Smart3G – pn5732P Ethernet PLC User Guide

Smart3G – pn5732P Ethernet PLC User Guide
Smart3G – pn5732P
Ethernet PLC
User Guide
(Document Revision 1.4)
(Updated: April 04, 2016)
© 2016 Vital Systems Inc
Phoenix, AZ USA
For more information please visit the product web page:
www.vitalsystem.com/smart3g
Smart-3G User’s Guide
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Contents
Smart-3G - Ethernet Programmable Controller .........................................................................................................2
1. Module Description ................................................................................................................................................2
2. Electrical Specs .......................................................................................................................................................2
3. Operating Modes ....................................................................................................................................................3
3.1 Remote I/O controller Mode ............................................................................................................................3
3.2 Programmable Logic controller Mode..............................................................................................................3
4. Network Configuration and Protocols ....................................................................................................................4
4.1 IP Address .........................................................................................................................................................4
4.2 Ethernet/IP Protocol.........................................................................................................................................4
Input/Produce Message Format.........................................................................................................................4
Output/Consume Message Format ....................................................................................................................5
4.3 Modbus / TCP Protocol.....................................................................................................................................7
4.4 S3G-Master/Slave Protocol ..............................................................................................................................7
4.5 ProfiNET ............................................................................................................................................................8
Import XML Device Profile..................................................................................................................................8
Ethernet Configuration .......................................................................................................................................9
Real Time Settings ........................................................................................................................................... 10
I/O Data ........................................................................................................................................................... 10
5. Programming and Configuring Smart-3G Devices ............................................................................................... 11
7. Control Bit File ..................................................................................................................................................... 20
8. Smart-3G Network Topology Examples............................................................................................................... 21
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Smart-3G - Ethernet Programmable Controller
The Smart-3G - Ethernet Programmable Controller provides networked 24volts Digital I/O for MDR
Powered Roller Conveyor systems, as well as general purpose Fast Local/Remote Machine I/O. These
Devices are fully programmable for any type of control application, and can act as a programmable master
device, or a slaved Remote I/O device. The modules communicate over Ethernet to master or peer devices
using Ethernet/IP, Modbus/TCP and S3G-Master/Slave protocols. For MDR systems, interlocking messaging
bits e.g., upstream, downstream, merge, divert, etc are handled by the firmware for simplified Ladder Logic
Programming.
1. Module Description
Ethernet
Port 1
2. Electrical Specs
CPU Input Power
I/O Voltage
Total Max I/O Current
I/O Type
Output Current
Input Voltage Range
Input Threshold Voltage
Network
Ethernet Switch
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18-30Volt DC, 350mA
18-30Volt DC
8 Amps
PNP (Sourcing)
2 Amps Per Output
0…30Volts
4 Volts. (Logic Low: 0...4v, Logic High: 4.1v...30v)
Ethernet 100MB/S
2 Ports. (Always use Port 1 when single port is required)
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3. Operating Modes
The Smart-3G controller has two main operating modes:
 Remote I/O controller
 Programmable Logic Controller
3.1 Remote I/O controller Mode
Using the SuperLogic configuration window, if the Remote I/O check box is ON, the device allows an
external master to control the I/O directly over Ethernet. Any of the three protocols can be used to control
the I/O this way. This mode is active be default from factory. The controller does not execute any user
downloaded ladder logic program.
The CPU Led blinks in the following two patterns:
 When a Master Is Online:
One second On/Off cycle with 2% duty cycle. (very short blips)
 When Master Is Not Online:
One second On/Off cycle with 50% duty cycle
3.2 Programmable Logic controller Mode
If the Remote I/O check box is OFF, the device executes the downloaded user ladder logic program to
control the I/O. In this mode, any Master device can still connect to the device, but the outputs will remain
in the Ladder Logic program control. The master can write to Control Word file which the device can pick up
and take appropriate actions as defined by the user ladder logic program.
In this mode, the CPU Led blinks in the following patterns:
 Ladder Logic Run Mode: Heart-beat blink mode (blip-blip, blip-blip, blip-blip…)
 Ladder Logic Stopped: One second On/Off cycle with 50% duty cycle.
The ladder logic program controls the local I/O as well as access and control the I/O on remote Smart-3G
devices using the S3G-Master/Slave protocol. The remote I/O appears as local I/O and is accessed the same
way as the local I/O. You can control up to eight remote Smart-3G devices from a single master Smart-3G
device, providing a total of 72 inputs and 72 outputs.
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4. Network Configuration and Protocols
4.1 IP Address
The Device IP address is configured partly by the rotary switches and partly by the SuperLogic software
configuration window. The default IP address is set to 192.168.0.1. With the rotary switches, the address
range for the device is 192.168.0.1 thru 192.168.0.99. The first three digits of IP address can be changed
using the software configuration tool. In addition to the IP address, the default Gateway and Address Mask
can also be changed by the configuration software.
4.2 Ethernet/IP Protocol
Configuration Parameters
Device Type
Generic
Name
Any user defined name
Data Format
SINT (byte)
IP Addr
Device IP Address
Input
112, Size 12 Bytes (Produce Data)
Output
111, Size 8 Bytes (4 Bytes in case of RSLogix)
Config
113, Size 0
Input/Produce Message Format
Size: 12 Bytes (4 byte header and 8 byte data); Type: SINT(8bit)
Byte 0 = 1 Header 4 Bytes (always set to 1)
Byte 1 = 0
Byte 2 = 0
Byte 3 = 0
Byte 4 = Input States, 8 bits
Byte 5 = Output Enable Bit, 1 bit
Byte 6 = Output States, 8 bits
Byte 7 = 0
Byte 8, 9 = Contents of Control Word 1 (CW:1)
Byte 10, 11 = Contents of Control Word 2 (CW:2)
Data to Ethernet/IP Master is read from Smart-3G Internal control words file CW:1 and CW:2, 16bit integers.
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Output/Consume Message Format
Using Allen Bradley RSLogix:
Size: 4 Data Bytes
Type: SINT(8bit)
NOTE: Allen Bradley RSLogix does not use Header bits when mapping outputs, so output size should
be set to 4.
Byte 0, 1
Control Word 9 (or directly to the Output pins)
Byte 2, 3
Control Word 10
Data from Ethernet/IP Master controller is saved in CW:9 and CW:10 in Smart-3G internal control
words file.
If Remote I/O check-box is checked in SuperLogic configuration window, Byte 0 is mapped to outputs
for direct master PLC control:
Byte 0
Outputs 1…8 (bits 0...7 are mapped to Outputs 1…8).
Using 3GScan Software Library for Windows and Linux:
The output size is set to 8 bytes.
Byte 0 = 1
Byte 1 = 0
Byte 2 = 0
Byte 3 = 0
Header 4 Bytes (Always set to 1)
Byte 4, 5
Control Word 9 (or directly to Outputs)
Byte 6, 7
Control Word 10
If Remote I/O check-box is checked in SuperLogic configuration window, Byte 4 is mapped to outputs
for direct PC software control:
Byte 4
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Outputs 1…8 (bits 0...7 are mapped to Outputs 1…8).
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Ethernet/IP Configuration Example
Below is an example of a typical Ethernet/IP Master configuration using a 10ms polling interval and a 5
second connection timeout.
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4.3 Modbus / TCP Protocol
Modus/TCP protocol can read the entire Control Words file CW: 1…54 via Modbus Holding Registers.
Writes (or Output-Holding) are only allowed to Registers 9, 10, 23 and 24.
Modbus Slave address is ignored.
Reading Modbus Holding Register 1 through 54 will read Control Words 1 thru 54 in the card.
Writing to Modbus Holding Register 9 and 10 will write to Control Words 9 and 10 in the card. Can be used
for any general purpose.
The following special condition applies to Register 23 and 24:
Read Holding Reg 23 =
Read 8 Inputs (bits 0…7) and new barcode bit (bit 15)
Read Holding Reg 24 =
Read 8 Outputs (bits 0…7) and I/O Power State (bit 15)
Write Holding Reg 23 =
Write Holding Reg 24 =
Write to CW:23
Write to CW:24, or Write to output pins if Remote I/O Checkbox is on.
4.4 S3G-Master/Slave Protocol
The Smart-3G controller allows expanding the local I/O by using remote Smart-3G devices (configured as
Remote I/O). Up to eight slave Smart-3G cards can be scanned by the master, providing a total of 72 inputs
and 72 outputs. The ladder logic program controls the local I/O as well as access and control remote I/O of
Smart-3G devices using the S3G-Master/Slave protocol.
The remote Smart-3G devices must have their Remote I/O check box turned ON, so they do not run their
own ladder program. To enable scanning of remote Smart-3G device(s), enter the device id (last digit of the
IP address) in Control Words 41 thru 48 inside the ladder logic program. The default value is 0, which
disables the particular slot of the slave scanner.
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The remote I/O is accessed as follows:
Remote Device
Address Control Word
Input File
Output File
#1
41
IN: 9..16
OUT: 9..16
#2
42
IN:17..24
OUT:17..24
#3
43
IN:25..32
OUT:25..32
#4
44
IN:33..40
OUT:33..40
#5
45
IN:41..48
OUT:41..48
#6
46
IN:49..56
OUT:49..56
#7
47
IN:57..64
OUT:57..64
#8
48
IN:65..72
OUT:65..72
For example, to scan device at 192.168.0.88, copy 88 to CW:41. The I/O of device 88 will appear in
files IN:9..16 and OUT:9..16.
4.5 ProfiNET
Simatic TIA Setup for Siemens
Import XML Device Profile
The Smart3G ProfiNET Device Profile can be imported into a ProfiNET
project by selecting the XML device profile from Vital System Inc.
After successfully importing the Smart3G device profile, it should then be
available in the project’s Hardware Catalog.
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Ethernet Configuration for Profinet
The Smart3G IP address is always specified on the device itself depending on the rotary switch selection.
NOTE: The IP Address of the Smart3G device cannot be configured via ProfiNET. It can, however, be
configured from the Deploy3G or SuperLogic applications.
The Profinet device name must be set to the text “smart3g-xxx”, where “xxx” is the last octet of the IP
Address written in a 3-digit notation. This is also specified by the rotary switch selection.
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Real Time Settings
These settings control the Smart3G I/O polling rate, and the timeout duration. The polling rate can be set as
low as 4 millisecond.
Modules and I/O Data
Slot#
1
2
3
Subslot# Module
Description
1001
Digital I/O
Digital Inputs (1-byte or 8-bits)
Digital Outputs (1-byte or 8-bits)
1002
Status Bits
(16-bits); Bit0 = IO Power; Bit1 = RemoteIO; Bit2 = Run Mode;
1003
Control Bits
(16-bits); CB:1 – 6; 9 – 12; 14 – 15; 18 – 19;
1001
CW:01
Read-only Control Word (2-bytes or 16-bits)
1002
CW:02
Read-only Control Word (2-bytes or 16-bits)
1003
CW:03
Read-only Control Word (2-bytes or 16-bits)
1004
CW:04
Read-only Control Word (2-bytes or 16-bits)
1005
CW:25
Read-only Control Word (2-bytes or 16-bits)
1006
CW:26
Read-only Control Word (2-bytes or 16-bits)
1007
CW:27
Read-only Control Word (2-bytes or 16-bits)
1001
CW:09
Writable Control Word (2-bytes or 16-bits)
1002
CW:10
Writable Control Word (2-bytes or 16-bits)
1003
CW:28
Writable Control Word (2-bytes or 16-bits)
1004
CW:29
Writable Control Word (2-bytes or 16-bits)
1005
CW:30
Writable Control Word (2-bytes or 16-bits)
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SYCON Setup for Hilscher Profinet I/O Controller
1. Import the Smart3G XML Device Description.
2. Add the Hilscher Profinet I/O Controller on the main bus line. This can be found in the Device Catalog
under the “Master” section of “Profinet I/O”.
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3. Add the Smart3G as a Profinet I/O Device on the Hilscher Controller’s bus line. This can be found under
the “Slave” section of “Profinet I/O”. The Smart3G device can then be configured.
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4. In the Smart3G configuration, modules can be added or removed as necessary. Refer to the Profinet
Modules section for more information.
5. In the Hilscher Device Configuration, the firmware for “Profinet I/O Controller” will need to be
downloaded to the device. Click on “Download” to set the active firmware.
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6. After the successfully downloading the firmware, the Hilscher device will need to be set as the active
device from the “Device Assignment” section.
7. Configure the Network settings of the Hilscher Device. Ensure that the Profinet slaves and master are all
on the same network.
8. Set Process image storage format to Little Endian for compatibility with other applications. Also
Watchdog time can be set to a high value (~2000 millisec) to avoid false disconnects when scanning very
high number of devices.
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9. Set the Station Name for all Smart3G devices according to their set IP Address. See this section on how
to set the proper station name.
10. Set the IP Address for each Smart3G device to its set IP Address. Uncheck the “Inherit” setting to
prevent the Hilscher device from setting the Smart3G IP Address.
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11. Configure the “Update Time” which controls the data exchange interval, and the “Watchdog Time”
which controls the connection timeout.
12. After hitting “OK”, the configuration can then be downloaded to the Hilscher Device in order to initiate
the Profinet Network operation.
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5. Programming and Configuring Smart-3G Devices
The Programming and configuration of Smart-3G devices is accomplished by the SuperLogic and Deploy3G
PC software. SuperLogic software allows editing, downloading, monitoring/debugging of the ladder logic
program. The configuration window in this program allows editing the IP address and other parameters of
the device. Please refer to the SuperLogic Software manual for more detail.
Deploy3G PC software is used to commission large system with many Smart3G cards. It maintains a
database of ladder program and device configuration for the entire project.
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6. Control Word File
The Control Word file is a 16-bit integer file. The ladder logic program can read and write any Control
Word using the CW:n syntax, although some Control Words are read only as mentioned in the following
table. Device ID is the last digit of the IP address. Modbus/TCP can read any control word and
write is allowed to only certain control words. Ethernet/IP can read/write certain locations only.
File Index
Description
CW:1,2
Data is transmitted to master in Ethernet/IP or Profinet poll. Can be used to transmit status
info to master.
CW:3,4,5
Reserved
CW:6
Merge Device ID (Read Only)
CW:7
Divert 1 Device ID (Read Only)
CW:8
Divert 2 Device ID (Read Only)
CW:9, 10
Profinet, Ethernet/IP or Modbus/TCP – Data Write from Master
CW:11
Local Device ID
CW:12
Downstream Device ID
CW:13
Upstream Device ID
CW:14
Master/Slave Protocol Scan List Status. Bits 0…7 indicate online status for each device. Bits
8…15 indicate Output Power Status.
CW:15
User Defined. This value is read from the SuperLogic Zone Count configuration parameter.
(Read Only).
CW:16
Ladder Logic Transmit Message Destination Device ID
CW:17…22 Ladder Logic Transmit Message Data. Each control word can have value of 0 thru 255.
CW:23, 24
Special Definition for Modbus/TCP Holding Register
Read CW:23 = Read 8 Inputs (Bit 0..7) and new serial port data bit (Bit 15)
Read CW:24 = Read 8 Outputs (Bit 0..7) and Output Enable Bit (Bit 15)
Write CW:23 = Write to CW:23
Write CW:24 = Write to CW:24, or Write directly to output pins if Remote I/O Checkbox is
checked.
CW:25…30 Ladder Logic Receive Message Data. Each control word can have value of 0 thru 255.
CW:31…40 Serial Data Received from Serial Port. Must be terminated by carriage return or Line feed.
CW:41…48
Device IDs for remote (slave) Smart-3G controllers. Used to enable slave device scanning for
the S3G Master/Slave protocol. Value of 0 disables scanning.
CW:49..56
Input / Output data for slave devices for S3G protocol. Bit 0…7 are inputs and bits 8…15 are
outputs. This data is also accessible using the IN/OUT file, eg IN:55, OUT:71 etc.
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7. Control Bit File
The Control bit file is a binary file. This file is used to pass status and control data between the user
ladder logic program and the firmware. Some locations of this file are read only.
File Index
Description
CB:1
Package Arriving from Merge Branch. (Input, Read Only)
CB:2
Merge Ready Status to Branch (Output, Read / Write)
CB:3
Package Available for Divert Branch 1. (Output, Read / Write)
CB:4
Divert Branch 1 is Ready (Input, Read Only)
CB:5
Package Available for Divert Branch 2. (Output, Read / Write)
CB:6
Divert Branch 2 is Ready (Input, Read Only)
CB:7
FIFO is Empty (Read Only)
CB:8
FIFO is FULL (Read Only)
CB:9
Output Power On (Read Only)
CB:10
New Barcode Received (Read / Write)
CB:11
Package Available Status to Downstream main line (Output, Read / Write)
CB:12
Ready to Take Packages from Upstream main line (Output, Read / Write)
CB:13
Reserved
CB:14
Slug(0) or Singulation(1). Set in the SuperLogic PC Software Configuration screen. (Read Only
for Ladder program). This bit indicates how the packages are released. Implementation of
release mode is done by the user ladder program. If release mode selection is not supported
by the ladder program, this bit can be used for any other configuration selection.
CB:15
Barcode Overrun. This control bit activates when a new barcode is received while CB:10 is
still in the active state. In this case, the newly scanned barcode is ignored. CB:10 must be
deactivated in order to indicate that the current barcode scan may be overwritten with a
newer scan.
CB:16
Reserved
CB:17
Reserved
CB:18
Package Available from Upstream main line. (Input, Read Only)
CB:19
Downstream main line is ready to take packages. (Input, Read Only)
CB:20
ProfiNET Active. This control bit is activated when a ProfiNET connection is currently online
and actively transmitting I/O data.
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8. Smart-3G Network Topology Examples
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