUES

C704

C764

FUNCTION CODE 16 - PRESET [WRITE] MULTIPLE HOLDING REGISTERS

1

EVEN NUMBER OF L-BYTES

3

4

C0

PLC L-VALUES

LSB MSB LSB MSB

L0

Ln

NOT USED NOT USED

NOT USED NOT USED

PLC C-VALUES

L0

Ln

2

C767

LSB MSB

Cn

NOT USED

LSB MSB

1. AN EVEN NUMBER OF L-VALUES ARE FETCHED FROM

THE BOTTOM OF THE PCS L-MEMORY AREA. (NEXT LOWEST EVEN

NUMBER IS USED AT PCS IF AN ODD NUMBER OF L-VALUES

ARE SPECIFIED.)

2. C-VALUES ARE FETCHED FROM THE BOTTOM OF THE PCS

C-MEMORY AREA.

3. THE L- AND C-VALUES ARE TRANSFERRED TO THE PLC

C-VALUE MEMORY SEGMENT.

4. AT THE PLC, USER MOVES L-VALUES FROM THE TOP OF

THE C-VALUE MEMORY SEGMENT TO THE L-VALUE MEMORY

SEGMENT.

Figure 6-6. Writing L- and C-Values

MODBUS2

6-5

53MC9015 53MC5000 PLC and Printer Interfaces

6.4.12 PCS MODBUS MASTER COMMANDS

The PCS Modbus RTU interface application uses Initialization, Read, and Write Modbus messages to communicate with the PLC. During InItialization, the PCS sends a Restart Communications Option function to the PLC. The Read Modbus message causes data (L-values, C-values, or L- and

C-values) to be sent from the Modbus PLC to the PCS master, and the Write Modbus message causes data (L-values, C-values, or L- and C-values) to be sent from the PCS master to the Modbus PLC. The Modbus command set that is used for the Modbus messages is listed in Table 6-1 as follows:

Table 6-1. PCS Modbus Master Commands

Function

Code

1

Data

Type

Title

L Read Coil [Output] Status

2

3

4

5

6

8

15

L Read Input Status

L and

C

L and

C

Read Holding Registers

Read Input Registers

L Preset [Write] a Single Coil

C Preset [Write] Single Holding

Register

N/A Loopback Diagnostic Test

L Force [Write] Multiple Coils

Description

1 of 2

This command obtains the current status

(ON/OFF states) of a group of logic coils (Lvalues).

This command obtains the current status

(ON/OFF states) of a group of discrete inputs

(L-values).

This command obtains the current binary value contained in one or more holding registers (Cvalues). It can also be used to obtain L-values stored in other PLC memory segments; however, those L-values must first be moved by the user into the lower memory addresses

(top) of the holding register memory segment before the L- and C-values are read from the memory.

This command obtains the current binary value contained in one or more input registers (Cvalues). It can also be used to obtain L-values stored in other PLC memory segments; however, those L-values must first be moved by the user into the lower memory addresses

(top) of the input register memory segment before the L- and C-values are read from the memory.

This command causes the last bit of the Lmemory area (DDI-A - L2047, DDI-B - L1535) to be written to a single coil in the PLC.

This command places a binary value into a holding register.

This command provides an assortment of

Diagnostic Code functions to help evaluate

Modbus communications processing. It is described in greater detail in Section 6.4.12.

This command forces a series of consecutive logic coils to specified ON or OFF states.

6-6

MODBUS2

Section 6. MODBUS RTU Mode

Table 6-1. PCS Modbus Master Commands

Function

Code

16

Data

Type

L and

C

Title

Preset [Write] Multiple

Registers

Description

2 of 2

This command places specific binary values into a series of consecutive holding registers.

It can also be used to write L-and C-values together to the PLC. The L- and C-values are first written to the PLC holding register memory segment. The L-values are written in first at the top of the holding register memory segment, followed by the C-values. The user must then move the L-values from the holding register memory segment to the appropriate Lvalue memory segment.

6.4.13 PCS MODBUS MASTER DIAGNOSTIC COMMAND

The Diagnostic command (Function Code 8) provides access to device diagnostic information and a loopback test that can be used to check the Modbus communications system. The command has sub-functions called Diagnostic Codes that specify the various types of diagnostic information being accessed, counters that are being cleared, or the loopback test. The appropriate Modbus documentation should be referenced to implement the various Diagnostic Codes of the Diagnostic command. It should also be referenced to determine the significance of the diagnostic information returned, as it might be register bit defined by PLC type (e.g., bit 9 set in the 484 Controller diagnostic register means ROM chip 0000-07FF failed the memory test). The Diagnostic codes are listed as follows:

Diagnostic Code

High Low

00 00

00

00

00

00

00

00

00

01

02

03

04

10

11

12

Sub-Function

Return Query Data

Restart Communications

Option

Return Diagnostic Register

Change Input Delimiter

Character

Force Slave to Listen Only

Mode (LOM)

Clear Counters and

Diagnostic Register

Return Bus Message Count

Return Bus CRC Error

Count

Diagnostic Code

High Low

00 13

00

00

00

14

15

16

Sub-Function

Return Bus Exception

Error Count

Return Slave Message

Count

Return Slave No

Response Count

Return Slave NAK Count

00

00

00

00

17

18

19

20

Return Slave Busy Count

Return Bus Character

Overrun Count

Return Overrun Error Count

Clear Overrun Error Count and Flag

MODBUS2

6-7

53MC9015 53MC5000 PLC and Printer Interfaces

The Diagnostic command is implemented at the PCS with the Modbus Write Control Bytes (see Table 6-5). The control bytes in the table that are necessary to initiate a Diagnostic command are the

PLC Address, Diagnostic Code Low, Diagnostic Code High, Diagnostic Reply Data Low, Diagnostic

Reply Data High, and Function Code. Diagnostic information is returned in control bytes Diagnostic Reply Data Low and Diagnostic Reply Data High. The PLC Address control byte contains the address of the Modbus PLC being queried by the Diagnostic command; the Diagnostic Code Low and

Diagnostic Code High control bytes specify the sub-function to be performed by the PLC; and the

Function Code control byte must be set to 8 to indicate Diagnostic command.

When the Diagnostic Loopback test is initiated from the PCS, the Function control byte has an 8 for Diagnostic command, the Diagnostic Code Low and Diagnostic Code High control bytes are 00

00 for Return Query Data and the PLC Address control byte contains the address of the PLC under test. Unless there is a Modbus communications malfunction, the PCS perpetually sends to the

PLC, and receives from it, two bytes that contain a decimal 170

10

( hexadecimal AA

16

). The 1 appears in the Diagnostic Reply Data High control byte and the 70 appears in the Diagnostic Reply

Data Low control byte.

6.4.14 PCS MODBUS MASTER CONTROL BYTES

The APB Setup Bytes, Control and Status Bytes, Read Control Bytes, and Write Control Bytes for

PCS Modbus master operation are presented in Tables 6-2 through 6-5. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.)

Table 6-2. APB Setup Bytes for PCS Modbus Master

Title Definition Set

By

DDI-A DDI-B

User B290 B456

Default

0 Mode

Baud

Rate

It designates the APB communications functionality as follows:

0 = Off, 3 = Modbus RTU Mode

This datapoint should be left at 0 and configured to a 3 after all of the other control bytes are configured because setting this datapoint causes the Modbus PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400, 9 = 28800, 8 = 14400, 7 = 19200,

6 = 9600, 5 = 4800, 4 = 2400, 3 = 1200,

2 = 600, 1 = 300, 0 = 110

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

User B292 B458

User B293 B459

0

0

6-8

MODBUS2

Section 6. MODBUS RTU Mode

Table 6-3. Control and Status Bytes for PCS Modbus Master

Title Definition

Setup

Error

Scan

Time

It indicates the following: 0 = No Error, 1 = L-bytes to read > 64, 2 = C-words to read > 64, 3 = L-bytes to write

> 64, 4 = C-words to write > 64, 5 = Invalid Function

Code, 6 = Write command 6 specifies more than 1 word of L or C data, 10 = Scan Time at 0. These error codes cause DDI channel operation to halt.

It is the PCS time period for the read and write phases of a PCS-PLC transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms. (See

Section 3.7.)

Scan

Overruns

Counter*

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Scan Time should be increased. (See Section 3.7.)

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B684 B660 Software

B685 B661 User

B686 B662 Software

Default

0

0

0

Table 6-4. Read Control Bytes for PCS Modbus Master

Title

PLC Address

1 of 2

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B664 B640 User

Default

0

0 Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

The two byte PLC memory starting address.

Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer, e.g., the PLC hexadecimal address 4180

16

would be entered as 65

10

in the high byte B666 [or

B642] and 128

10

in the low byte B665 [or

B641]. (See Appendix A for decimal conversions.)

Number of L-Bytes to

Read

Number of C-Words to Read

Function Code

The number of L-bytes that are to be accessed from the PLC.

The number of C-words that are to be accessed from the PLC.

It is the read command function code as follows:

1 = Read Output Status (L)

2 = Read Input Status (L)

3 = Read Holding Registers (C - PLC

registers may contain L-values.)

4 = Read Input Registers (C - PLC

registers may contain L-values.)

B665 B641 User

B666 B642 User

B667 B643 User

B668 B644 User

B669 B645 User

0

0

0

0

MODBUS2

6-9

53MC9015 53MC5000 PLC and Printer Interfaces

Table 6-4. Read Control Bytes for PCS Modbus Master

Title Definition

PLC Error Code*

(Exception Response

Code)

Communications

Error*

Exception Response Codes 1-7 can be sent from the PLC to the PCS master (see the

Modbus documentation for complete definitions.)

01 - Illegal Function: Does not exist as a

valid function code.

02 - Illegal Data Address: Not an allowable

address.

03 - Illegal Data Value: The fetch quantity

requested is not allowed.

04 - Failure In Associated Device: The

slave failed to respond to the message.

05 - Acknowledge: The slave has accepted

and is processing a long duration

command.

06 - Busy, Rejected Message: The slave is

busy processing a long duration com-

mand.

07 - NAK, Negative Acknowledgement: The

program function just requested can not

be performed.

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates unexpected data was found in the reply from the PLC. 252 and

251 = PCS hardware malfunction.

Error Count* This byte is a running total of the Exception

Response Codes and the Communication

Errors listed above.

*User can reset by writing zeros into the datapoints.

2 of 2

DDI-A DDI-B Set

By

B671 B647 Software

B672 B648 Software

B673 B649 Software

Default

0

0

0

6-10

MODBUS2

Section 6. MODBUS RTU Mode

Table 6-5. Write Control Bytes for PCS Modbus Master

Title

PLC Address

1 of 2

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B674 B650 User

Default

0

0 Starting PLC Memory

Address Low (or

Diagnostic Code Low)

Starting PLC Memory

Address High (or

Diagnostic Code

High)

Number of L-Words to Write (Diagnostic

Reply Data Low)

Number of C-Words to Write (Diagnostic

Reply Data High)

Function Code

PLC Error Code*

(Exception Response

Code)

The two byte PLC memory address that states where to start writing data into the

PLC memory. Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer

(see Table 6-4, Read Control Bytes for PCS

Modbus Master). For Diagnostic Command information, see Section 6.4.13.

The number of L-words that are to be written to the PLC. For Diagnostic

Command information, see Section 6.4.13.

The number of C-words that are to be written to the PLC. For Diagnostic

Command information, see Section 6.4.13.

It is the write command function code as follows:

6 = Preset Single Holding Register (C)

8 = Loopback Diagnostic (see Section

6.4.13)

15 = Force Multiple Coils (L)

16 = Preset Multiple Holding Registers

(PLC registers may contain L-values.)

Exception Response Codes 1-7 can be sent from the PLC to the PCS master (see the

Modbus documentation for complete definitions.)

01 - Illegal Function: Does not exist as a

valid function code.

02 - Illegal Data Address: Not an allowable

address.

03 - Illegal Data Value: The fetch quantity

requested is not allowed.

04 - Failure In Associated Device: The

slave failed to respond to the message.

05 - Acknowledge: The slave has accepted

and is processing a long duration

command.

06 - Busy, Rejected Message: The slave is

busy processing a long duration com-

mand.

07 - NAK, Negative Acknowledgement: The

program function just requested can not

be performed.

B675 B651 User

B676 B652 User

B677 B653 User

B678 B654 User

B679 B655 User

B681 B657 Software

0

0

0

0

0

MODBUS2

6-11

53MC9015 53MC5000 PLC and Printer Interfaces

Table 6-5. Write Control Bytes for PCS Modbus Master

Title Definition

Communications

Error*

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates unexpected data was found in the reply from the PLC. 252 and

251 = PCS hardware malfunction.

Error Count* This byte is a running total of the Exception

Response Codes and the Communication

Errors listed above.

*User can reset by writing zeros into the datapoints.

2 of 2

DDI-A DDI-B Set

By

B682 B658 Software

B683 B659 Software

Default

0

0

6.4.15 PCS MODBUS MASTER SET-UP PROCEDURE

The Modbus PLC documentation must be referenced to install and configure the PLC.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. This section provides an illustration of the required custom RS-232 cable if J1 of the ITB is to be connected to the PLC; otherwise, the standard RS-485 four wire bundle can be used if TB2 is to be connected to the PLC.

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the PLC memory map as determined from the quantity of L-bytes and C-words to be transferred between the PCS and PLC. The size and address locations of the PCS L- and Cmemory areas are defined in Section 3.1 and illustrated in Figures 3-1 and 3-2.

6. At the PCS, configure all of the appropriate DDI channel datapoints set by the user as follows:

PCS APB Setup Bytes (Table 6-2)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the PLC.

Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC.

PLC Control and Status Bytes (Table 6-3)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

PLC Read Control Bytes (Table 6-4)

PLC Address (B664, B640) - This is a decimal value of the PLC address.

Starting PLC Memory Address Low and High Bytes (B665, B641, B666, B642) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-bytes to Read (B667, B643) - Can not exceed 64.

Number of C-words to Read (B668, B644) - Can not exceed 64.

6-12

MODBUS2

Section 6. MODBUS RTU Mode

PLC Read Control Bytes (Table 6-4) (Cont)

Function Code (B669, B645) - This code defines the type of value to be read from the PLC (e.g., coil, status, holding register, input register)

PLC Write Control Bytes (Table 6-5)

PLC Address (B674, B650) - This is a decimal value of the PLC address.

Starting PLC Memory Address Low and High Bytes (B675, B651, B676, B652) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-bytes to Write (B677, B653) - Can not exceed 64.

Number of C-words to Write (B678, B654) - Can not exceed 64.

Function Code (B679, B655) - The destination code for coils or holding registers.

APB Setup Bytes (Table 6-2)

Mode (B290, B456) - 3 to start the Modbus RTU PLC interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-PLC activity.

6.4.16 PCS MODBUS MASTER FAULT ISOLATION AIDS

Table 6-6 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 6-6. PCS Modbus Master Fault Isolation Aids 1 of 2

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

Setup Errors 1 through 4 (Table 6-3) - Violating memory map restrictions. Setup Errors 5 and 6 =

Invalid Function Code and Bad Write Command. Setup Error 10 - Scan Time at 0. PCS APB

Setup bytes (Table 6-2) - Should agree with the communication setup of the PLC system.

Scan Overrun Counter (Table 6-3 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Proper cable fabrication between the RS-232/485 ITB and the PLC (Figures 6-2 and 6-3).

Communication Error and Error Count (Tables 6-4 and 6-5) - For checksum (Block Check

Character [BCC]) and bad message errors, the PCS does not use the data but will try again, for example: if a checksum error occurs during the read, the PCS will perform the write in that Scan

Time and attempt another read the next Scan Time. If there are five consecutive read errors or five consecutive write errors, the PCS causes a re-initialize sequence.

PCS Master only - Execute the Diagnostic command (Function code = 8) and the Return Query

Data Diagnostic Code 00 00 (Loopback Test) to test the communications link.

Possible PLC Problems

PLC Error Code and Error Count (Tables 6-4 and 6-5) - Reference the appropriate PLC documentation for the required action indicated by the returned Exception Response Code.

Execute the Diagnostic command (Function code = 8) and the Return Diagnostic Register

Diagnostic Code 00 02 to determine if there are any PLC hardware failures. Reference the PLC documentation for the Diagnostic Register error code bit assignments by product model.

MODBUS2

6-13

53MC9015 53MC5000 PLC and Printer Interfaces

Table 6-6. PCS Modbus Master Fault Isolation Aids 2 of 2

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-PLC transactions attempted with timeout errors.

A hung PLC can be cleared with the Diagnostic command (Function Code = 8) and the Restart

Communications Option Diagnostic Code 00 01.

6.5 PCS MODBUS SLAVE OPERATION

In Modbus slave operation, the PCS does not initiate any read or write commands, but only responds to commands it receives. PCS Modbus slave operation is defined as operating with zero Lbytes and C-words to read, and zero L-bytes and C-words to write.

6.5.1 PCS MODBUS SLAVE MEMORY MAP

The PCS Modbus slave memory map is the same for the DDI-A or DDI-B channels. It has an Lvalue range of L0000 - L2047 (2048 coils) and a C-value range of C000 - C767 (768 holding registers). It is unlike PCS master mode operation, which has dedicated L- and C-memory areas in memory that serve as transfer buffers to other PCS memory areas under F-TRAN control. The

PCS Modbus slave provides access to all of the L- and C-values (coils and holding registers); however, a single read of slave memory cannot exceed 512 L-values or 64 C-values. Access to all of the L- and C-values allows them to be altered by any unit functioning as a Modbus master; therefore, PCS control operation can be affected. Prudent judgement should be used when altering

PCS memory contents that have an affect on process control. A Modbus master can send data to a PCS slave so that it can be viewed on the status displays (status display information is provided in the PCS instruction bulletin referenced in the Preface of this manual). Also, it should be noted that the L- and C-memory areas of a DDI channel in Modbus master mode are open to changes from an external Modbus device functioning as a master if the other DDI channel is in Modbus slave mode (e.g., if DDI-A is functioning as a slave and DDI-B is functioning as a master, then the master device connected to DDI-A can send data that overwrites the memory areas used by DDI-

B).

6-14

MODBUS2

Section 6. MODBUS RTU Mode

6.5.2 PCS MODBUS SLAVE COMMANDS

The commands that the PCS Modbus slave responds to are listed in Table 6-7 as follows:

Table 6-7. PCS Modbus Slave Commands

Function

Code

1

Data

Type

Title

L Read Coil Status

3

5

6

8

15

16

C Read Holding Registers

L Force Single Coil

(for Slave Mode only)

C Preset [Write] Single Holding

Register

N/A Loopback Diagnostic Test

L Force [Write] Multiple Coils

C Preset [Write] Multiple

Registers

Description

This command causes the PCS to respond with consecutive variables in the range of L000 to L2047.

This command causes the PCS to respond with consecutive variables in the range of

C000 to C767.

This command sets the value of one PCS coil in the range of L000 to L2047.

This command sets the value of one PCS holding register in the range of C000 to C767.

Legal values are 16 bit unsigned integers (see

Section 3.5).

This command is used to check the communications link to the PCS Modbus

Slave. Four diagnostic codes are supported:

Diagnostic Code = 00, Return Query Data -

This command causes the PCS Modbus Slave to loopback received data.

Diagnostic Code = 01, Restart Communications Option - This command clears the listenonly mode.

Diagnostic Code = 02, Return Diagnostic

Register - This command returns zero data.

Diagnostic Code = 04, Force Listen Only Mode

This command disables outgoing responses from the PCS Modbus Slave.

This command allows the state of consecutive coils to be changed in the range of L000-L2047.

This command allows the values of consecutive holding registers to be changed in the range of C000 to C767. Legal values are 16 bit unsigned integers (see Section 3.5).

MODBUS2

6-15

53MC9015 53MC5000 PLC and Printer Interfaces

6.5.3 PCS MODBUS SLAVE CONTROL BYTES

The APB Setup Bytes, Control and Status Bytes, and applicable Error Code Bytes for Modbus slave operation are provided in Tables 6-8 through 6-10. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.)

Table 6-8. APB Setup Bytes for PCS Modbus Slave

Title Definition Set

By

DDI-A DDI-B

User B290 B456

Default

0 Mode

Baud

Rate

It designates the APB communications functionality as follows:

0 = Off, 3 = Modbus RTU Mode

This datapoint should be left at 0 and configured to a 3 after all of the other control bytes are configured because setting this datapoint causes the Modbus PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400, 9 = 28800, 8 = 14400, 7 = 19200,

6 = 9600, 5 = 4800, 4 = 2400, 3 = 1200,

2 = 600, 1 = 300, 0 = 110

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

3 = 7 bits, 1 stop bit, even parity

4 = 7 bits, 1 stop bit, odd parity

5 = 7 bits, 2 stop bits, no parity

User B292 B458

User B293 B459

0

0

Table 6-9. Control and Status Bytes for PCS Modbus Slave

Title Definition DDI-A DDI-B Set

By

B670 B646 User Self

Address

Setup

Error

It is the PCS slave address used to respond to all messages.

10 = Scan Time at 0.

Scan

Time

It is the PCS time period for the read and write phases of a PCS-PLC transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms. (See

Section 3.7.)

Scan

Overruns

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Counter* Scan Time should be increased. (See Section 3.7.)

*User can reset by writing zeros into the datapoints.

B684 B660 Software

B685 B661 User

B686 B662 Software

Default

0

0

0

0

6-16

MODBUS2

Section 6. MODBUS RTU Mode

Table 6-10. Error Code Bytes for PCS Modbus Slave

Title Definition

Exception Response

Code*

Communications

Error*

Exception Response Codes 1-3 are sent from the PCS slave to the Modbus master.

01 - Illegal Function: Does not exist as a

valid function code.

02 - Illegal Data Address: Not an allow-

able address for the specified slave

location (L address over L2047 or C

address over C767).

03 - Illegal Data Value: The data value is

not allowable in the slave (the fetch

quantity requested of a PCS slave

exceeded 512 L-values or 64

C- values).

0 = no errors. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253

= bad message - bad message indicates that errors were found in the predictable portion of the message from the master device. 252 and 251 = PCS hardware malfunction.

Error Count* This byte is a running total of the

Exception Response Codes and the

Communication Errors listed above.

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B671 B647 Software

B672 B648 Software

B673 B649 Software

Default

0

0

0

MODBUS2

6-17

53MC9015 53MC5000 PLC and Printer Interfaces

6.5.4 PCS MODBUS SLAVE SET-UP PROCEDURE

The Modbus PLC documentation must be referenced to install and configure the PLC.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. This section provides an illustration of the required custom RS-232 cable if J1 of the ITB is to be connected to the PLC; otherwise, the standard RS-485 four wire bundle can be used if TB2 is to be connected to the PLC.

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the PLC memory map as determined from the quantity of L-bytes and C-words to be transferred between the PCS and PLC. The size and address locations of the PCS L- and Cmemory areas are defined in Section 6.5.1.

6. At the PCS, configure all of the appropriate DDI channel datapoints set by the user as follows:

PCS APB Setup Bytes (Table 6-8)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the PLC.

Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC.

Self Address (B295, B461) - Use the assigned PCS slave address.

PLC Control and Status Bytes (Table 6-9)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

APB Setup Bytes (Table 6-8)

Mode (B290, B456) - 3 to start the Modbus RTU PLC interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-PLC activity.

6-18

MODBUS2

Section 6. MODBUS RTU Mode

6.5.5 PCS MODBUS SLAVE FAULT ISOLATION AIDS

Table 6-11 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 6-11. Modbus Slave Fault Isolation Aids

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

Setup Error 10 (Table 6-9) - Set Scan Time to non-zero value. PCS APB Setup bytes (Table 6-

8) - Should agree with the communication setup of the master device system.

Scan Overrun Counter (Table 6-9 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Proper cable fabrication between the RS-232/485 ITB and the master device (Figures 6-2 and 6-

3). Communication Error and Error Count (Table 6-10) - Execute the Diagnostic command

(Function code = 8) from the master device to the PCS Modbus slave to test the communications link.

Possible PLC Problems

Reference the appropriate PLC documentation for the required action.

Exception Response Codes 1-3 (Table 6-10) - Check Function, Data Address, and Data Values in master device commands being sent to PCS Modbus slave.

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and master device resulting from manual database alterations made at either device, or just no DDI channel activity. Active indicators on the RS-

232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-master device transactions attempted with timeout errors.

MODBUS2

6-19

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

6-20

MODBUS2

Section 7. Siemens S5 Mode

7.0 SIEMENS S5 MODE

7.1 PURPOSE

The Siemens interface application permits data transfers between the Process Control Station

(PCS) and a Siemens Programmable Logic Controller (PLC) via the 3964 protocol. The PCS supports the following commands for both read and write operations:

1. D - Data Block

2. A - Absolute Address

The PCS supports the following commands for read-only operations:

3. Z - Counter Locations

4. E - Input Bytes

5. A - Output Bytes

6. M - Flag Bytes

The Data Block and Absolute Address commands handle data in 16 bit words and can be used for

L- and/or C-type data. L-data quantities must be even numbers (odd numbers will be decremented by one). The Counter Locations command reads data in 16 bit words. The upper 6 bits are masked out and the resulting 10 bit words are handled as C-type data. The remaining three commands handled data in bytes and can only be used with L-type data.

The maximum data transfer in either direction is 128 bytes, which corresponds to 64 PCS L-bytes and 32 PCS C-words.

7.2 INSTALLATION CONFIGURATION

As shown in Figure 7-1, communication between the PCS and Siemens PLC is point-to-point.

53MC5000

PCS

RS-232/485

ITB

SIEMENS

PLC

COMPLEX

Figure 7-1. Point-to-Point Installation Configuration

7-1

SIEMENS

53MC9015 53MC5000 PLC and Printer Interfaces

7.3 RS-232/485 ITB-PLC CABLE

A custom RS-232 cable is required for connection from the RS-232/485 ITB J1 to the PLC. The recommended cable for this PLC application is illustrated in Figure 7-2. In the figure, one end of the cable has a 9 pin female connector for J1 of the RS-232/485 ITB and the other end has a 25 pin male or female plug as required by the PLC.

The typical maximum cable length for this RS-232 connection is 50 feet (15.2 m).

RS-232/485 ITB, J1

(FEMALE DB-9

CABLE END)

RxD (IN)

TxD (OUT)

GND

2

3

5

7

8

SIEMENS PLC

(MALE/FEMALE, DB-25

CABLE END) (MODELS

DL405 AND DL305

WITH DCU)

2 TxD (OUT)

3 RxD (IN)

7 GND

4 RTS

5 CTS

Figure 7-2. RS-232/485 ITB J1 to Siemens PLC Cable

7-2

SIEMENS

Section 7. Siemens S5 Mode

7.4 CONTROL BYTES FOR SIEMENS

The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write

Control Bytes are presented in Tables 7-1 through 7-4. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective (there is a 10 second interval between PCS checks for setup changes.)

Table 7-1. APB Setup Bytes for Siemens

Title Definition

Mode

Baud

Rate

It indicates the APB communications functionality as follows:

0 = Off, 4 = Siemens

This datapoint should be left at 0 and configured to a 4 after all of the other control bytes are configured because setting this datapoint causes the Siemens PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400, 9 = 28800, 8 = 14400, 7 = 19200,

6 = 9600, 5 = 4800, 4 = 2400, 3 = 1200, 2 = 600,

1 = 300, 0 = 110

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

Set

By

DDI-A DDI-B

User B290 B456

Default

0

User B292 B458

User B293 B459

0

0

Table 7-2. PLC Control and Status Bytes for Siemens

Title Definition

Setup

Error

It indicates the following: 0 = No Error; 1 = L-bytes to read > 64; 2 = C-words to read > 64; 3 = L-bytes to write

> 64; 4 = C-words to write > 64; 5 = Invalid Command

Code; 6 = Total bytes to read > 128 (command 1 or 2); 7

= Total bytes to write > 128 (command 1 or 2); 8 =

Specifying C-words in commands 3,4,5 or 6; 9 = L-type data specified for command 3; 10 = Scan Time at 0.

These error codes cause DDI channel operation to halt.

Scan

Time

It is the PCS time period for the read and write phases of a PCS-PLC transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms.

Scan

Overruns

Counter*

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Scan Time should be increased.

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B684 B660 Software

B685 B661 User

B686 B662 Software

Default

0

0

0

SIEMENS

7-3

53MC9015 53MC5000 PLC and Printer Interfaces

Table 7-3. Siemens PLC Read Control Bytes

Title Definition

1 of 2

DDI-A DDI-B Set

By

B665 B641 User

Default

0 Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

Number of L-Bytes to

Read

Number of C-Words to Read

Command Code

PLC Error Code*

Communications

Error Code*

The two byte PLC memory starting address.

For Command 1, the low byte is the Data

Word (DW) number and the high byte is the

Data Block (DB) number. For commands 2-

6, the high and low bytes form a 16 bit unsigned binary integer. For command 2, it is a PLC memory address. For commands

3-6, it is the number of the selected entity

(e.g., input byte 3 or flag byte 32). An example of both bytes functioning together as a 16 bit unsigned binary integer is as follows: the PLC hexadecimal address

4180

16

is entered as 65

10

in the high byte

B666 [or B642] and 128

10

in the low byte

B665 [or B641] because each byte requires a decimal number. (See Appendix A for decimal conversions.)

Count must not exceed 128 bytes total. For command codes 1 and 2, maximum count is: L = 64 bytes (512 contacts) and C = 32 words, or L = 0 bytes and C = 64 words.

For command code 3, maximum count is L

= 0 bytes and C = 64 words. For command codes 4 - 6, maximum count is: L = 64 bytes (512 contacts) and C words are not applicable.

It is the read command code as follows:

1 = D: DataBlock (word, L & C)

2 = S: Absolute Address (word, L & C)

3 = Z: Counter Locations (word, C only)

4 = E: Input Bytes (byte, L only)

5 = A: Output Bytes (byte, L only)

6 = M: Flag Bytes (byte, L only)

The PLC Error Codes are reported in decimal; however, they are listed in hexadecimal in the PLC manual. See the

Siemens PLC manual for the error code definitions.

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

B666 B642 User

B667 B643 User

B668 B644 User

B669 B645 User

B671 B647 N/A

B672 B648 Software

0

0

0

0

N/A

0

7-4

SIEMENS

Section 7. Siemens S5 Mode

Table 7-3. Siemens PLC Read Control Bytes

Title Definition

Error Count* This byte is a running total of PLC Error

Codes and non-zero Communications Error

Codes.

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B673 B649 Software

2 of 2

Default

0

Table 7-4. Siemens PLC Write Control Bytes

Title Definition

Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

The two byte PLC memory address that states where to start writing data into the

PLC memory. Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer.

(See Siemens Read Control Bytes for example.)

Number of L-Words to Write

Number of C-Words to Write

Count must not exceed 128 bytes total. For command codes 1 and 2, maximum count is: L = 64 bytes (512 contacts) and C = 32 words, or L = 0 bytes and C = 64 words.

Command Code

PLC Error Code*

It is the write command code as follows:

1 = D: DataBlock (word, L & C)

2 = S: Absolute Address (word, L & C)

The PLC Error Codes are reported in decimal; however, they are listed in hexadecimal in the PLC manual. See the

Siemens PLC manual for the error code definitions.

Communications

Error*

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

Error Count* This byte is a running total of PLC Error

Codes and non-zero Communications Error

Codes.

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B675 B651 User

B676 B652 User

B677 B653 User

B678 B654 User

B679 B655 User

B681 B657 N/A

B682 B658 Software

B683 B659 Software

Default

0

0

0

0

0

N/A

0

0

SIEMENS

7-5

53MC9015 53MC5000 PLC and Printer Interfaces

7.5 SET-UP PROCEDURE

The Siemens PLC documentation must be referenced to install and configure the PLC.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. Figure 7-2 in this section provides information to fabricate a custom RS-232 cable required to connect J1 of the ITB to the PLC.

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the PLC memory map as determined from the quantity of L-bytes and C-words to be transferred between the PCS and PLC. The size and address locations of the PCS L- and Cmemory areas are defined in paragraph 3.1 and illustrated in Figures 3-1 and 3-2.

6. At the PCS, configure all of the appropriate DDI channel datapoints set by the user as follows:

PCS APB Setup Bytes (Table 7-1)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the PLC.

Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC.

PLC Control and Status Bytes (Table 7-2)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

PLC Read (Fetch) Control Bytes (Table 7-3)

Starting PLC Memory Address Low and High Bytes (B665, B641, B666, B642) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-bytes to Read (B667, B643).

Number of C-words to Read (B668, B644).

Command Code (B669, B645)

PLC Write (Send) Control Bytes (Table 7-4)

Starting PLC Memory Address Low and High Bytes (B675, B651, B676, B652) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-bytes to Write (B677, B653).

Number of C-words to Write (B678, B654).

Command Code (B679, B655).

APB Setup Bytes (Table 7-1)

Mode (B290, B456) - 4 to start the Siemens PLC interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-PLC activity.

7-6

SIEMENS

Section 7. Siemens S5 Mode

7.6 FAULT ISOLATION AIDS

Table 7-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 7-5. Fault Isolation Aids

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

Setup Errors 1 through 4 (Table 7-2) - Violating memory map restrictions. Setup Errors 5 and 6 =

Invalid Function Code and Bad Write Command. Setup Error 10 = Scan Time at 0. PCS APB

Setup bytes (Table 7-1) - Should agree with the communication setup of the PLC system.

Scan Overrun Counter (Table 7-2 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Proper cable fabrication between the RS-232/485 ITB and the PLC (Figure 7-2).

Communication Error and Error Count (Tables 7-3 and 7-4) - For checksum (Block Check

Character [BCC]) and bad message errors, the PCS does not use the data but will try again, for example: if a checksum error occurs during the read, the PCS will perform the write in that Scan

Time and attempt another read the next Scan Time. If there are five consecutive read errors or five consecutive write errors, the PCS causes a re-initialize sequence.

Possible PLC Problems

PLC Error Code and Error Count (Tables 7-3 and 7-4) - Convert decimal PLC Error Code to hexadecimal using Appendix A and reference the Siemens PLC documentation for possible explanation.

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-PLC transactions attempted with timeout errors.

SIEMENS

7-7

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

7-8

SIEMENS

8.0 KOYO MODE

Section 8. Koyo Mode

8.1 PURPOSE

The Koyo interface application permits data transfers between the Process Control Station (PCS) and an addressed Koyo Programmable Logic Controller (PLC) or a Koyo vended PLC for companies such as General Electric, GE Fanuc, Texas Instruments, and Siemens (e.g., Series One ries One  PLUS, Series One Junior, Series 305, Series 405, SIMATIC

®

, Se-

SIMATIC

®

TI305 , and

TI405  PLCs). Data transfers are via the Koyo DirectNET communications protocol.

8.2 INSTALLATION CONFIGURATIONS

As shown in Figure 8-1, the PCS supports point-to-point and multidrop installation configurations.

In a multidrop configuration, communication with network PLCs is bidirectional with one node; however, the read and write functions can be separated across two PLCs if necessary. Communicating with other network PLCs requires reconfiguring the PCS with their network addresses.

53MC5000

PCS

53MC5000

PCS

MASTER

RS-232/485

ITB

KOYO

PLC

Point-to-Point

RS-485

RS-232/485

ITB

KOYO

PLC

(TO BE READ)

KOYO

PLC

(TO BE WRITTEN)

Multidrop

NOTE

WHEN KOYO PLCs ARE INSTALLED IN A MULTIDROP CONFIGURATION,

TB2 OF THE RS-232/485 BOARD MUST BE USED. TB-2 IS FOR THE

RS-485 (422) INTERFACE. ALL BUT THE DL240 KOYO PLC HAVE

MULTI-PIN D-CONNECTORS THAT SUPPORT BOTH RS-232 AND RS-422.

WHEN USING THE KOYO DL240 PLC, THE USER MUST SUPPLY

RS-232-TO-RS-422 CONVERTERS FOR EACH PLC ON THE NETWORK.

Figure 8-1. Installation Configurations

8-1

KOYO

53MC9015 53MC5000 PLC and Printer Interfaces

8.3 RS-232/485 ITB-PLC CABLES

For point-to-point installations, a custom RS-232 cable is required to connect the RS-232/485 ITB

J1 to the PLC. The required cable pin connections vary depending on the Koyo PLC model number. In Figure 8-2 only the RS-232/485 ITB J1 connector end is illustrated; because of the various

Koyo PLC model numbers, the PLC documentation should be referenced to determine the required connector type for that cable end. The typical maximum cable length for this RS-232 connection is

50 feet (15.2 m).

RS-232/485 ITB, J1

(FEMALE DB-9

CABLE END)

KOYO PLC

CABLE END

RxD (IN)

TxD (OUT)

GND

2

3

5

TxD

RxD

GND

7

8

(USED WITH KOYO POINT-TO-POINT INSTALLATIONS)

Figure 8-2. RS-232/485 ITB J1 to Koyo PLC Cable

For multidrop installations, the standard four wire bundle with shield is used to connect TB2 of the

RS-232/485 board to the Koyo PLC RS-422 input. The TB2 lug connections are illustrated in Figure 8-3. The maximum cable length for RS-485 (422) is 4000 feet (1219 m).

RS-232/485 ITB TB2

CONNECTION

MODBUS

CONNECTION

RECEIVE (R-) 1

RECEIVE (R+) 2

TRANSMIT (T-) 3

TRANSMIT (T+) 4

SHIELD 5

TRANSMIT (T-)

TRANSMIT (T+)

RECEIVE (R-)

RECEIVE (R+)

GROUND

(USED WITH KOYO MULTIDROP INSTALLATIONS)

Figure 8-3. RS-232/485 ITB TB2 to Koyo PLC Cable

8.4 PCS MEMORY MAP FOR KOYO OPERATING MODE

The DDI-A and DDI-B PCS memory maps shown in Figures 3-1 and 3-2 apply to Koyo operating mode; however, all data is transferred as 16 bit words. Each L- or C-word is a 16 bit unsigned integer. Data is accessed from the PCS memory on word boundaries. Only words are transferred even if a single datapoint L-value is to be written to the PLC. The transfer order for reads and writes is L-values first, followed by C-values.

8-2

KOYO

Section 8. Koyo Mode

8.5 KOYO HEADER BLOCK COMMAND BYTE

The two command codes that are used in the read/write byte of the Koyo DirectNET header block are 30 for read and 38 for write.

8.6 CONTROL BYTES FOR KOYO

The APB Setup Bytes, PLC Control and Status Bytes, PLC Read Control Bytes, and PLC Write

Control Bytes are presented in Tables 8-1 through 8-4. If any Control Byte is changed during operation, it takes up to 10 seconds to become effective. (There is a 10 second interval between PCS checks for setup changes.)

Table 8-1. APB Setup Bytes for Koyo

Title Definition

Mode

Baud

Rate

It indicates the APB communications functionality as follows:

0 = Off, 5 = Koyo

This datapoint should be left at 0 and configured to a 5 after all of the other control bytes are configured because setting this datapoint causes the Koyo PLC Interface functionality to start.

It designates the data transfer rate as follows:

10 = 38400, 9 = 28800, 8 = 14400, 7 = 19200,

6 = 9600, 5 = 4800, 4 = 2400, 3 = 1200, 2 = 600,

1 = 300, 0 = 110

Set-Up It designates the data format transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

Set

By

DDI-A DDI-B

User B290 B456

Default

0

User B292 B458

User B293 B459

0

0

Table 8-2. PLC Control and Status Bytes for Koyo

Title Definition

Setup

Error

It indicates the following: 0 = No Error, 1 = L-words to read > 32, 2 = C-words to read > 64, 3 = L-words to write > 32, 4 = C-words to write > 64, 5 = Memory type not 31, 10 = Scan Time at 0. These error codes cause

DDI channel operation to halt.

Scan

Time

It is the PCS time period for the read and write phases of a PCS-PLC transaction. It is entered as a number from 1 to 255 which represents 100 to 25,500 ms.

Scan

Overruns

Counter*

This counter is incremented each time the read-write phases exceed the specified Scan Time. It indicates the

Scan Time should be increased

*User can reset by writing zeros into the datapoints.

DDI-A DDI-B Set

By

B684 B660 Software

B685 B661 User

B686 B662 Software

Default

0

0

0

KOYO

8-3

53MC9015 53MC5000 PLC and Printer Interfaces

Table 8-3. Koyo PLC Read Control Bytes

Title

PLC Address

Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B664 B640 User

The two byte PLC memory starting address.

Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer, e.g., the PLC hexadecimal address 4180

16

would be entered as 65

10

in the high byte B666 [or

B642] and 128

10

in the low byte B665 [or

B641]. (See Appendix A for decimal conversions.)

B665 B641 User

B666 B642 User

B667 B643 User Number of L-Words to Read

Number of C-Words to Read

Memory Type

The number of L-words that are to be accessed from the PLC.

The number of C-words that are to be accessed from the PLC.

This byte must be a 31.

Communications

Error Code*

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

Error Count* This byte is a running total of the non-zero

Communications Error Codes

*User can reset by writing zeros into the datapoints.

B668

B669

B673

B644

B645

B649

User

User

B672 B648 Software

Software

Default

0

0

0

0

0

0

0

0

8-4

KOYO

Section 8. Koyo Mode

Table 8-4. Koyo PLC Write Control Bytes

Title

PLC Address

Starting PLC Memory

Address (Low)

Starting PLC Memory

Address (High)

Definition DDI-A DDI-B Set

By

It is the address of the PLC to be accessed. B674 B650 User

The two byte PLC memory address that states where to start writing data into the

PLC memory. Each byte is a decimal number; however, both bytes together function as a 16 bit unsigned binary integer

(see Koyo Read Control Bytes for example).

B675 B651 User

B676 B652 User

B677 B653 User Number of L-Words to Write

Number of C-Words to Write

Memory Type

The number of L-words that are to be written to the PLC.

The number of C-words that are to be written to the PLC.

This byte must be 31.

Communications

Error*

0 = no errors. 255 = timeout error - a timeout error indicates no response came back from the PLC. 254 = bad checksum

(CRC) - a bad checksum indicates even though the frame was formatted properly, the data can not be used. 253 = bad message - bad message indicates that errors were found in the predictable portion of the message from the PLC. 252 and 251

= PCS hardware malfunction.

Error Count* This byte is a running total of the non-zero

Communications Error Codes.

*User can reset by writing zeros into the datapoints.

B678

B679

B683

B654

B655

B659

User

User

B682 B658 Software

Software

Default

0

0

0

0

0

0

0

0

8.7 SET-UP PROCEDURE

The Koyo PLC documentation must be referenced to install and configure the PLC.

1. Reference the 53MC5000 Process Control Station book listed in the Preface to install the PCS.

2. See Section 2 of this book to mount the RS-232/485 ITB and cable connect it to the PCS.

3. See Figure 8-2 in this section to fabricate a custom RS-232 cable required to connect J1 to the

PLC or see Figure 8-3 in this section to fabricate a custom RS-485 (422) cable required to connect TB2 to the PLC.

4. See Section 2 of this book for the required power connections to the RS-232/485 ITB.

5. Define the PLC memory map as determined from the quantity of L-bytes and C-words to be transferred between the PCS and PLC. The size and address locations of the PCS L- and Cmemory areas are defined in Section 3.1 and illustrated in Figures 3-1 and 3-2.

KOYO

8-5

53MC9015 53MC5000 PLC and Printer Interfaces

6. At the PCS, configure all of the appropriate DDI channel datapoints set by the user as follows:

PCS APB Setup Bytes (Table 8-1)

Mode (B290, B456) - 0 (to ensure interface is off.)

Baud Rate (B292, B458) - Set to match the PLC.

Set-Up (B293, B459) - Data format transfer protocol is set to match the PLC.

PLC Control and Status Bytes (Table 8-2)

Scan Time (B685, B661) - See Section 3.7 to calculate the Scan Time.

PLC Read Control Bytes (Table 8-3)

PLC Address (B664, B640) - This is a decimal value of the PLC address.

Starting PLC Memory Address Low and High Bytes (B665, B641, B666, B642) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-words to Read (B667, B643) - Can not exceed 32.

Number of C-words to Read (B668, B644) - Can not exceed 64.

Memory Type (B669, B645) - This value must be 31.

PLC Write Control Bytes (Table 8-4)

PLC Address (B674, B650) - This is a decimal value of the PLC address.

Starting PLC Memory Address Low and High Bytes (B675, B651, B676, B652) - Also, see Section 3.4 to ensure these values are properly calculated.

Number of L-words to Write (B677, B653) - Can not exceed 32.

Number of C-words to Write (B678, B654) - Can not exceed 64.

Function Code (B679, B655) - The destination code for coils or holding registers.

APB Setup Bytes (Table 8-1)

Mode (B290, B456) - 5 to start the Koyo PLC interface protocol.

RS-232/485 ITB

XMT (CR13) and RCV (CR14) LEDs alternately blink whenever there is PCS-PLC activity.

8-6

KOYO

Section 8. Koyo Mode

8.8 FAULT ISOLATION AIDS

Table 8-5 summarizes information provided in this section and other sections of the book that can be referenced as an aid to fault isolation.

Table 8-5. Fault Isolation Aids

Environmental/Power

See Table 1-1 for RS-232/485 ITB environmental and power specifications; see 53MC5000 PCS

Instruction Bulletin for PCS environmental and power specifications.

PCS Setup Errors

Setup Errors 1 through 4 (Table 8-2) - Violating memory map restrictions. Setup Error 5 =

Memory type not 31. Setup Error 10 - Set Scan Time to non-zero value. PCS APB Setup bytes

(Table 8-1) - Should agree with the communication setup of the PLC system.

Scan Overrun Counter (Table 8-2 and Section 3.7) - Expand Scan Time if the count increases at an unacceptable rate.

Communications

Proper cable fabrication between the RS-232/485 ITB and the PLC (Figure 8-2 or 8-3).

Communication Error and Error Count (Tables 8-3 and 8-4) - For checksum (Block Check

Character [BCC]) and bad message errors, the PCS does not use the data but will try again, for example: if a checksum error occurs during the read, the PCS will perform the write in that Scan

Time and attempt another read the next Scan Time. If there are five consecutive read errors or five consecutive write errors, the PCS causes a re-initialize sequence.

Possible PLC Problems

Reference the Koyo PLC documentation for possible PLC problems.

RS-232/485 ITB Activity Indicators

Inactivity from the XMT (CR13) and RCV (CR14) LEDs could indicate line problems, a hung device, a misconfiguration between the PCS and PLC resulting from manual database alterations made at either device, or just no DDI channel activity. Active indicators on the RS-232/485 ITB do not necessarily mean error free operation, e.g., repeated PCS-PLC transactions attempted with timeout errors.

KOYO

8-7

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

8-8

KOYO

Section 9. Printer Interface

9.0 PRINTER INTERFACE

9.1 PURPOSE

When configured to printer interface mode, the DDI-A/B channel(s) can output serial data under control of the resident standard format datalog program or user generated free format datalog programs executing in the Process Control Station (PCS). The standard format datalog program generates datalog printout data streams and is the only PCS resident program designed to use the printer interface. It is assumed user generated free format datalog programs will require the printer interface to produce datalog printouts similar to the standard format datalog program. The information in this section is therefore presented within that context. This section contains information to connect a printer to the PCS RS-232/485 ITB, to printout a standard datalog, and examples of free format datalog printouts.

9.2 CABLE CONNECTIONS

The output of the DDI-A/B channel(s) is RS-485/422 serial data. In general these signals are converted to RS-232 serial data by the RS-232/485 ITB. As shown in Figure 9-1, PCS J5 connects to

J5 of an ITB for the DDI-A channel output, and PCS J9 connects to J4 of an ITB for DDI-B channel output. A user provided serial data cable is required that connects J1 of the ITB to a serial- to-parallel converter or directly to a serial printer. Pin designators for this cable are illustrated in Figure 9-1. Also, if the printer has a parallel interface, then a serial-to-parallel converter and a parallel cable must be provided by the user. The serial-to-parallel converter should have a minimum buffer size large enough for the datalog output (e.g., the standard datalog is 1000 characters and requires a serial-to-parallel converter with a minimum 1

Kbyte buffer).

9.3 DDI CHANNEL SETUP BYTES

The printer interface is a unidirectional communications channel. As such, any device connected to DDI-A or DDI-B when configured as a printer interface must be capable of operating at one of the baud rates and set-up values given in Table 9-1 below without requiring dataflow control.

Table 9-1. DDI Setup Bytes for Datalog

Title

Mode

Baud

Rate

Definition

0 = Off, 10 = Datalog

It designates the data transfer rate as follows:

10 = 38400 6 = 9600 2 = 600

9 = 28800 5 = 4800 1 = 300

8 = 14400 4 = 2400 0 = 110

7 = 19200 3 = 1200

Set-Up It designates the data transfer protocol as follows:

0 = 8 bits, 1 stop bit, no parity

1 = 8 bits, 1 stop bit, even parity

2 = 8 bits, 1 stop bit, odd parity

3 = 7 bits, 1 stop bit, even parity

4 = 7 bits, 1 stop bit, odd parity

5 = 7 bits, 2 stop bits, no parity

DDI-A DDI-B Default

B290 B456 0

B292 B458 0

B293 B459 0

9-1

PRINTER

53MC9015 53MC5000 PLC and Printer Interfaces

TO PARALLEL PRINTER

OR

PARALLEL

SERIAL-TO-

PARALLEL

CONVERTER

SERIAL

TO SERIAL PRINTER

SERIAL I/F RS-232/485 ITB J1

(FEMALE DB-9

CABLE END)

RxD 3 TxD

COM (GND) 5 GND

DDI-A

J1 J5

RS-232/485 ITB

686B720U01

J4

TB2

1 R-

2 R+

3 T-

4 T+

5 SH

TB1

1

2

TO PARALLEL PRINTER

OR

PARALLEL

SERIAL-TO-

PARALLEL

CONVERTER

SERIAL

TO SERIAL PRINTER

SERIAL I/F RS-232/485 ITB J1

(FEMALE DB-9

CABLE END)

RxD 3 TxD

COM (GND) 5 GND

DDI-B

J1 J5

RS-232/485 ITB

686B720U01

J4

TB2

1 R-

2 R+

3 T-

4 T+

5 SH

TB1

1

2

53MC5000

CONTROLLER

J8

J9

✉ ✉ ✉

TB3

J4

J5

J6

J7

16

17

18

19

20

21

22

8

9

10

11

12

13

14

15

TB1

1

2

3

4

5

6

7

TB2

✉ ✉ ✉ ✉ ✉

NOTE: ONE RS-232/485 ITB PER

DDI CHANNEL

Figure 9-1. DDI-A and DDI-B Printer Connections

9-2

PRINTER

Section 9. Printer Interface

9.4 STANDARD DATALOG

The standard datalog format allows up to 16 Status Display Module (SDT) datapoints and 24 Parameter Module (PAR) datapoints to be logged. The number of SDT datapoints to be included in the datalog is specified by the value of datapoint B328 (maximum is 16, one for each SDT datapoint in the standard datalog). The number of PAR datapoints to be included in the datalog is specified by the value of datapoint B329 (maximum is 24, one for each datapoint pair). The selected SDT datapoints are configured by the user for status indicator display attributes and so are the selected PAR datapoints, which are configured to access the values from specified point locations.

The general format of the standard datalog is illustrated in Figure 9-2. It is divided into three sections: header, status block, and parameter block. The first line of the standard datalog has the header, which contains the Unit Tag Name, Time, and Date. The month for the date is entered as a numeric value from 1 to 12. The status block follows the header and it contains information derived from the SDT modules’ Name, State, Mode, and Alarm Enable values. Each line in this block contains up to four SDT entries which are allocated in the following order: SDT1.8 NAME, SDT1.7

NAME, . . . SDT0.1 NAME. The parameter block appears in the standard datalog after the status block. It contains information derived from the PAR modules. Each line in this block contains up to two PAR entries which are allocated as follows: PAR7.3 NAME, PAR7.3 DESIGNATOR,

PAR7.2 NAME, PAR7.2 DESIGNATOR, . . . PAR0.1 NAME, PAR0.1 DESIGNATOR.

The value configured into datapoint B330 selects the channel to which the standard datalog is directed. If a 4 is entered into datapoint B330, then the standard datalog is directed out of DDI-A. If a 3 is entered into datapoint B330, then the standard datalog is directed out of DDI-B.

Datapoints B328 through B330 can be summarized as follows:

Datapoint

B328

B329

B330

Standard Datalog Function

Determines the number of SDT datapoints presented in the datalog

(maximum is 16).

Determines the number of PAR datapoints (datapoint pairs) presented in the datalog (maximum is 24).

Determines the output channel: 4 = DDI-A, 3 = DDI-B.

A standard datalog configuration and printout example are given in Figure 9-3.

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53MC9015 53MC5000 PLC and Printer Interfaces

A008 - UNIT TAG NAME

A071 - SDT1 POINT 8

NAME

A067 - SDT1 POINT 4

NAME

A062 - SDT0 POINT 8

NAME

A058 - SDT0 POINT 4

NAME

A041 - PAR7 POINT 3

NAME

A039 - PAR7 POINT 1

NAME

A036 - PAR6 POINT 2

NAME

A033 - PAR5 POINT 3

NAME

A031 - PAR5 POINT 1

NAME

A028 - PAR4 POINT 2

NAME

A025 - PAR3 POINT 3

NAME

A023 - PAR3 POINT 1

NAME

A020 - PAR2 POINT 2

NAME

A017 - PAR1 POINT 3

NAME

A015 - PAR1 POINT 1

NAME

A012 - PAR0 POINT 2

NAME

B259:B258

HOURS:MINUTES

A070 - SDT1 POINT 7

NAME

A066 - SDT1 POINT 3

NAME

A061 - SDT0 POINT 7

NAME

A057 - SDT0 POINT 3

NAME

F107 - PAR7 POINT 3

DESIGNATOR

F105 - PAR7 POINT 1

DESIGNATOR

F103 - PAR6 POINT 2

DESIGNATOR

F101 - PAR5 POINT 3

DESIGNATOR

F099 - PAR5 POINT 1

DESIGNATOR

F097 - PAR4 POINT 2

DESIGNATOR

F095 - PAR3 POINT 3

DESIGNATOR

F093 - PAR3 POINT 1

DESIGNATOR

F091 - PAR2 POINT 2

DESIGNATOR

F089 - PAR1 POINT 3

DESIGNATOR

F087 - PAR1 POINT 1

DESIGNATOR

F085 - PAR0 POINT 2

DESIGNATOR

B260 - B261 - B262

DAY - MONTH - YEAR

A069 - SDT1 POINT 6

NAME

A065 - SDT1 POINT 2

NAME

A068 - SDT1 POINT 5

NAME

A064 - SDT1 POINT 1

NAME

A060 - SDT0 POINT 6

NAME

A059 - SDT0 POINT 5

NAME

A056 - SDT0 POINT 2

NAME

A040 - PAR7 POINT 2

NAME

A037 - PAR6 POINT 3

NAME

A035 - PAR6 POINT 1

NAME

A032 - PAR5 POINT 2

NAME

A029 - PAR4 POINT 3

NAME

A027 - PAR4 POINT 1

NAME

A024 - PAR3 POINT 2

NAME

A021 - PAR2 POINT 3

NAME

A019 - PAR2 POINT 1

NAME

A016 - PAR1 POINT 2

NAME

A013 - PAR0 POINT 3

NAME

A011 - PAR0 POINT 1

NAME

A055 - SDT0 POINT 1

NAME

F106 - PAR7 POINT 2

DESIGNATOR

F104 - PAR6 POINT 3

DESIGNATOR

F102 - PAR6 POINT 1

DESIGNATOR

F100 - PAR5 POINT 2

DESIGNATOR

F098 - PAR4 POINT 3

DESIGNATOR

F096 - PAR4 POINT 1

DESIGNATOR

F094 - PAR3 POINT 2

DESIGNATOR

F092 - PAR2 POINT 3

DESIGNATOR

F090 - PAR2 POINT 1

DESIGNATOR

F088 - PAR1 POINT 2

DESIGNATOR

F086 - PAR0 POINT 3

DESIGNATOR

F084 - PAR0 POINT 1

DESIGNATOR

VALUES PRINTED FOR A071 - A064 AND A062 - A055 ARE BASED ON THE MODE, ALARM ENABLE

AND STATE DATAPOINTS OF THE CORRESPONDING STATUS DISPLAY MODULE.

SDT

Mode

0

0

0

1

1

Alarm

Enable

0

1

1

0 or 1

0 or 1

SDT

State

0 or 1

1

0

0

1

SDT Characters

Printed

10

10

None

First 5

Second Five

Figure 9-2. Standard Datalog Datapoint Parameters

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Section 9. Printer Interface

CONFIGURATION:

B328 = 16 FOR 16 SDT DATAPOINTS AND B329 = 21 FOR 21 PAR DATAPOINT PAIRS

ALL SDT RELATED DATAPOINTS = 0 (MODE, ALARM ENABLE, AND STATE)

A008

PRINT DEMO

B259:B258

11:11

B260 - B261 - B262

28-9-94

A071

HOURLY REP

A067

(SPACE)

A070

ORT FOR FL

A066

(SPACE)

A069

OW AND TOT

A065

(SPACE)

A068

ALS

A064

(SPACE)

A062

LOCATION 5

A058

(SPACE)

A041

INPUT 0

A039

INPUT 1

A036

INPUT 2

A033

INPUT 3

A031

INPUT 4

A028

INPUT 5

A061

67 RATIO

A057

(SPACE)

F107

H000 (ANI0)

F105

H001 (ANI1)

F103

H002 (ANI2)

F101

H003 (ANI3)

F099

H004 (ANI4)

A060

LOADER

A056

(SPACE)

A040

TOTAL 0

A037

TOTAL 1

A035

TOTAL 2

A032

TOTAL 3

A029

TOTAL 4

A059

(SPACE)

A055

(SPACE)

F106

H032 (TOTALIZER 0)

F104

H033 (TOTALIZER 1)

F102

H034 (TOTALIZER 2)

F100

H035 (TOTALIZER 3)

F098

H036 (TOTALIZER 4)

A025

INPUT 6

A023

INPUT 7

A020

PLC IN0 (INPUT 0)

A017

HART 4

A015

(SPACE)

PRINTOUT:

F097

H005 (ANI5)

F095

H006 (ANI6)

F093

H007 (ANI7)

F091

C704

F089

C644

F087

A200 (

C

R

F

F

)

A027

TOTAL 5

F096

H037 (TOTALIZER 5)

A024

TOTAL 6

A021

TOTAL 7

A019

TOTAL

A016

TOTAL

F094

H038 (TOTALIZER 6)

F092

H039 (TOTALIZER 7)

F090

C440

F088

C441

NOTE: A200 CONTAINS CARRIAGE RETURN AND FORM

FEED CHARACTERS ENTERD AT FACEPLATE.

PRINT DEMO 11:11 28-9-94

HOURLY REPORT FOR FLOW AND TOTALS

LOCATION 567 RATIO LOADER

INPUT 0 119.734380 TOTAL 0 4887.00000

INPUT 1 20.0107430 TOTAL 1 1521.00000

INPUT 2 30.0009770 TOTAL 2 2272.00000

INPUT 3 40.0000000 TOTAL 3 3001.00000

INPUT 4 123.769990 TOTAL 4 44589.0000

INPUT 5 345.666990 TOTAL 5 237654.000

INPUT 6 476.779000 TOTAL 6 87531.0000

INPUT 7 17.4399990 TOTAL 7 23875.0000

PLC IN0 12345.0000 TOTAL 61725.0000

HART 4 2.00000000 TOTAL 45998.0000

Figure 9-3. Standard Datalog Example

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53MC9015 53MC5000 PLC and Printer Interfaces

9.4.1 STANDARD DATALOG DISPLAY

Standard display program 33 provides a convenient way for an operator to trigger the standard datalog via the faceplate push buttons. This display is invoked by either directly configuring datapoint B005 to a 33 or by adding a 33 to the display list. (Instructions to add a display to the display list are provided in Table 5-15, System and Miscellaneous Module of IB53MC5000, Revision 2,

PCS.) Once the standard datalog display is invoked, the standard datalog can be triggered by pressing the F3 push button. The word PRINTING appears on the display to indicate the data is being transmitted to the DDI-A/B output port. It should be noted that due to print data buffering, printer activity may continue beyond the PRINTING indication. Illustrations of the standard datalog display before and during a print operation are provided in Figure 9-4.

Figure 9-4. Standard Datalog Display (Display 33)

9.5 RUNNING DATALOGS IN THE BACKGROUND

The standard datalog and free format datalog can be triggered independent of the current display through a background operation. To enable background datalog operations datapoint B008

(BACK) must be set to a 2. After background datalogging is enabled, a standard datalog can be triggered by setting datapoint L073 (RUNLOG) to a 1 or a free format datalog can be triggered by setting L074 (RUNULOG) to a 1. (When the datalog is completed the respective datapoint must be reset by the program.) If both datalogs are triggered at the same time, the free format datalog will output first, followed by the standard datalog.

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Section 9. Printer Interface

9.5.1 TRIGGERING BACKGROUND DATALOGS FROM FCS

To trigger a standard datalog with datapoint L073 or a free format datalog with datapoint L074 from an FCS wirelist, configure either Parameter Loader A or B to pulse L073 [L074] to a 1. For example, to trigger the standard datalog when the CCI0 input goes from 0 to 1, a typical wirelist would be as follows:

B127 = 0

B128 = 96

B129 = 5

B130 = 0

B131 = x

B132 = 0

B133 = 71

CCI0 (L000) is wired to the A input of Logic A.

Logic B output (L096) is wired to the B input of Logic A.

Logic A FC = 5 (A AND NOT B).

CCI0 (L000) is wired to the A input of Logic B.

Logic B input B does not require a connection.

Logic B FC = 0 (A).

The A input of Parameter Loader A is wired to a permanent 1 (L071).

B134 = 97 The B input of Parameter Loader A is wired to the output (L097) of

Logic A.

B135 = 73 [or 74] The output of Parameter Loader A is wired to L073 (RUNLOG) or

L074 (RUNULOG).

9.5.2 TRIGGERING BACKGROUND DATALOGS FROM F-CIM

To trigger a standard datalog with datapoint L073 or a free format datalog with datapoint L074 from an F-CIM program, use a Write module to pulse L073 [L074] to a 1. For example, to trigger the standard datalog when the CCI0 input goes from 0 to 1, the following F-CIM section is required:

Step Function x+0 86 x+1 86 x+2 91 x+3 90 x+4 86 x+5 87

T Sn-1 A

R

R

Sx+2

L00

R x

R

R x Sx+0

L71

R x L73 [or

L74]

B

Sx+3

C Comments

Generate oneshot from CCI0 by ANDing CCI0 with last scan’s NOT CCI0.

Read in a 1.

Trigger datalog via oneshot.

9.5.3 TRIGGERING BACKGROUND DATALOGS FROM F-TRAN

To trigger a standard datalog with datapoint L073 or a free format datalog with datapoint L074 from an F-TRAN program, simply set L073 [L074] to a 1. For example, to trigger a user generated free format datalog when CCI0 goes from 0 to 1, the following F-TRAN instruction sequence could be used:

:

:

IF L000 L800 ! &

{

L74 = 1;

}

L800 = L000

:

:

\IF CCI0 0 TO 1 EDGE\

\TRIGGER THE USER DATALOG\

\ARM THE EDGE DETECTOR\

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53MC9015 53MC5000 PLC and Printer Interfaces

9.6 FREE FORMAT DATALOG

Although the DDI-A/B channel options each provide resident standard datalog capabilities and the standard datalog display, users can write F-TRAN programs to generate datalogs tailored to their needs. These user written datalogs are called free format datalogs. Like the standard datalog, free format datalogs can be triggered as a background operation or as part of a display program.

Before attempting to generate a free format datalog, the programmer must have a thorough understanding of F-TRAN programming operations and principles, as well as the controller database layout. This information is provided in instruction bulletins 53MC5000 Process Control Station,

53MC5000 Customization Guide, and 53HC3300 Custom Program Interface.

In general, free format programs are a series of PRINT commands which have been directed to a port device. In fact, creating free format datalogs as part of a user written display program requires selecting the character set that corresponds to the desired output, and PRINTing the character strings, print control characters, and datapoints required for the free format datalog. The output port is selected with the character set selector datapoint, B009 (CHRSEL). When B009 contains either an 8 or 9, all PRINT command output is directed to the DDI-B or DDI-A channels respectively.

Generating a free format datalog that will be triggered in the background, independent of the current display program, requires additional programming considerations:

• Datapoint B008 (BACK) must be set to a 2 to enable datalog background operation, and datapoint L074 (RUNULOG) must be set to a 1 to trigger the datalog. After the datalog operation is completed (and not before), L074 should be reset to 0 by the program.

• When L074 is set to a 1, the background program calls the subroutine G255; the free format datalog program should therefore be contained in, or called from, the G255 subroutine. This subroutine should not contain any code unrelated to the datalog operation.

• For compatibility with display programs, the value of B009 (CHRSEL) should appear to remain unchanged between the execution of display programs; this requires the value of B009 to be saved and restored around datalog PRINT operations.

Because the background and display programs execute at the same task level, to en- sure timely display refresh updates, a large free format datalog program may have to be partitioned into smaller code segments which are executed within a cases of structure controlled by a state variable.

Two free format datalog examples are provided in the sections that follow.

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Section 9. Printer Interface

#define CHRSEL

#define OLDCHR

#define DDIB

#define HOURS

#define MINUTES

#define SECONDS

#define DAY

#define MONTH

#define YEAR

#define BTCHNUM

#define RECNUM

#define ADD_A_TAR

#define ADD_B_TAR

#define MIXTIME

#define COOKTEMP

#define COOKTIME

#define COOLTEMP

#define COOLTIME

#define EMPTYTIME

#define ADD_A_ACT

#define ADD_B_ACT

#define LOGPRNT

#define BELL

#define HT

#define LF

#define FF

#define CR

#define SO

#define ON

#define OFF

1

0

\***** SAVE VALUE OF CHRSEL *****\

OLDCHR=CHRSEL

\***** PRINT DESTINATION *****\

CHRSEL=DDIB

\***** BATCH LOG TITLE *****\

PRINT ’SO’

PRINT "*********"

PRINT "BATCH REPO"

PRINT "RT"

PRINT "*********"

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

\***** BATCH REFERENCE NUMBER *****\

PRINT "BATCH NUMB"

PRINT "ER "

PRINT BTCHNUM

PRINT ’CR’

PRINT ’LF’

7

9

10

12

13

14

H092

H093

L074

C461

C463

C465

C466

C467

C101

C468

C469

B009

B467

8

B259

B258

B257

B260

B261

B262

B465

B466

9.6.1 FREE FORMAT DATALOG EXAMPLE 1

This is a free format datalog F-TRAN program for a batch report. The report output is illustrated in

Figure 9-5.

\***** BATCH COMPLETE TIME *****\

PRINT "TIME "

PRINT " "

PRINT HOURS

PRINT ":"

PRINT MINUTES

PRINT ":"

PRINT SECONDS

PRINT ’CR’

PRINT ’LF’

\***** BATCH COMPLETE DATE *****\

PRINT "DATE "

PRINT " "

PRINT DAY

PRINT "/"

PRINT MONTH

PRINT "/"

PRINT YEAR

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

\***** PRINT RECIPE NUMBER *****\

PRINT "RECIPE NUM"

PRINT "BER "

PRINT RECNUM

PRINT ’CR’

PRINT ’LF’

\***** PRINT PRODUCT NAME *****\

PRINT "PRODUCT NA"

PRINT "ME "

CASESOF RECNUM

CASE 1

{

PRINT "Secret For"

PRINT "mula 1"

}

CASE2

{

PRINT "Secret For"

PRINT "mula 2"

}

OTHERWISE

{

PRINT "Unknown Fo"

PRINT "rmula"

}

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

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53MC9015 53MC5000 PLC and Printer Interfaces

\***** PRINT MATERIALS HEADER *****\

PRINT "MATERIALS"

PRINT ’CR’

PRINT ’LF’

PRINT " "

PRINT " "

PRINT "TARGET "

PRINT " "

PRINT " "

PRINT "MEASURED"

PRINT ’CR’

PRINT ’LF’

\***** PRINT TOTAL ADDITIVE A *****\

PRINT "ADDITIVE A"

PRINT6 ADD_A_TAR

PRINT " "

PRINT " "

PRINT6 ADD_A_ACT

PRINT ’CR’

PRINT ’LF’

\***** PRINT TOTAL ADDITIVE B *****\

PRINT "ADDITIVE B"

PRINT6 ADD_B_TAR

PRINT " "

PRINT " "

PRINT6 ADD_B_ACT

PRINT ’CR’

PRINT ’LF’

\***** PRINT MIXING TIME *****\

PRINT "MIX TIME "

PRINT " "

PRINT6 MIXTIME

PRINT ’CR’

PRINT ’LF’

\***** PRINT COOK TEMPERATURE *****\

PRINT "COOK TEMP"

PRINT "ERATURE "

PRINT " "

PRINT6 COOKTEMP

PRINT ’CR’

PRINT ’LF’

\***** PRINT COOK TIME *****\

PRINT "COOK TIME "

PRINT " "

PRINT6 COOKTIME

PRINT ’CR’

PRINT ’LF’

\***** PRINT COOL DOWN TEMPERATURE *****\

PRINT "COOL TEMP"

PRINT "ERATURE "

PRINT " "

PRINT6 COOLTEMP

PRINT ’CR’

PRINT ’LF’

\***** PRINT COOL DOWN TIME *****\

PRINT "COOL TIME "

PRINT " "

PRINT6 COOLTIME

PRINT ’CR’

PRINT ’LF’

\***** PRINT TIME TO EMPTY REACTOR *****\

PRINT "EMPTY TIME "

PRINT " "

PRINT6 EMPTYTIME

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

\***** PRINT END OF BATCH REPORT MESSAGE *****\

PRINT " "

PRINT " "

PRINT "***** END "

PRINT "OF BATCH R"

PRINT "EPORT ****"

PRINT "*"

PRINT ’FF’

PRINT ’BELL’

\***** RETURN VALUE OF CHRSEL *****\

CHRSEL=OLDCHR

\***** TURN OFF LOG TRIP *****\

LOGPRNT=OFF

R

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Section 9. Printer Interface

* * * * * * * * * BATCH REPORT * * * * * * * * *

BATCH NUMBER 102

TIME 4: 37: 46

DATE 2/ 0/ 0

RECIPE NUMBER 0

PRODUCT NAME Unknown Formula

MATERIALS

TARGET MEASURED

ADDITIVE A 1000.0 CHANGE ME

ADDITIVE B 1000.0 CHANGE ME

MIX TIME 60.000

COOK TEMPERATURE 250.00

COOK TIME 120.00

COOL TEMPERATURE 0.0

COOL TIME 180.00

EMPTY TIME 90.000

***** END OF BATCH REPORT *****

Figure 9-5. Free Format Datalog Example 1

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53MC9015 53MC5000 PLC and Printer Interfaces

9.6.2 FREE FORMAT DATALOG EXAMPLE 2

This is a free format datalog F-TRAN program for an hourly report. The report output is illustrated in Figure 9-6.

#define CHRSEL

#define OLDCHR

#define DDIB

#define HOURS

#define MINUTES

#define SECONDS

#define DAY

#define MONTH

#define YEAR

#define VALUE_A

#define VALUE_B

#define VALUE_C

#define VALUE_D

B009

B464

8

B259

B258

B257

B260

B261

B262

H092

H093

H092

H093

PRINT SECONDS

PRINT ’CR’

PRINT ’LF’

\***** DATE *****\

PRINT "DATE "

PRINT " "

PRINT DAY

PRINT "/"

PRINT MONTH

PRINT "/"

PRINT YEAR

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

#define TEXT_A1

#define TEXT_A2

#define TEXT_B1

#define TEXT_B2

#define TEXT_C1

#define TEXT_C2

#define TEXT_D1

#define TEXT_D2

#define LEGEND1

#define LEGEND2

#define LOGPRNT

A200

A201

A202

A203

A204

A205

A206

A207

A208

A209

L074

\***** PRINT VALUE A *****\

PRINT TEXT_A1

PRINT TEXT_A2

PRINT6 VALUE_A

PRINT ’CR’

PRINT ’LF’

\***** PRINT VALUE B *****\

PRINT TEXT_B1

PRINT TEXT_B2

PRINT6 VALUE_B

PRINT ’CR’

PRINT ’LF’ #define BELL

#define HT

#define LF

#define FF

#define CR

#define SO

#define ON

#define OFF

7

9

10

12

13

14

1

0

\***** PRINT VALUE C *****\

PRINT TEXT_C1

PRINT TEXT_C2

PRINT6 VALUE_C

PRINT ’CR’

PRINT ’LF’

\***** SAVE VALUE OF CHRSEL *****\

OLDCHR=CHRSEL

\***** PRINT DESTINATION *****\

CHRSEL=DDIB

\***** PRINT VALUE D *****\

PRINT TEXT_D1

PRINT TEXT_D2

PRINT6 VALUE_D

PRINT ’CR’

PRINT ’LF’

\***** BATCH LOG TITLE *****\

PRINT ’SO’

PRINT "*********"

PRINT LEGEND1

PRINT LEGEND2

PRINT "*********"

PRINT ’CR’

PRINT ’LF’

PRINT ’LF’

\***** PRINT END OF BATCH REPORT MESSAGE *****\

PRINT " "

PRINT " "

PRINT "***** END "

PRINT "OF REPORT "

PRINT "*****"

PRINT ’FF’

PRINT ’BELL’

\***** RETURN VALUE OF CHRSEL *****\

CHRSEL=OLDCHR

\***** TIME *****\

PRINT "TIME "

PRINT " "

PRINT HOURS

PRINT ":"

PRINT MINUTES

PRINT ":"

\***** TURN OFF LOG TRIP *****\

LOGPRNT=OFF

R

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Section 9. Printer Interface

* * * * * * * * * HOURLY REPORT * * * * * * * * *

TIME 4: 37: 46

DATE 14/ 6/ 94

FLOW RATE A (GPM) 250.00

FLOW RATE B (GPM) 150.00

FLOW RATE C (GPM) 75.000

FLOW RATE D (GPM) 37.500

***** END OF REPORT *****

Figure 9-6. Free Format Datalog Example 2

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53MC9015 53MC5000 PLC and Printer Interfaces

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9-14

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Section 10. Parts Replacement

10.0 PARTS REPLACEMENT

10.1 PARTS REPLACEMENT

The parts replacement procedure to access the DDI-A and DDI-B APB boards is provided in Table

10-1; see Figure 10-1.

WARNING

ALWAYS REMOVE POWER BEFORE ATTEMPTING TO INSTALL,

DISASSEMBLE, OR SERVICE THE CONTROLLER. FAILURE TO

REMOVE POWER MAY RESULT IN SERIOUS PERSONAL INJURY

AND/OR EQUIPMENT DAMAGE.

Table 10-1. Parts Replacement 1 of 2

Step Procedure

1 Insert a small screwdriver into the notch at the top center of the front display panel (item 4).

2 Twist the screwdriver to release the latch and slide the bezel straight forward.

3 Disconnect the display ribbon cable (item 8) from its socket at the back of the panel.

4 Use the plastic front edge board ejector to pry the expansion board (item 7) free of its options connector board (item 6) socket.

5 Carefully slide the expansion board forward to access the ribbon cable (item 9) socket behind the option cards.

6 Disconnect the ribbon cable from J11 on the expansion board.

7 Continue to slide the expansion board from the cabinet.

8 Remove the two screws that secure the option card retaining bar to the expansion board brackets.

9 Grasp the suspect APB option card (item 11 or 12) at the edges and gently pull it free of its expansion board sockets (2 sockets). The option card may have to be rocked slightly top to bottom (not side to side).

10 To replace an option card: Note: Before installing the new APB card ensure jumpers J1 through J4 ( •—•) are set as shown below and illustrated in Figure 10-2:

J2 T- •—•

J1 R- •—•

J4 T+ •—•

J3 R+ •—•

(All of the jumpers are connected across the two pins in their own row and none of the jumpers are cross connected into each other’s row of pins.)

Align the new card pin edges with the expansion board sockets and gently push the card in until it is seated.

11 To install the option card retaining bar: Place the side of the retaining bar that has the foam tape against the edges of the option cards and align each end of the retaining bar to a bracket mounting hole. Install the two screws that secure the retaining bar to the end brackets.

12 To install the expansion board: Reconnect the expansion ribbon cable to the expansion board socket J11 and slide the board into the cabinet. Seat the board into its socket until the ejector latch engages the lock pins.

10-1

PARTS

53MC9015 53MC5000 PLC and Printer Interfaces

Table 10-1. Parts Replacement 2 of 2

Step Procedure

13 To install the front display panel: Reconnect the ribbon cable to the display J5 socket.

Insert the display bottom tabs into the cabinet notches and push the front of the display to latch it in place.

10.2 TECHNICAL ASSISTANCE

When replacing parts, should technical assistance be required, contact a MicroMod Automation Inc.

office.

NECESSARY ORDERING INFORMATION

When communicating with MMA for replacement of the main PCB, reference the unit’s serial number to ensure the correct replacement assembly is supplied. The necessary ordering information is provided on the instrument data tag and on the manufacturing specification sheet supplied with that particular controller.

In the event of a hardware malfunction, a replacement PCB can be quickly substituted for the defective assembly to minimize downtime. Contact MicroMod Automation Inc. for instructions before returning equipment. The defective PCB should be carefully packaged and returned, shipping charges prepaid, to the Repair Dept. Do not wrap PCBs in plastic, as it can cause static damage. It is suggested that the defective PCB be returned in the special bag in which the replacement module was supplied.

10.3 PARTS LIST

The parts list is provided in Table 10-2; see Figure 10-1.

Table 10-2. Parts List

Item Part Number

11 & 12 686B700U01

686B720U01

Description

Auxiliary Processor Board (APB)

RS-232/485 ITB

10-2

PARTS

Section 10. Parts Replacement

PARTS

10-3

53MC9015 53MC5000 PLC and Printer Interfaces

APB JUMPER CONFIGURATION FOR DDI-A

AND DDI-B PLC/PRINTER OPTIONS

J2 T

-

J1 R

-

J4 T+

J3 R+-

READING LINE 5 OF THE TABLE BELOW:

IF THE CONTROLLER WERE CONFIGURED WITH THE

PRINTER/PLC DDI-A OPTION AND MicroLink B

COMMUNICATIONS OPTION, THEN THE EXPANSION

BOARD WOULD HAVE AN APB OPTION CARD IN

SLOT 3, AN MLAC OPTION CARD IN SLOT 2, AND AN

MLBC OPTION CARD IN SLOT 1.

SD-53-2675

Printer/PLC

No

No

Option

DDI-A

No

DDI-B

No

No

No

16DI/DO or

6DI/4DO

DIDO

No

Yes

Yes

Micro-

Link B

MLBC

Yes

No

Yes

5

Expansion Board Slots

4

DIDO

DIDO

3 2

MLAC

MLAC

MLAC

1

MLBC

MLBC

Yes

Yes

No

No

No

No

Yes

Yes

No

No

No

Yes

No

Yes

No

No DIDO

APB

APB

MLAC

MLAC

MLAC

MLAC

MLBC

APB

APB

Yes Yes No No APB MLAC APB

Notes: DDI-A/B = Digital Device Interface-A/B, APB = Auxiliary Processor Board, DIDO = 16 Digital Input/Digital Output or 6 Digital Input/4 Digital Output Board, MLBC = MicroLink B Communications Board, MLAC = MicroLink A Communications Board (It is required if there is an MLBC Board.

It is assumed in the example that the PCS always has a minimum MicroLink A Communications option).

Figure 10-2. Auxiliary Processor Board (APB)

10-4

PARTS

Appendix A. Base 2/8/10/16 Table

APPENDIX A: BASE 2/8/10/16 TABLE

A numbering system is called a base. Numbers in the binary system are to the base 2; numbers in the octal system are to the base 8, etc. The base of a number is usually indicated as a subscript after the last digit of the number (e.g., 11010000

2

indicates this is an eight digit binary number and not a decimal number in the ten-millions).

Decimal-to-binary conversion is performed by subtracting the weights from the decimal number until 0 remains. A binary 1 digit is set for each position where the weight can be subtracted from the decimal number. For example, to convert 208

10

to binary: 208 - 128 = 80 (bit 2

16 (bit 2

2

3

6

= 1); 16 - 32 can not be performed (bit 2

through 2

0

5

= 0); 16 - 16 = 0 (bit 2

are 0. The binary number is 11010000

2

4

7

= 1); 80 - 64 =

= 1); all other digits

. This number can then be converted into an octal number by grouping the binary digits into three’s (11 010 000 = 320

8

) or a hexadecimal number by grouping the binary digits into four’s (1101 0000 = D0

16

).

Binary-to-decimal conversion is performed by adding the decimal weights of the binary 1 digits.

Using the same example as above, the binary number 11010000 has 2

7

, 2

6

, and 2

4 set to 1; therefore, the decimal weights of these three digits are added together to calculate the decimal equivalent: 128 + 64 + 16 = 208

10

. Octal or hexadecimal numbers can be converted into decimal numbers by first converting them into binary form. Each octal number requires three binary digits and each hexadecimal number requires four binary digits (320

8

= 11 010 000

2

; D0

16

=

1101 0000

2

). The binary string is then converted to a decimal number by adding the decimal weights of the binary 1 digits.

The above conversions can be summarized as follows:

Powers of 2:

11010000

2

= 320

8

= 208

10

= D0

16

2

7

2

6

2

5

2

4

2

3

2

2

2

1

2

Decimal Weights: 128 64 32 16 8 4 2 1

0

Highest Number: 1 1 1 1 1 1 1 1

2

= 255

10

for 8 binary digits

Binary Notation: 1 1 0 1 0 0 0 0

2

Octal = Groups of Three = 11 010 000

2

= 320

8

Hexadecimal = Groups of Four = 1101 0000

2

= D0

16

Decimal = Added Decimal Weights = 128 + 64 + 0 + 16 + 0 + 0 + 0 + 0 = 208

10

As a quick reference, Table A-1 is provided as a base 2/8/10/16 conversion table for numbers ranging from 0 to 255

10

.

A-1

APPENDIX

53MC9015 53MC5000 PLC and Printer Interfaces

5

6

3

4

1

2

8 10 16

0 0 0

1

2

1

2

3

4

5

6

5

6

3

4

7 7

10 8

11 9 9

12 10 A

7

8

13 11 B

14 12 C

15 13 D

16 14 E

17 15 F

20 16 10

21 17 11

22 18 12

23 19 13

24 20 14

25 21 15

26 22 16

27 23 17

30 24 18

31 25 19

32 26 1A

33 27 1B

34 28 1C

35 29 1D

36 30 1E

37 31 1F

40 32 20

41 33 21

42 34 22

43 35 23

44 36 24

45 37 25

46 38 26

47 39 27

50 40 28

51 41 29

52 42 2A

53 43 2B

54 44 2C

Table A-1. Base 2/8/10/16 Conversion Table

2

00000000

00000001

00000010

00000011

00000100

00000101

00000110

00000111

00001000

00001001

00001010

00001011

00001100

00001101

00011110

00011111

00100000

00100001

00100010

00100011

00100100

00100101

00100110

00100111

00101000

00101001

00101010

00101011

00101100

00001110

00001111

00010000

00010001

00010010

00010011

00010100

00010101

00010110

00010111

00011000

00011001

00011010

00011011

00011100

00011101

1 of 2

2

00101101

00101110

00101111

00110000

00110001

00110010

00110011

00110100

00110101

00110110

00110111

00111000

00111001

00111010

8 10 16 2 8 10 16

55 45 2D 01011010 132 90 5A

56 46 2E 01011011 133 91 5B

57 47 2F 01011100 134 92 5C

60 48 30 01011101 135 93 5D

61 49 31 01011110 136 94 5E

62 50 32 01011111 137 95 5F

63 51 33 01100000 140 96 60

64 52 34 01100001 141 97 61

65 53 35 01100010 142 98 62

66 54 36 01100011 143 99 63

67 55 37 01100100 144 100 64

70

71

72

56

57

58

38

39

3A

01100101

01100110

01100111

145 101

146 102

147 103

65

66

67

00111011

00111100

00111101

00111110

73 59 3B 01101000 150 104 68

74 60 3C 01101001 151 105 69

75 61 3D 01101010 152 106 6A

76 62 3E 01101011 153 107 6B

00111111 77 63 3F 01101100 154 108 6C

01000000 100 64 40 01101101 155 109 6D

01000001 101 65 41 01101110 156 110 6E

01000010 102 66 42 01101111 157 111 6F

01000011 103 67 43 01110000 160 112 70

01000100 104 68 44 01110001 161 113 71

01000101 105 69 45 01110010 162 114 72

01000110 106 70 46 01110011 163 115 73

01000111 107 71 47 01110100 164 116 74

01001000 110 72 48 01110101 165 117 75

01001001 111 73 49 01110110 166 118 76

01001010 112 74 4A 01110111 167 119 77

01001011 113 75 4B 01111000 170 120 78

01001100 114 76 4C 01111001 171 121 79

01001101 115 77 4D 01111010 172 122 7A

01001110 116 78 4E 01111011 173 123 7B

01001111 117 79 4F 01111100 174 124 7C

01010000 120 80 50 01111101 175 125 7D

01010001 121 81 51 01111110 176 126 7E

01010010 122 82 52 01111111 177 127 7F

01010011 123 83 53 10000000 200 128 80

01010100 124 84 54 10000001 201 129 81

01010101 125 85 55 10000010 202 130 82

01010110 126 86 56 10000110 203 131 83

01010111 127 87 57 10000100 204 132 84

01011000 130 88 58 10000101 205 133 85

01011001 131 89 59 10000110 206 134 86

A-2

APPENDIX

Appendix A. Base 2/8/10/16 Table

Table A-1. Base 2/8/10/16 Conversion Table

2 8 10 16

10000111 207 135 87

10001000 210 136 88

10001001 211 137 89

10001010 212 138 8A

10001011 213 139 8B

10001100 214 140 8C

10001101 215 141 8D

10001110 216 142 8E

10001111 217 143 8F

10010000 220 144 90

10010001 221 145 91

10010010 222 146 92

10010011 223 147 93

10010100 224 148 94

10010101 225 149 95

10010110 226 150 96

10010111 227 151 97

10011000 230 152 98

10011001 231 153 99

10011010 232 154 9A

10011011 233 155 9B

10011100 234 156 9C

10011101 235 157 9D

10011110 236 158 9E

10011111 237 159 9F

10100000 240 160 A0

10100001 241 161 A1

10100010 242 162 A2

10100011 243 163 A3

10100100 244 164 A4

10100101 245 165 A5

10100110 246 166 A6

10100111 247 167 A7

10101000 250 168 A8

10101001 251 169 A9

10101010 252 170 AA

10101011 253 171 AB

10101100 254 172 AC

10101101 255 173 AD

10101110 256 174 AE

10101111 257 175 AF

10110000 260 176 B0

10110001 261 177 B1

10110010 262 178 B2

10110011 263 179 B3

2 of 2

2 8 10 16 2 8 10 16

10110100 264 180 B4 11100001 341 225 E1

10110101 265 181 B5 11100010 342 226 E2

10110110 266 182 B6 11100011 343 227 E3

10110111 267 183 B7 11100100 344 228 E4

10111000 270 184 B8 11100101 345 229 E5

10111001 271 185 B9 11100110 346 230 E6

10111010 272 186 BA 11100111 347 231 E7

10111011 273 187 BB 11101000 350 232 E8

10111100 274 188 BC 11101001 351 233 E9

10111101 275 189 BD 11101010 352 234 EA

10111110 276 190 BE 11101011 353 235 EB

10111111 277 191 BF 11101100 354 236 EC

11000000 300 192 C0 11101101 355 237 ED

11000001 301 193 C1 11101110 356 238 EE

11000010 302 194 C2 11101111 357 239 EF

11000011 303 195 C3 11110000 360 240 F0

11000100 304 196 C4 11110001 361 241 F1

11000101 305 197 C5 11110010 362 242 F2

11000110 306 198 C6 11110011 363 243 F3

11000111 307 199 C7 11110100 364 244 F4

11001000 310 200 C8 11110101 365 245 F5

11001001 311 201 C9 11110110 366 246 F6

11001010 312 202 CA 11110111 367 247 F7

11001011 313 203 CB 11111000 370 248 F8

11001100 314 204 CC 11111001 371 249 F9

11001101 315 205 CD 11111010 372 250 FA

11001110 316 206 CE 11111011 373 251 FB

11001111 317 207 CF 11111100 374 252 FC

11010000 320 208 D0 11111101 375 253 FD

11010001 321 209 D1 11111110 376 254 FE

11010010 322 210 D2 11111111 377 255 FF

11010011 323 211 D3

11010100 324 212 D4

11010101 325 213 D5

11010110 326 214 D6

11010111 327 215 D7

11011000 330 216 D8

11011001 331 217 D9

11011010 332 218 DA

11011011 333 219 DB

11011100 334 220 DC

11011101 335 221 DD

11011110 336 222 DE

11011111 337 223 DF

11100000 340 224 E0

APPENDIX

A-3

53MC9015 53MC5000 PLC and Printer Interfaces

This page intentionally left blank.

A-4

APPENDIX

The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice, or to make engineering refinements that may not be reflected in this bulletin.

Micromod Automation assumes no responsibility for errors that may appear in this manual.

© 2004 MicroMod Automation, Inc. Printed in USA

MicroMod Automation, Inc.

75 Town Center Drive

Rochester, NY USA 14623

Tel. 585-321-9200

Fax 585-321-9291 www.micromodautomation.com

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