GE Fanuc Series Six Plus Manual

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Programmable Control Products
Archive
Document
This electronic manual was created by scanning a
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character-recognition software.
Please be aware that this process may have
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use of a printed manual is recommended.
Series Six Plus
Programmable Logic Controller
User’s Manual
GEK-96602A
November 1987
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GFL-002
Warnings, Cautions, and Notes
as Used in this Publication
Warning notices are used in this publication to emphasize that
hazardous voltages, currents, temperatures, or other conditions that
could cause personal injury exist in this equipment or may be
associated with its use.
In situations where inattention could cause either personal injury or
damage to equipment, a Warning notice is used.
Caution notices are used where equipment might be damaged if care is
not taken.
Note
Notes merely call attention to information that is especially significant to
understanding and operating the equipment.
This document is based on information available at the time of its publication. While
efforts have been made to be accurate, the information contained herein does not
purport to cover all details or variations in hardware or software, nor to provide for
every possible contingency in connection with installation, operation, or maintenance.
Features may be described herein which are not present in all hardware and software
systems. GE Fanuc Automation assumes no obligation of notice to holders of this
document with respect to changes subsequently made.
GE Fanuc Automation makes no representation or warranty, expressed, implied, or
statutory with respect to, and assumes no responsibility for the accuracy, completeness,
sufficiency, or usefulness of the information contained herein. No warranties of
merchantability or fitness for purpose shall apply,
The following are trademarks of GE Fanuc Automation North America, Inc.
Alarm Master
CIMPLICITY
CIMPLICITY PowerTRAC
CIMPLICITY 90-ADS
CIMSTAR
Field Control
GEnet
Genius
Genius PowerTRAC
Helpmate
Logicmaster
Modelmaster
ProLoop
PROMACRO
Series Five
Series 90
Series One
Series Six
Series Three
VuMaster
Workmaster
*Copyright 1995 GE Fanuc Automation North America, Inc.
AI1 Rights Reserved
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...
iii
Preface
GEK-96602
PREFACE
This is the second edition of the Series Six’” Plus Programmable Logic Controller User’s
Manual. This manual provides the user with the information required to configure,
install, implement and maintain the Series Six’” Plus Programmable Logic Controller.
Chapter 1. Introduction to the Series Six Plus PLC. This chapter describes the features,
functions and specifications of the Series Six Plus PLC, along with information on
programming, communications options and optional peripheral equipment that can be
included as part of your Series Six Plus PLC system. A cross reference guide is included
listing the compatibility of the Series Six Plus PLC vs the previously available Series Six
family of PLCs.
Chapter 2. Physicaf Equipment Configuration. This chapter describes the hardware
components included in a Series Six Plus PLC system. The CPU rack configuration is
such that it contains all of the necessary modules for a complete PLC system, including
communications options, with up to 6 slots for I/O modules in the rack. All of the system
interface modules required when adding I/O racks to contain up to the maximum of 32 K
of I/O (16K Inputs and l6K Outputs) are described. A description of the various available
communications options is included.
Chapter 3. Installation Instructions. This chapter contains installation specifications
and instructions required in order to configure, and rack, panel or walI mount and wire
your Series Six Plus Programmable Logic Controller system.
Chapter 4. Expanded CPU Operation. This chapter describes the Expanded functions and
Expanded mode of operation for the Series Six Plus Programmable Logic Controller.
Included is a description of how to configure the Expanded functions on the Workmaster
computer using Logicmaster 6 software. Also included in this chapter is information on
how to use the Genius I/O diagnostics with the Expanded functions in a Series Six Plus
Programmable Logic Controller.
This chapter provides the basic information
required to maintain your Series Six Plus Programmable Logic Controller system,
including the CPU and I/O system. The troubleshooting method described emphasizes a
logical approach to analyzing any faults and subsequent replacement of any failed
modules.
Chapter 5. Troubleshooting and Repair.
Appendix A. Glossary of Terms. This is a glossary of commonly used programmable
logic controller terminology to aid the user in understanding those unique terms.
A comprehensive index is provided as an aid to quickly finding a particular subject in this
manual.
Shoufd additional information be required, contact your GE Fanuc-NA Distributor, GE
Fanuc-NA salesperson or GE Fanuc Automation North America, Inc., P.O. Box 8106,
Charlottesville, Virginia, 22906.
Henry A. Konat
Senior Technical Writer
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iv
Preface
GEK-96602
RELATED PUBLICATIONS
For more information on subjects discussed in this manual, refer to these publications:
GEK-25361
Series Six
GEK-25365
Application Guide for the Series Six Programmable Controller, which
provides information on how to developement typical applications using a
PLC.
GEK-25364
Series Six Data Communications Manual, which describes the function and
operation of the Communications Control Modules (CCM).
GEK-25367
Series Six Data Sheet Manual, which contains technical descriptions,
Installation and Maintenance Manual, which describes the
earlier models of Series Six programmable logic Controllers.
specifications, and wiring information on available modules.
GEK-25368
Series Six Axis Positioning Module Type 1 Manual, which describes
installation, programming and application of the APM, Type 1.
GEK-25398
Series Six ASCII/BASIC Module Manual, which describes installation
programming and troubleshooting procedures for the ABM.
GEK-25373
WORKMASTER G u i d e t o O p e r a t i o n , which provides information for
configuration and installation of the Workmaster computer.
GEK-25379
Logicmaster 6 User’s Manual, which provides the information required to
program and document a Series Six Plus PLC.
GEK-90486
G enius
l/O S y s t e m U s e r ’ s M a n u a l , which provides configuration,
programming, operation, and troubleshooting information to aid in
implementing the Genius I/O system into a Series Six Plus PLC system.
GEK-90800
Series Six Axis Positioning Module Type II User’s Manual, which describes
installation, programming and application of the APM, Type 2.
GEK-90802
ProLoop Process Controllers, which contains the information required to
use t he family of ProLoop Process Controllers. Includes data on
stand-alone operation and the Loop Management Module, which interfaces
the process controllers to a Series Six Plus PLC system.
GEK-90817
Series Six Operator interface
Terminal User’s Manual, which describes the
configuration, installation, programming, and operation of the OIT for use
with a Series Six Plus PLC.
GEK-90820
VuMaster
Co/or G r a p h i c s T e r m i n a l , which describes the installation,
configuration, and operation of a color graphics system as an operator
interface for data collection and analysis.
GEK-90825
Series Six PC l/O link Local Module User’s Manual, which describes the
link between a Series Six Plus PLC and the I/O structure for the Series
One family and Series Three PLCs.
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FCC Note
V
GEK-96602
The Series Six Plus Programmable Logic Controller and its associated modules have been
tested and found to meet or exceed the requirements of FCC Rule, Part 15, Subpart J.
The FCC requires that the following note be published.
NOTE
This equipment generates, uses, and can radiate radio frequency energy and if
not installed and used in accordance with the instruction manual, may cause
interference to radio communications. It has been tested and found to comply
with the limits of a Class A computing device pursuant to Subpart J of Part 15
of FCC Rules, which are designed to provide reasonable protection against such
interference when operated in a commercial environment. Operation of this
equipment in a residential area is likely to cause interference, in which case
the user at his or her own expense will be required to take whatever measures
may be required to correct the interference.
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vii
Contents
GEK-96602
CONTENTS
CHAPTER f .
TITLE
PAGE
INTRODUCTION TO THE SERIES SIX PLUS
PROGRAMMABLE LOGIC CONTROLLER
1-1
What are Programmable Logic Controllers?
Advantages of Programmable Logic Controllers
Series Six Plus Programmable Logic Controller
features of the Series Six Plus PLC
General Specifications
Genius I/O System
Programming the Series Six Plus PLC
Workmaster Industrial Computer
Other Software Packages
Programming Language for the Series Six Plus PLC
Programmable Logic Controller Concepts
Function of the Central Processor Unit
Memory Types Used in the Series Six Plus PLC
Function of the Input/Output Circuitry
Optional Devices Supporting the Series Six Plus PLC
Redundant Processor Unit
Operator Interface Unit
Operator Interface Terminal
ProLoop Process Controllers
ASCII/BASIC Module
Axis Positioning Module
Communications Control Modules
GEnet Factory LAN
Series Six PLC Network Interface
Datagram Communications Service
Global Data Service
RS-232 to RS-422 Adaptor Unit
System Planning
Typical Applications Using PLCs
PLC Terminology
PLC Compatibility Guide
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CHAPTER 2. PHYSICAL EQUIPMENT CONFIGURATION
Product Structure for the Series Six Plus PLC
19 Inch CPU Rack Configuration
13 Inch CPU Rack Configuration
Basic Unit Configuration
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Contents
GEK-96602
CONTENTS
TITLE
CHAPTER 2.
PAGE
PHYSICAL EQUIPMENT CONFIGURATION (Continued)
Power Supply for the Series Six Plus PLC
Terminal Block Connections
Power Supply Specifications
Outputs and System Control Signals
Power Supply Auxiliary Circuit Board
l/O Control Module
User Connections
Status Indicators
User Configurable Jumpers
Logic Control Module
Arithmetic Control Module
Status Indicators
Combined Memory Module
Logic Memory Function
Register Memory Function
Internal Memory Function
Detection of Active Override in System
Scratch Pad Items
Type of Memory Used
Battery Status Indicator
Location in Rack
Precautions When Handling Memory Modules
Memory Protection
Bus Controller Module
Versions of Bus Controller
Communications Control Modules
Communications Control Module, Type 2 (CCM2)
System Configuration
User Items
Communications Control Module, Type 3 (CCM3)
CCM2 Mode
CCM3 Remote Terminal Unit (RTU) Mode
Dual Mode Usage
I/O Communications Control Module (l/O CCM)
I/O Link Local Module
l/O Structure for the Series Six Plus PLC
l/O Racks
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Contents
GEK-96602
CONTENTS
TITLE
CHAPTER 2.
PAGE
PHYSICAL EQUIPMENT CONFIGURATION (Continued)
I/O Addressing
Normal Mode I/O Addressing
Expanded Mode l/O Addressing
Channel Reference Numbering
Real I/O Memory Allocation
Internal Discrete Reference Memory Allocation
Expanded Mode I/O References
I/O System Configuration
I/O Rack Interconnections
CPU I/O Station
Local I/O Station
Remote l/O Station
l/O Interface Modules
I/O Receiver
I/O Chain Signal Continuation or Termination
Module Connections
Status Indicators
Advanced l/O Receiver
Module Connections
I/O Signal Continuation or Termination
Status and Diagnostic Indicators
I/O Transmitter
Isolation Circuitry
Location in Rack and I/O Channel Addressing
Status Indicators
Configuration Jumpers
Connector
Remote l/O System
System Connections
Remote System Response Time
Remote l/O Addressing
Printed Circuit Board Jumpers
Remote I/O Driver
Remote I/O Driver Addressing
Status Indicators
Option Jumpers
Remote I/O Receiver
Connectors
Status Indicators
Option Jumpers
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GEK-96602
CONTENTS
TITLE
CHAPTER 2.
PHYSICAL EQUIPMENT CONFIGURATION (Continued)
AuxiIiary I/O System
Workmaster Computer to
Series Six Plus PLC Connections
Workmaster to Series Six Interface Adaptor Boards
Connection to I/O Control or
I/O Receiver Modules
Connection to an I/O Transmitter Module
Connecting Cable
Connections Using the Serial Version of
Logicmaster 6
Using the Cimstar I Computer With a
Series Six Plus PLC
Parallel Version of Logicmaster 6 Software
Serial Version of Logicmaster 6 Software
Programming a Series Six Plus PLC With an IBM PC
CHAPTER 3.
PAGE
INSTALLATION INSTRUCTIONS FOR THE SERIES
SIX PLUS PROGRAMMABLE LOGIC CONTROLLER
Introduction
Quality Control
Packaging
Visual Inspection
Preinstallation Check
Rack Installation
Extraction/Insertion Tool
Inserting a Printed Circuit Board
Removing a Printed Circuit Board
Module Installation
Combined Memory Module
Battery Installation
External AuxiIiary Battery Select ion
Arithmetic Control Module
Logic Control Module - Advanced, Expanded
or Expanded II
l/O Control Module
Auxiliary I/O Module
Communication Control Modules
CPU Power Supply
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Contents
GEK-96602
CONTENTS
TITLE
CHAPTER 3.
PAGE
INSTALLATION INSTRUCTIONS FOR THE SERIES
SlX PLUS PROGRAMMABLE LOGIC CONTROLLER
(Continued)
System Grounding Procedures
Recommended Grounding Practices
Ground Conductors
Series Six Plus PLC Equ ipment Ground ing
I/O System Configuration
I/O Power Supply
AC Power Source Connections
DC Power Source Connections
I/O System Interface Modules
I/O Receiver or Advanced I/O Receiver
I/O Transmitter
Remote I/O Driver
Remote l/O Receiver
Parallel I/O Chain Cables
Parallel I/O Cable Configuration
Serial Link Cable to Remote I/O System
I/O Point Selection
Power Supply Load Capacity
Load Capacity for a Series Six Plus CPU Rack
Load Capacity for an I/O Rack
Initial Start-up Instructions for a
New Series Six CPU
Running Expanded l/O on the Series Six Plus PLC
As Internal Coils Only
To Be Solved to Real World I/O Points
How It Works
System Design Considerations
CHAPTER 4. EXPANDED CPU OPERATION
Introduction
Normal Mode of Operation
Expanded Functions
Series Six PLC I/O Diagnostics for
Series Six Plus PLCs
l/O Transmitter Diagnostic Feature
Interrupt Module Location
Normal Mode l/O Addressing
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Contents
.-
GEK-96602
CONTENTS
TITLE
CHAPTER 4.
PAGE
EXPANDED CPU OPERATION (Continued)
Expanded Mode l/O Addressing
I/O Channels
Channel Reference Numbering
Real I/O Mapping
Internal Mapping of Discrete References
Register Memory Size
Expanded Mode I/O References
Summary of Required I/O References
Summary of Required Register References
Dynamic User Memory Checksum
Memory Checksum Calculation
Logicmaster 6 Display of Checksum Error
Restarting a CPU Stopped by a Checksum Error
Configuration of Expanded Functions Through
Logicmaster 6 Software
Expanded Functions Menu
CPU Configuration Set Up Menu
Making Entries on the CPU
Configuration Set Up Page
Cancelling Entries to the CPU
Configuration Set Up Menu
CPU Configuration Menu: Definitions
Displaying and Editing the Genius Bus
Controller Locations Page
Editing the Bus Controller Map
Cancelling Changes to the Bus Controller Map
Displaying and Clearing Genius I/O Faults
Displaying the Genius I/O Fault Table
Genius I/O Fault Table Definitions
Viewing Additional Fault Listings
Clearing Faults
Floating Point Functions
Floating Point Display Format
Valid Number Format
Programming Floating Point Arithmetic Functions
Floating Point Addition
Floating Point Subtraction
Floating Point Multiplication
Floating Point Division
Floating Point Greater Than
Convert Integer to Floating Point
Convert Floating Point to Integer
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GEK-96602
CONTENTS
TITLE
CHAPTER 4.
PAGE
EXPANDED CPU OPERATION (Continued)
Window (DPREQ) Function
Entering a Window Function
Using the Do l/O Function to Address
16K Inputs and Outputs
Entering a Do I/O Function
Expanded Time Reference (Real-Time Clock)
Format of the Real-Time Clock
Genius I/O Diagnostics
Diagnostic Fault Table
Register Memory Size VS Genius I/O Diagnostics
Fault Table Pointer
Input Data From Bus Controller
Selecting Addresses for Diagnostic
Data Storage
Bus Controller Status Byte 2 (Address 0),- Input 1
Bus Controller Status Byte 1 (Address 0) - Input 2
Bus Controller Status Byte 1 (Address 0) Inputs 3, 4, 5, 6)
Bus Controller Status Byte 1 (Address 0) - Input 3
Bus Controller Status Byte 1 (Address 0) - Input 4
Bus Controller Status Byte 1 (Address 0) - Input 5
Bus Controller Status Byte 1 (Address 0) - Input 6
Bus Controller Status Byte 1 (Address 0) Input 7 & 8
Fault Table Registers
Register 1 - Genius l/O Bus Controller
Address Decoding
Register 2
Register 3
Register 4 and 5
Register 5 (Upper Byte) and Register 6
Register 7
Registers 8, 9, 10
Bus Controller Output Data
Output 1 (Bit 0) Definition, Disabled Outputs
Output 2 (Bit 1) Definition, Clear All Faults
Output 3 (Bit 2) Definition, Clear Circuit Fault
Output 4 (Bit 3) Definition, Pulse Test
Output 9 (Bit 0 of Byte 2) Definition,
Circuit Type
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Contents
GEK-96602
CONTENTS
TITLE
CHAPTER 4.
PAGE
EXPANDED CPU OPERATION (Continued)
Point Status Bit Map
Bus Status/Control Byte Location
Input Status Definitions
Output Control Definitions
Computer Mail Box
Using the Computer Mail Box to Communicate
With Genius I/O Bus Controllers
Operation of the Computer Mail Box
Communication Window Opens
Register R - Bus Controller Address
Command Data Registers
Register R+1 - Operation (Read or Write)
Register R+2 - Communications Status
Register R+3 - Target Block Start Address
Register R+4 - Mailbox Address for Data
Register R+5 - Data Buffer Length
Data Registers
Command Verification
Terminating Computer Mail Box Communication
Using the DPREQ Function to Communicate
With Genius I/O
Typical DPREQ Operation
Contents of First Register
Contents of Second Register
Contents of Third Register
Contents of Fourth Register
Contents of Fifth Register
CHAPTER 5. TROUBLESHOOTING AND REPAIR
Introduction
Minimum Downtime
Logical Troubleshooting
Troubleshooting
Replacement Module Concept
Isolate the Problem
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Contents
GEK-96602
CONTENTS
PAGE
TITLE
CHAPTER 5.
Section 1
Section 2.
TROUBLESHOOTING AND REPAIR (Continued)
Central Processing Unit Troubleshooting
Fault Isolation and Repair
Check Condition of Status Indicator Lights
Check Position of Key Switches
Battery Light Out
Alarm Relay
I/O System Troubleshooting
Troubleshooting the I/O Rack Power Supply
I/O Indicator Chart
I/O Rack Connections
Suggested Troubleshooting Sequences
Examples of Intermittent Fault Conditions & Causes
Troubleshooting with the Advanced I/O Receiver Module
Example of Determining the Output Byte Address
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APPENDIX
APPENDIX A. GLOSSARY OF TERMS
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GEK-96602
FIGURES
PAGE
Figure 1.1
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Programmable Logic Controller Block Diagram
Typical Series Six Plus PLC Rack
Genius l/O Typical Communications Link
Workmaster Industrial Computer
Redundant Processor Unit Configuration
Operator Interface Unit
Operator Interface Terminal
Typical Proloop System Equipment
GEnet Factory LAN
LAN Interface Module Connects a Series Six Plus PLC
to a Carrierband Network
RS-232 to RS-422 Adaptor Unit
Product Structure for Series Six Plus PLC
Basic CPU Rack Configuration for the Series Six Plus
Brackets in Position for Rack Mounting
Brackets in Posit ion for WalI or Panel Mounting
Illustration of Power Supplies
CPU Terminal Block Connections
CPU Power Supply Block Diagram
Power Supply Auxiliary Circuit Board
l/O Control Module
Example of Logic Control Module
Arithmetic Control Module
Basic Word Structure
Typical Combined (Logic) Memory Module
Illustration of CCM2 Module
Illustration of I/O CCM Module
I/O Link Local Module to Series One or
Series Three Remote I/O Racks
I/O Link Local Module
Typical I/O Rack
l/O Point Address Switches
Dip Switch Settings for 8-Circuit Modules
CPU l/O Station
Local l/O Station
Remote I/O Station Configuration
I/O Receiver User Items
I/O Receiver Dip Shunt/Jumper Rack Configuration
Location of User Items
l/O Transmitter Module
Typical Remote I/O System Connections
Remote I/O Driver Module
Remote I/O Receiver Module
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2-27
2-28
2-29
2-31
2-32
2-38
2-39
2-41
2-43
2-44
2-47
2-50
2-52
2-55
2-58
xvii
Contents
GEK-96602
PAGE
Figure 2.31
2.32
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.1
5.2
5.3
Auxiliary I/O Module Board Layout
Workmaster Computer Connections to the Series Six Plus PLC
Rack Mounting (19” Rack)
Wall or Panel Mounting (19” Rack)
Extraction/Insertion Tool
Position of Extraction/insertion Tool for Board Insertion
Positioning the Extraction/Insertion Tool for Board Removal
CPU Module Location Guide
Memory Board Battery Connect ion
Printed-Circuit Board Orientation in a Rack
Logic Control to Arithmetic Control Ribbon Cable
I/O Control Module Jumper Location
CPU Power Supply Connections
PLC System Grounding
Rack Safety Ground Wiring
Series Six Plus PLC Rack Signal Ground Connections
I/O Station Grounding
Programming Device Ground Connection
Typical I/O Rack
I/O Power Supply Connect ions
Parallel I/O Chain Cable
Remote I/O Twisted Pair Cable
Remote I/O Cable for RS-232 Modems
Dip Switch Settings for I/O Point Selection
for 8 Circuit Modules
Example 1 - Correct Configuration
Example 2 - Correct Configuration
Example 3 - Incorrect Configuration
Example 4 - Incorrect Configuration
I/O Transmitter Dip Switch Settings for
Expanded I/O Channel Selection
Expanded l/O Reference Format
Memory Map for 8K and 16K Registers
Memory Map for 1K Registers
Floating Point Arithmetic Display Format
Bus Controller Input Status Reference Definition
Fault Table Registers
Bus Controller Output Status Reference Definition
Register Format for Computer Mail Box
Series Six Plus CPU Indicators and Switches
Power Supply Output Voltage Terminals (TB1)
CPU Power Supply Block Diagram
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2-61
2-63
3-3
3-3
3-4
3-5
3-6
3-7
3-9
3-10
3-11
3-12
3-14
3-16
3-16
3-17
3-18
3-18
3-19
3-20
3-25
3-26
3-26
3-27
3-35
3-36
3-37
3-38
4-4
4-4
4-6
4-7
4-21
4-31
4-29
4-36
4-40
5-5
5-7
5-8
Contents
GEK-96602
FIGURES
PAGE
Figure 5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Battery Mounting Clips and Connectors
CPU Power Supply Terminal Board
Input Voltage Terminal Board
Output Voltage Terminal Board for Standard Power Supply
Output Voltage Terminal Board for High Capacity
Power Supply
CPU to I/O Rack Configuration
I/O Rack to I/O Rack Configuration
Typical I/O Rack Wiring Scheme
Advanced I/O Receiver Status Indicators
5-17
5-18
5-21
5-21
5-21
5-28
5-29
5-30
5-38
TABLES
Table 1 .1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
Series Six Plus PLC Features
General Specifications
Programming Functiona Groups
Standard I/O Modules
Genius l/O Blocks
Other Modules
Typical PLC Applications
Common PLC Terminology
Compatibility Guide Series Six Plus PLC vs Series Six PLCs
Power Supply User Items
Conditions Causing Alarms
Power Supply Specifications
I/O Control Module Indicators
Arithmetic Control Module Status Indicators
Combined Memory Modules
Scratch Pad Storage Items
Combined Memory Module Status Indicators
CCM2 Status Indicator Definitions
l/O Rack and Power Supply Specifications
l/O Point References and Register Mapping for
Expanded Mode Operation
I/O lnterf ace Modules
I/O Receiver Status Indicators
Status and Diagnostic Indicator Definitions
l/O Transmitter Status Indicator Definitions
Typical System Response Times to Remote I/O
I/O Point Ranges in Remote I/O Stations
Remote I/O Driver Status Byte
Remote I/O Driver Status Indicators
1-4
1-5
1-9
1-12
1-13
1-13
1-22
1-23
1-24
2-5
2-7
2-7
2-10
2-14
2-16
2-17
2-18
2-23
2-30
2-35
2-42
2-45
2-48
2-51
2-53
2-54
2-56
2-57
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xix
Contents
GEK-96602
TABLES
PAGE
Table 2.20
2.21
2.22
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.0
4.9
5.1
5.2
5.3
5.4
Remote l/O Driver Option Settings
Remote l/O Receiver Status indicator Definitions
Remote I/O Receiver Options
Combined Memory Modules
I/O Control Option Jumpers
Expanded I/O Channel Selection
Parallel I/O Chain Cable Catalog Numbers
CPU Rack Power Supply Capacities
Summary of Units of Load for CPU Rack Modules
Summary of Units of Load for I/O Modules
Memory Map for Expanded Mode I/O References
Reserved l/O References
Reserved Register References
Bus Controller Addresses for Diagnostic Storage
Decoding of Byte 6 for Circuit Fault Types
FauIt Types in Register 6
Analog I/O Block Reference Example
Bit Status Meaning for Analog Blocks
Bus Controller Status/Control Byte Definition
CPU Indicator Chart
Conditions Causing Alarm Relays to Switch
I/O Power Supplies
I/O Module Status indicator Definitions
2-57
2-59
2-60
3-8
3-12
3-22
3-24
3-28
3-29
3-30
4-8
4-9
4-10
4-29
4-31
4-35
4-37
4-38
4-39
5-4
5-19
5-20
5-22
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1-1
Introduction To The Series Six Plus PLC
GEK-96602
CHAPTER 1
INTRODUCTION TO THE SERIES SIX* PLUS
PROGRAMMABLE LOGIC CONTROLLER
The Series Six Plus Programmable Logic Controller is an enhanced version of the Series
Six* family of programmable logic controllers. The Series Six family of programmable
logic controllers was first introduced in 1980 and is used extensively in factory
automation. Series Six Plus Programmable Logic Controllers are used worldwide in an
ever growing variety of applications.
Programmable Logic Controllers (PLCs) are also referred to as Programmable Controllers
(PCs). In this manual, in order to avoid any confusion, we will refer to these electronic
control devices as programmable logic controllers or PLCs, since the use of the acronym
PC is universally used when referring to Personal Computers.
WHAT ARE PROGRAMMABLE LOGIC CONTROLLERS?
Programmable logic controllers are general purpose microprocessor controls, that have
been designed specifically for operation in the harsh environment usually encountered in
the factory. A programmable logic controller accepts data from input devices, such as
limit switches, proximity switches, and sensors. It then performs logical decisions in an
orderly and repetitive sequence as determined by a program entered in memory by the
user, and provides output control for machines or processes.
Input modules convert electrical signals provided by the input devices to logic levels for
processing by the Central Processing Unit (CPU) and Output modules convert signals from
the CPU to the proper electrical signals for control of machines or processes. The Input
and Output (I/O) modules also provide electrical isolation, for signals in the CPU, from
electrical noise typically found in the factory environment. Figure 1.1 is a basic block
diagram of a programmable logic controller.
a42063
r ---v-- -I
1
I
mF@Mt,,/JER
CPU
1
LOGIC STORAGE 4
* PREsOR MEMCRY’,
L - - - - - - -l
SUPPLY
c-w
I/O
+ OUTPUTS
POWER
SUPPLY
,’
1
FIELD ‘
DEVICES 1
i-i
Figure 1 .I PROGRAMMABLE LOGIC CONTROLLER BLOCK DIAGRAM
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l-2
Introduction To The Series Six Plus PLC
GEK-96602
ADVANTAGES OF PROGRAMMABLE LOGIC CONTROLLERS
Programmable Logic Controllers offer many advantages over other control devices, such
as electrical timers and counters, relays, and drum type mechanical controllers. Some of
the many advantages to be considered when planning a system include:
-
Improved reliability, you do not need to be concerned with frequent breakdown
of electro-mechanical devices.
-
Less space required, since a proliferation of relays, electrical timers, etc., are
not needed
-
Easier to maintain. Built-in diagnostics and reliable solid-state devices equate
to few breakdowns. When failures do occur, they are quickly detected and
repaired. In fact, the revolutionary Genius* I/O system with its enhanced
diagnostics, when used in the I/O structure, reduces failure detection and repair
time to an absolute minimum.
-
Easily reprogrammed if control requirements change.
-
Flexibility - one device is able to perform many functions.
SERIES SIX PLUS PROGRAMMABLE LOGIC CONTROLLER
The Series Six Plus PLC is an extension of the Series Six family of Programmable Logic
Controllers; previously available models 60, 600 and 6000. The Series Six Plus PLC is
available as a single 19” or 13” rack, (referred to as the CPU rack) that can be configured
to meet the application requirements. Memory is available on a combined memory board
that contains the internal memory, up to 64K of logic memory and up to 16K of register
memory. Up to 16K of I/O points (16K Inputs/l6K Outputs) are available to the user in a
system.
All of the existing Series Six I/O modules are compatible with and can be used in a Series
Six Plus PLC system. The 6 left slots in the 19” CPU rack are available for I/O modules
(3 slots available for I/O in a 13” rack). If the PLC system is to include an Auxiliary I/O
module, which must be placed in slot 6 or 7 (numbered from the right), 5 slots are
available for l/O modules in the 19” CPU rack, or 2 slots in the 13” CPU rack.
When more than the 3 (13” rack) or 6 (19” rack) I/O modules that can be contained in the
CPU rack are required, standard Series Six I/O racks are available to add to the l/O
system. I/O racks connected directly to the CPU through the I/O Control module can be
located up to 50 feet (15 meters) from the CPU in a daisy chain in a CPU station. I/O
racks in a Local I/O station can be located up to 500 feet (150 meters) from the CPU,
connected by I/O Transmitters to I/O Receivers or Advanced I/O Receivers, through
cables on the parallel I/O bus. Up to 4 I/O Transmitters can be used in series to allow up
to 2400 feet (600 meters) from the CPU station to the most distant I/O Receiver.
In addition, the I/O racks in a Remote I/O station can be located up to 10,000 feet (3 km)
from a CPU or Local I/O station, when connected by a serial link through a 2-pair twisted
cable. For virtually unlimited distances between I/O racks or the CPU and I/O racks,
connection can be made through a serial communications link using RS-232 compatible
modems.
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Introduction To The Series Six Plus PLC
1-3
GEK-96602
Figure 1.2 is an illustration of a Series Six Plus Programmable Logic Controller showing
the location of modules in the CPU rack. l/O and CPU racks are available as either 13”
or 19” racks.
a4i !069
Figure 1.2 TYPICAL SERIES SIX PLUS PLC RACK
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l-5
Introduction To The Series Six Plus PLC
GEK-96602
General Specifications
General specifications for the Series Six Plus PLC are listed below.
Table 1.2 GENERAL SPECIFICATIONS
Operating Temperature
Storage Temperature
Humidity
(Non-Condensing)
0 to 60°C (32 to 140°F)
(at outside of rack)
-20 to 70°C (-4 to 158°F)
5% to 95%
AC Power Source
Frequency
Maximum Load
95 to 260 V ac
47 to 63 Hz
250 VA
DC Power Source
20 to 32 V dc (24 V dc Supply)
Or
100 to 150 V dc (125 DC Supply)
180 VA
Maximum Load
Rack Weight, 19" (Filled)
37 lbs. (17 kg>
Rack Dimensions (19", 11 slots)
Rack Mount
19.0(W) x 14.0(H) x 10.3(D) inches
483 x 356 x 261 millimeters
Panel
20.0(W) x 14.0(H) x 10.3(D) inches
508 x 356 x 261 millimeters
Mount
Rack Dimensions (13", 8 slots)
Rack Mount
16.0(W) x 13.25(H) x 9.3(D) i n c h e s
406 x 337 x 236 millimeters
Rack Mount with Brackets for
standard 19" Rack
19.0(W) x 13.25(H) x 9.3(D) inches
483 x 337 x 236 millimeters
Panel Mount (Brackets on sides)
16.0(W) x 13.25(H) x 9.3(D) inches
Panel Mount (Brackets on Top
and Bottom, Side by Side Mount)
13.25(W) x 16.15(H) x 9.3(D) inches
337 x 410 x 236 millimeters
Typical Battery Life, Loaded 1
Battery Shelf life, No Load 1
about 1 year
8 to 10 years
Typical Scan Rate (Relay Functions)
.8 mSec per K of user memory
Maximum Number
of I/O Points
Normal Mode 2
2K Inputs
2K Outputs
Expanded Mode * 16K Inputs
16K Outputs
1.
Depending
2.
Mode
Upon
selected
Workmaster
Temperature
by
enabling
desired
mode
on
the
CPU
Configuration
Set
Up
Menu
computer, using Logicmaster 6 software, Version 3.01 or greater.
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on
a
Introduction To The Series Six Plus PLC
1-6
GEK-96602
GENIUS I/O SYSTEM
In addition to the standard rack-based I/O modules, the Series Six Plus PLC fully supports
the Genius I/O system. This revolutionary l/O system is a major improvement over
existing l/O systems. It can be mixed with the rack-based I/O or can comprise the total
I/O system. The Genius I/O is available in units called blocks, and includes both discrete
and analog blocks.
Genius l/O blocks are connected to the Series Six Plus CPU through a Bus Controller by a
single twisted-pair communications link. The total number of Bus Controllers in a system
is limited only by the l/O capacity of the Series Six Plus PLC. Each Bus Controller can
have up to 30 blocks connected to it in a daisy chain, thereby providing up to 480
.
addressable l/O points on each bus.
For detailed information on the Genius I/O system, refer to GEK-90486, the Genius l/O
System User’s Manual. Some of the many benefits of the Genius l/O system are as
follows:
Each block is a stand-alone unit, no separate rack or power supply required.
Each discrete block can be configured to be inputs, outputs, or any combination of
inputs and outputs.
Extensive diagnostics monitor not only the blocks, but also field devices.
There are no fuses to be concerned with, since the discrete outputs have built-in
electronic fusing for circuit protection.
A convenient, easy to use Hand Held monitor is used for system configuration,
calibration and troubleshooting.
Easier installation and troubleshooting, and fewer spare parts required in inventory
provide a signif icant cost savings over traditional I/O systems.
a41057
SERIES~X PLUS
figure 1.3 GENIUS l/O TYPICAL COMMUNICATIONS LINK
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1-7
Introduction To The Series Six Plus PLC
GEK-96602
PROGRAMMING THE SERIES SIX PLUS PLC
Programs are entered, edited, and monitored using the Workmaster* industrial computer
or the CIMSTAR I
industrial computer. Programming the Series Six Plus with
Expanded II functions requires version 4.01 or later of the Logicmaster* 6 software.
Prior versions of Logicmaster 6 may be used to program the Expanded II instruction set
provided that no Auxiliary I/O references are used (no Auxiliary I/O chain) and no
Expanded II features are required. An lBM* PC, PC-XT or PC-AT personal computer
can also be used with unbundled software. For detailed information on programming the
Series Six Plus PLC, refer to the Logicmaster 6 Programming and Documentation
Software User’s Manual, GEK-25379.
a40532
Figure 1.4 WORKMASTER INDUSTRIAL COMPUTER
*IBM
is
a
registered
trademark
of
International
Business
Machines
Incorporated
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tntroduction To The Series Six Plus PLC
1-8
GEK-96602
Workmaster Industrial Computer
The Workmaster industrial computer, with Logicmaster 6 software, is the main device
used for developing and entering new user’s programs, editing existing programs, or
real-time system monitoring of the PLC. The Workmaster computer is built around a
portable, industrial hardened, IBM* compatible personal computer. It can be configured
to have either one or two diskette drives or one or two diskette drives and a 20 megabyte
fixed hard disk.
The diskette drives are 3.5” drives. The capacity of each diskette is 720 K bytes (double
sided, double density) after formatting. The small physical size of the diskettes makes
them convenient to handle and store. Once your program has been developed on the
Workmaster computer and stored on a diskette, it is retained for future use even through
power fail conditions.
Other Software Packages
In addition to program development and entry for the Series Six Plus PLC, many other
software packages can be run on the Workmaster computer by adding the required
software and hardware options. Some of these are Processmaster, which is used to
configure and monitor ProLoop Process Controllers; Modelmaster Factory Modeling
System, which is a graphically enhanced flexible modeling system used to simulate
factory manufacturing facilities; Vumaster, an intelligent color graphics operator
interface; Motionmaster, which provides a powerful tool for the development and
maintenance of motion control software in conjunction with the Axis Positioning (APM1
and APM2) Modules; Alarm Master, which is used to create fault and alarm monitoring
programs, and Logicmaster 1 and 3 software, which is used for developing and entering
programs on the Series One family or Series Three PLCs. In addition, there are a number
of Vendor Logo software packages available for use with a Series Six Plus PLC system.
For information on other programs that can be run on the Workmaster computer, contact
your local GE Fanuc - NA sales off ice or GE Fanuc Automation North America, Inc.,
Charlottesville, Va.
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Introduction To The Series Six Plus PLC
1-9
GEK-96602
Programming Lanquage for the Series Six Plus PLC
The basic programming language used by the Series Six Plus PLC is relay ladder logic.
This has been expanded to include instructions for applications more complex than those
requiring only the basic relay ladder logic functions. Three versions of programming
instruction sets are available, Advanced, Expanded, and Expanded II. The instruction
sets are contained in PROMS on the appropriate Logic Control module. The version of
the module must be selected, depending on the programming (instruction set)
requirements (Advanced Functions, Expanded Functions, or Expanded II Functions.
The Expanded functions include a group of 7 instructions that provide the capability for
floating point math calculations to be performed. Several other functions are enhanced
to expand their capabilities to allow their use with the full 32K of l/O and 16K of user
accessible 16-bit data registers and permit the use of the powerful Genius I/O
diagnostics. The Expanded II functions include all of the functions available with the
Expanded functions. Additionally, instructions are included for accessing a new I/O
system to be available in the future, and changes in the microcode have been made to
allow operation which provides faster execution of ladder logic programs. Available
programming functions are listed below.
Table 1.3 PROGRAMMING FUNCTIONAL GROUPS
ADVANCED FUNCTIONS
RELAY
Normally Open and Normally Closed Contacts
"Real World" Output Coils
Internal Coils
Latches
One-shots
Timing (0.01, 0.1, and 1.0 Second Increments)
Counting (up and down)
Auxiliary I/O References
ARITHMETIC
Addition
Unsigned Binary
Subtraction
Compare
1
Shift
Double Precision
Addition, Subtraction
Signed 2's
Multiply, Divide
Complement
I
Greater Than
CONTROL
Master Control Relay and Skip
Do Subroutine, Do I/O
Suspend I/O, Return, Status
MOVE/CONVERT
Data Moves
I/O Table to Register
Register to I/O Table
Table To Destination
Source To Table, Move Table, Move Table Extended
Move Right 8 Bits, Move Left 8 Bits
Block Move, Move A To B
Convert
Binary to BCD, BCD to Binary
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l-10
Introduction To The Series Six Pius PLC
GEK-96602
Table 1.3 PROGRAMMING FUNCTIONAL GROUPS(Continued)
- ADVANCED FUNCTIONS (Cont.1
COMM. REQUESTS
DPREQ and SCREQ
MATRIX
AND
Inclusive & Exclusive OR
Invert
Masked Compare
Set/Sense
Clear/Sense Bit
Shift Right
Shift Left
LIST
Add to Top
Remove from Bottom
Remove from Top
Sort
MISCELLANEOUS
End of Sweep, NO OP
EXPANDED
FUNCTIONS
RELAY
All Advanced Functions plus:
Valid Reference Range Expanded for
Full 32K I/O Points; an additional 68K
of discrete references and 16K Registers
ARITHMETIC
All Advanced Functions plus:
Floating Point Functions
Add, Subtract, Multiply, Divide
Greater Than
Integer to Floating Point
Floating Point to Integer
CONTROL
All Advanced Functions plus:
Do I/O enhanced and Status enhanced
COMM.
REQUESTS
MOVE/CONVERT
MATRIX, LIST
Miscellaneous
SCREQ - Same as Advanced
DPREQ Enhanced
All
All
All
Advanced
Advanced
Advanced
Functions
Functions
Functions
EXPANDED II FUNCTIONS
All Advanced and Expanded Functions plus:
-Changes in system microcode which provides faster execution
of ladder logic.
-Dynamic user program memory checksum calculation.
-Detection of active overrides in system.
- Instructions added to allow accessing a future I/O system.
-Support of 64K User Logic memory.
-Auxiliary I/O overrides.
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introduction To The Series Six Plus PLC
1-11
GEK-96602
PROGRAMMABLE LOGIC CONTROLLER CONCEPTS
When using a new product for the first time, there are always new concepts and terms to
become familiar with. Although PLCs are easy to install, program, and apply, there are
some simple principles to follow. The following paragraphs describe the components of a
Programmable Logic Controller.
Function of the Central Processor Unit
The Central Processor Unit (CPU) is basically a microprocessor containing the circuitry
that performs logical decision making functions. It reads in the status of the control
system, makes decisions based upon the logic that has been programmed, and then
provides decisions to the actuating portion of the control system.
The CPU also performs self checking of its internal operation to ensure reliable
operation. This is done by a circuit called the watchdog timer. The watchdog timer is a
hardware timer set at 300 ms +/-50 ms to ensure that memory or internal circuit faults do
not cause the CPU to enter an endless loop because of hardware failure. If a scan is not
completed at least once every 300 ms +/-50 ms, the hardware will shut the CPU down and
turn the outputs OFF. If an error is detected, it will shut itself down. The logic entered
by the programmer is actually stored in the CPU along with data storage and storage for
the operation of timers and counters.
Memory Types Used in the Series Six Plus PLC
All memory for the Series Six Plus PLC is located on one module, which is the Combined
Memory Module. This module contains all internal, register, and logic (user) memory.
The memory provided for these storage functions is normally measured in K words, where
K is an abbreviation for kilo or 1024. Typically, one word is required for storage of each
function such as a relay contact, timer preset or timer storage. These words can be of
various lengths such as 16 bits, 8 bits, or even 4 bits, with a bit being the lowest level of
measurement and can have only two states (on or off). The Series Six Plus uses the most
common measurement, 16 bits per word. The number of words required per function wilI
vary, however, with the more complex functions requiring up to 6 words each.
The most common type of memory used in PLCs to store both logic and data is CMOS.
CMOS is an acronym commonly used for CMOS RAM (Complimentary Metal-Oxide
Semiconductor, Random Access Memory). CMOS is a fast, low power memory that can
However, it is volatile, in that it can
be easily examined (read) and changed (written).
lose its content if power is removed.
To avoid reloading memory (and losing counts and system status) every time power is
turned off, the CMOS memory is provided with a Lithium-Manganese Dioxide battery to
maintain its content (not system operation) when power fails. Due to the low power drain
of CMOS technology, a single new lithium battery can maintain memory without
application of power for up to 1 year. The battery is not used when power is applied and
the system is operating normally. Its storage or shelf life is typically 8 to 10 years.
A dynamic user program memory checksum is available when the Expanded II Logic
Control module option is selected. The user program checksum feature provides more
data integrity within the user program. It traps certain types of errors not caught by
memory parity checking.
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Introduction To The Series Six Plus PLC
1-12
GEK-96602
Function of the Input/Output Circuitry
The final element of a PLC is the Input/Output section. Electrical noise such as spikes on
the power lines, inductive kickback from loads, or interference picked up from field
wiring is very prevalent in industrial applications. Since the CPU operates at relatively
low voltage levels (typically 5 volts), this noise would have serious impact on its operation
if allowed to reach the internal circuits of the CPU.
The I/O section, both inputs and outputs, protects the CPU from electrical noise entering
through the I/O modules or wiring. The I/O section is where status signals are filtered to
remove noise, voltage levels are validated, and where decisions made by the CPU are put
into operation. Inputs provide their status to a storage area within the CPU and outputs
are driven from similar stored status in the CPU.
For detailed information on the I/O module types and capacities available for use with a
Series Six Plus PLC, refer to the Series Six Data Sheet Manual, GEK-25367 and the
Genius l/O User’s Manual, GEK-90486. The exact type of l/O module to be specified, for
example, 115 V ac or 24 V dc, is usually determined by the field device selected by the
user. Tables 1.4 and 1.5 list the available I/O modules.
Table 1.4 STANDARD I/O MODULES
MODULE
TYPE
115 V ac/dc
115 V ac Isolated
115 V ac Protected
120 V dc
220 V ac/dc
220 V ac Isolated
12 V dc
24 V dc
48 V dc
5V TTL
10 to 50 V dc
Reed Relay
Analog (12 bit)
0 to +l0 V dc
4 to 20 mA/+l to +5 V dc
-10 to +lO V dc
4 to 20 mA
NUMBER OF CIRCUITS AND I/O CAPACITY
INPUT
OUTPUT
8
6
8
6 (ac/dc)
8 (ac/dc)
8 (ac/dc)
8 (ac/dc)
32
32
8
6
4
8
8
6
8
8
8
32
32
(2 Amp ac, 1.5 Amp dc)
(3 Amp)
(4 Amp)
(2 Amp)
(2 Amp)
(3 Amp)
(2 Amp Sink/Source)
(2 Amp Sink/Source)
(2 Amp Sink/Source)
(25 mA)
(250 mA Sink)
(500 mA Source>
6 (100 Va Max) NO or NC
8
a
a
Thermocouples (12 Bit)
(Types 3, K+, S, T, B, f, R)
8
Interrupts
8
4
(5 mA Max.)
(20 mA Max.)
4 (+/-5mA Max.>
4 (20 mA Max.)
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Introduction To The Series Six Plus PLC
GEK-96602
Table 1.5 GENIUS I/O BLOCKS
BLOCK TYPE
115 V ac Grouped
115 V ac/dc Isolated
24 to 48 V dc Source
24 to 48 V dc Sink
Analog,
12-bit
Analog, 12-bit
Relay Output, NC
Relay Output, NO
RTD Input
RTD Input
CURRENT/VOLTAGE
2 A, Total 15 A
2 A, Total 16 A
2 A, Total 16 A
2 A, Total 16 A
115 V ac Power Source
24 to 48 V dc Power Source
115/230 V ac, 2A
115/220 V ac, 2A
115 V ac/125 V dc
24 to 48 V dc
NUMBER OF CIRCUITS
8
8
16
16
4 In/2 Out
4 In/2 Out
16
16
6
6
In addition to l/O modules, other available modules include system interface modules,
communications modules, and intelligent modules.
Table 1.6 OTHER MODULES
SYSTEM
Local
>
INTERFACE
I/O Receiver
A vanced I/O Receiver
I 7 0 Transmitter
MODULES
Remote
Remote I/O Driver
Remote I/O Receiver
COMMUNICATIONS MODULES
CCM2
Communications Control Module, Type 2
Multi-Mode Protocol, Master/Slave/Peer
CCM3
Communications Control Module, Type 3
Has Functionality of CCM2 and Also Interfaces To
Process Controllers
I/O Link Local
Interfaces To Series One and Series Three PLCs.
Allows I/O Communications with Those PLCs.
I/O CCM
Functionality of CCM3 in an I/O slot
LAN
Local Area Network Interface Module provides
a direct LAN attachment to IEEE 802.4 carrierband
network, has two communication services for control
data transfer, and provides extensive station
configuration, management and diagnostic tools
Interface
INTELLIGENT
MODULES
Axis Positioning, Type 1 (Resolver)
Axis Positioning, Type 2 (Encoder)
High Speed Counter
ASCII/BASIC
Loop Management
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1-14
Introduction To The Series Six Plus PLC
GEK-96602
OPTIONAL DEVICES SUPPORTING THE SERIES SIX PLUS PLC
Several devices are available as options for the Series Six Plus PLC system. These
devices enhance a PLC system by providing capabilities not provided by the PLC itself.
Redundant
Processor Unit
The Redundant Processor Unit (RPU) allows two CPUs to operate in parallel, connected
to one I/O structure within one system. A fault in either system can be detected and
alarmed, and the alternate CPU will continue system operation. The RPU also allows a
second I/O structure to be added to the system, which allows switching between CPUs or
I/O systems. For a detailed description and operation of the RPU, refer to the Series Six
Redundant Processor Unit Manual, GEK-25366.
CPU#2
94tmp8
TO
AUXlLlhRY
l/o UODULE
CPU1 Ak CPU2
I I
I
ON/OFFPOWER SWlTCH
PU1/AUTO/CPUZ
TO AUXlLlARY l/o
C;AlN
1
NO. I AND HO.2
I/O CHAlN NO. I
I I T%il’6eL
ALARM
TERMINALS
1
I/O CHAIN NO.2
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Figure
1.5Group
REDUNDANT
PROCESSOR
UNIT
Introduction To The Series Six Plus PLC
1-15
GEK-96602
Operator Interface Unit
The Operator Interface Unit (OIU) is an ASCll device that can be driven by the CCM2 or
CCM3 module. This unit allows an operator to access, for the purpose of displaying or
altering, register data, l/O states, I/O override status, and timer or counter operation.
Up to 8 OlUs can be connected to one CPU. A detailed description of the OlU can be
found in the Series Six Data Sheet Manual, GEK-25367.
6830103
Figure 1.6 OPERATOR INTERFACE UNIT
Operator Interface Terminal
The Operator Interface Terminal (OIT) is an industrial hardened CRT terminal, designed
for use in the factory environment. The OIT connects to the CPU through an
ASCII/BASiC module, providing a powerful tool for monitoring and interfacing to a
control system. The OIT provides CRT background screens for the display of status from
the CPU. The user can configure the screens to allow the displays to fit a particular
application. Detailed information on operation and configuration of the OIT can be found
in the Operator Interface Terminal Manual, GEK-90817.
a41087
Figure 1.7 OPERATOR INTERFACE TERMINAL
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Introduction To The Series Six Plus PLC
1-16
GEK-96602
ProLoop
Process Controllers
The Protoop Process Controllers are a group of analog control devices that can be
integrated into any Series Six Pius PLC system. Each ProLoop Controller can operate
independent of, or under the supervision of a Series Six Plus PLC. The ProLoop
Controller system is suitable for applications requiring precise control of temperatures,
fluid levels, fluid flows, or pressures.
The ProLoop Controllers are available in a variety of configurations, including Single
Loop, Auto Tune, and Multi Loop. The Loop Management Module (LMM) is the interface
from the ProLoop Controllers to a PLC. Command and setup information is passed from
the PLC to the ProLoop Controllers and status information is returned from the ProLoop
Controllers to the PLC.
The ProLoop Controllers can be programmed using a low-cost Hand Held Configurator,
which plugs into the front panel of a ProLoop Controller, and allows access to digital
information in the ProLoop Controller. For more convenient programming of the
ProLoop Controllers, the Processmaste r software package is available. This software
package configures a series of screens on the CRT of a Workmaster computer or on the
Operator Interface Terminal. This allows the ProLoop Controller system to be easily
configured by moving the cursor and entering the proper data.
For complete information on the ProLoop Process Controllers, refer to the ProLoop
Process Controllers System Manual, GEK-90802.
f’R 0 LO 0 p
SINGLE
a40315
LOOP CONTROLLER
PROCESS
VARIABLE
II
VERTICAL
BARGRAPHS
POWER-ON
1NDlCATlON
Figure 1.8 TYPICAL PROLOOP SYSTEM EQUIPMENT
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Introduction To The Series Six Plus PLC
1-17
GEK-96602
ASCII/BASIC Module
The ASCII/BASIC Module is an intelligent module, which under control of a built-in
BASIC programming language, GE/BASIC, can manipulate and transfer data to and from a
Series Six Plus CPU. This module can be programmed to read the contents of the scratch
pad, any register or status tables (status tables in the Main I/O chain or channels 0 and 81
in a CPU. In addition, this module, under program control can write data into the
registers and status tables.
An ASCII/BASIC Module has two configurable serial ports, which give it the ability to
interface to external devices using either RS-232, RS-422 or 20 mA current loop, with
data rates up to 19.2 K bps. Through these ports, the module can communicate with
devices using an ASCII code. These devices typically can be printer terminals, bar code
readers, CRT terminals, other computers and other ASCII/BASIC Modules.
The ASCII/BASIC Module can also be used as a stand-alone microcomputer with
GE/BASIC developed programs entered, edited, and run independent of the CPU.
The ASCII/BASIC module is available in two versions. Catalog Number IC600BF944
which provides l2K bytes of user memory and Catalog Number IC600BF949 which
provides 28K bytes of user memory. Each module requires a single I/O slot and must be
installed in a CPU rack or High Capacity l/O rack.
For detailed information on the installation, theory and use of the ASCII/BASIC Module,
refer to the ASCII/BASIC Module Manual, GEK-25398.
Axis Positioninq Modules
The Axis Positioning Modules (APMs) are intelIigent programmable, single axis positioning
controllers that require only a single slot of a High Capacity I/O rack or a CPU rack.
They provide a real time interface between a Series Six Plus PLC and a servo or stepper
controlled axis and thereby fully integrate closed-loop position or velocity control with
overalI machine control.
The APMs are programmed and monitored using the Workmaster computer. Commands
and return data are passed to and from an APM through 32 consecutive inputs and
outputs. The various parameters exchanged between an APM and CPU user logic include
discrete commands, set up commands, move commands and special commands in the
output group and in the input group; discrete return data and return data.
The APM is available in two versions. Catalog Number IC600BF915 is APM Type 1
(Resolver Feedback) and Catalog Number IC600BF917 is APM Type 2 (Encoder Feedback).
For detailed information on Axis Positioning Modules refer to the applicable user’s
manual. These manuals are:
Axis Positioning Module, Type 1, GEK-25368.
Axis Positioning Module, Type 2, GEK-90800.
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Communications Control Modules
In addition to controlling peripheral devices, the Communications Control Modules (CCM)
provide for communications among all of the GE Fanuc - NA PLCs, which include the
Series Six Plus, Series Six, Series Three, Series One Plus, Series One, and Series One
Junior. In addition, the Workmaster and Cimstar I computers, Operator Interface
Terminals and host computers can be included in a communications system.
These devices all use the C C M protocol which supports point-to-point and multidrop
configurations with data rates from 300 to 38.4K baud. A master CCM device such as the
Series Six Plus PLC can poll up to eight slave devices controlled by the Communications
Request function (SCREQ).
GENET Factory LAN
For applications requiring much broader communications capabilities than the CCM can
provide or a Local Area Network (LAN) for communications with other factory
automation equipment, the GEnet Factory LAN is available. The GEnet Factory LAN is a
10M bps broadband token passing bus which provides high speed communications between
GE Fanuc - NA equipment, including Programmable Controllers, Numerical Control
equipment and higher level factory level management control systems.
The GEnet Factory LAN is based on accepted industry standards. It uses the
International Standards Organization’s Open System Interconnection (OSI) model as the
basis for its communications architecture. GEnet complies with the General Motors
Manufacturing Automation Protocol (MAP) specification and with the ANSI/IEEE
Standard 802.4-1985 for token bus networks.
The Programmable Controllers and Numerical Control equipment interface to the
broadband token bus through a Bus Interface Unit (BIU). The BIU is tailored by loading
device specific software to provide the required interface to the various automation
products. As an example, any device supporting the CCM protocol can access the GEnet
Factory LAN with translation to MAP through the BIU.
Other basic components of the GEnet Factory LAN are the Network Management Console
(NMC) and the Head End Remodulator. The NMC provides overall system configuration
management and control. It operates on a Workmaster or Cimstar I industrial computer
equipped with PLC-BIU hardware and network management software. The head end
contains the equipment required to provide for RF operation on the broadband cable.
For further information on the GEnet Factory LAN, refer to the System User’s Manual,
GEK-96608 and the Network Management Console User’s Manual, GEK-96607.
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1-19
Introduction To The Series Six Plus PLC
GEK-96602
Figure 1.9 is an illustration of a typical configuration for a GEnet Factory LAN.
a41051
2000 CNC
With MAP Option
Series Six Family
With CCM
Series Six Family
With CCM
P
I
z:
--a
.--0
-0
T
I
-
Series One Family
With DCU
RS-422 Multidrop
CCM Communications Bus
c
E
-
Series Three Family
CCM MAP
Interface
Software
BIU
l0Mb/s Broadband Token Bus
Head End
Remodulator
w
R
CCM
Other MAP
Compliant
Devlces
DEC, HP, or
IBM Host
Workmaster
Third Party
Graphics Station
With CCM
support
figure 1.9 GEnet FACTORY LAN
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1-20
Introduction To The Series Six Plus PLC
GEK-96602
Series Six PLC Network Interface
The Series Six PLC Network (or LAN) interface modute is a member of the family of
GEnet Factory LAN communications products. The Series Six LAN Interface module
provides a direct connection for a Series Six Plus PLC to a carrierband network. The
LAN consists of two boards (controller board and modem board) which plug directly into
slots 5 and 6 of the Series Six Plus CPU rack. The LAN Interface module connects
directly into the carrierband cable plant through the 5 Mbps carrierband modem board.
Intermediate devices such as bridges or gateways are not required. The direct connection
provides the high performance required for real-time applications. Carrierband networks
are designed to handle small to medium size applications with 6 to 20 stations as a typical
number which might be attached, although more stations can be connected. Carrierband
networks can extend over cable distances as far as 2000 feet.
a4 1993
CARRIERBAND
LAN
INTERFACE
IAN INTERFACE
MODULE
MODULE
SERIES SIX
PLUS CPU
SERIES SIX
PLUS CPU
.
I
NETWORK
IAN INTERfACE
MODULE
SERIES SIX
PLUS CPU
I
NETWORK
1
1 MANAGEMENT 1
]
CONSOLE
1
f
‘OFfEU
;
FIGURE 1.10 - LAN Interface Module Connects a Series Six Plus
PLC to a Carrierband Network
Datagram
Communications Service
There are two types of communication services which transfer control data on the
net work.
They are the Datagram Communication Service and the Global Data
Communication Service. The Datagram service is a real-time service which provides
peer-to-peer message transfers (read and write messages) from one station on the
network to another. Each request must be explicitly initiated in the ladder logic program
using the Series Six Serial Request [SCREQ] instruction, and the initiating station receives
immediate acknowledgement that the data was or was not transferred successfully. The
Datagram service anticipates MAP/EPA specifications and will evolve to comply with
them when they are approved as standards. Datagram services should be used to send
messages which are destined to a single station or whose delivery must be guaranteed.
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Introduction To The Series Six Plus PtC
1-21
GEK-96602
Global Data Service
Global Data service is a proprietary, real-time protocol which provides a means of
sharing data (such as blocks of registers or l/O points) among a group of stations. Once a
request is initiated using a single [SCREQ] instruction, data continues to be transferred at
a rate specified in the request. This service is not part of the MAP specification, but
co-exists on the network with MAP messages without interference. Global Data services
should be used when the application requires that data must be updated on a periodic
basis and shared by multiple stations on the network. In distributed control applications
it allows I/O points wired to one PLC to be made available to other PLCs quickly and
with minimum intervention by the ladder logic.
RS-232 to RS-422
Adaptor Unit
The RS-232 to RS-422 Adaptor Unit converts RS-232 signal levels to RS-422 signal levels
and can be used to isolate and repeat communications signals. If a device uses RS-422
signal levels for communications, the Adaptor, when connected between those devices
and devices requiring RS-232 signal levels can be used with no loss in baud rate. The
Adaptor unit also has a multidrop capability that can expand a normal eight device
RS-422 link into a 64 device link by using eight Adaptor units. If an RS-422 link should
be required to extend beyond its normal 4000 feet (1.2 Km), the Adaptor can be used as a
repeater to boost the signal levels and obtain another 4000 feet of driving distance for
the signals.
a42088
figure 1.11 RS-232 to RS-422 ADAPTOR UNiT
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Introduction To The Series Six Plus PLC
1-22
GEK-96602
SYSTEM PLANNING
Decisions such as the number of 115 V ac solenoids, 24 V dc solenoids, motor starters,
limit switches (operating voltages), control panel lamps (voltage required), pushbuttons,
and external relays have a major impact on the configuration of any PLC. These
parameters should be established as early as possible in the overall design of the control
system. Being a flexibte device, the PLC configuration, either on paper or in hardware,
can easily be changed if requirements change. Typically, the user provides the field
devices, wires them to the I/O section, and provides the power source to operate them.
TYPICAL APPLICATIONS USING PLCs
Programmable Logic Controllers are used in a wide variety of machine and process
control applications. These applications range from replacing a few relays to controlling
complete factory automation projects. Table 1.7 is a list of typical applications for the
Series Six Plus PLC. This list is only a very small sampling of possible PLC applications,
many others are possible and more are being identified all the time For further
information on any of the applications listed here or any other application you may have,
contact your local GE Fanuc - NA Programmable Logic Controller Distributor, GE Fanuc
- NA sales office or GE Fanuc Automation North America, Inc. in Charlottesville,
Virginia.
Table 1.7 TYPICAL PLC APPLICATIONS
Auto
Insertion
Bagging
Baking
Bonding
Boxing
Capping
Casting
Cement Batching
Combustion Control
CompressIon Molding
Conveyors
Cranes
Cutting
Data Collection
Dipping
Drawing
Drilling
Energy Management
Engines
Engine Test Stands
Extrusion
Forging
Gas Fields
Gauging
Generators
Grinding
Heat Treatlng
Injection Molding
Joining
Milling
Mining Operations
Navigation
Nuclear Plants
Oil Fields
Pipelines
Railroad Switching
Robots
Rolling
Routing
Security Systems
Sewage Treatment
Solar Energy
Sorting
Spool winding
Stackers
Tire Body Building
Traffic Control
Treating
Turbines
Water Treatment
Weaving
Welding
Well Flooding
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i
I
1-23
introduction To The Series Six Plus PLC
GEK-96602
PLC TERMINOLOGY
In the preceding discussion of Programmable Logic Controller concepts, many terms were
discussed that you should be familiar with relating to PLCs. Table 1.8 provides a list of
the most common PLC terms. A more complete list of terms is provided in the glossary
in the back of this manual.
Table1.8 COMMON PLC TERMINOLOGY
DEFINITION
TERM
PLC
Programmable Logic Controller or Programmable
Controller.
An industrial control device using
microprocessor technology to perform logic decision
making with relay 1adder diagram based programming.
Programmer
A device for entry, examination and alteration of the
PLC's memory including logic and storage areas.
Logic
A fixed set of responses (outputs) to various
conditions (inputs). All possible situations
synchronous and non-synchronous activity must
specified by the user.
Also referred to as
CPU
Central Processor Unit - the physical unit in which the
PLC's intelligence resides. Decision making is performed
here.
Memory
A physical place to store information such as programs
and/or data.
K
An abbreviatlon for kilo or exactly 1024 in the world of
computers.
Usually related to 1024 words of memory.
Word
A measurement of memory length, usually 4, 8, or 16 bits
long. In the Series Six Plus PLC, 16 bits.
CMOS
A read/write memory that requires a battery to retain its
content upon loss of power.
PROM
A read only memory that requires a special method of
loading, but is inherently retentive upon power loss.
I/O
Input/Output - that portion of the PLC to which field
devices are connected. Isolates the CPU from electrical
noise.
Noise
external
for both
be
the program.
Undesirable electrical disturbances to normal signals
generally of high frequency content.
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Introduction To The Series Six Plus PLC
1-24
GEK-96602
Table 1.8 COMMON PLC TERMINOLOGY (Continued)
Input
A signal, typically ON or OFF, that provides information
to the plc.
output
A signal typically ON or OFF, originating from the PLC with
user supplied power to control external devices based upon
commands from the CPU.
field Devices User supplied devices typically providing information to
the PLC (Inputs: pushbutton, limit switches, relay
contacts, etc.) or performing PLC tasks (Outputs: motor
starters, solenoids, indicator lights, etc.).
PLC COMPATIBiLITY GUIDE
Most of the hardware and software items can be used by both the Series Six Plus and the
earlier models of the Series Six CPU’s As an aid to the compatibility of these items, a
basic compatibility guide is provided in table 1.9. For comprehensive information on
compatibility of equipment, contact your GE Fanuc - NA sales office or PLC Distributor
Table1.9 COMPATIBILITY GUIDE
SERIESSIX PLUS PLC VS SERIES SIX PLCs
Catalog Number
Description
Power Supplies
IC6OOPM5OO
IC600PM541
IC6OOPM546
115/230 V ac Power Supply
24 V dc Power Supply
125 V dc power Supply
60
Model of PLC
6000
600
6+
CPU Racks, 8-Slot
IC6OOCP610
CPU Racks,
IC600CR201
IC6OOCR301
IC600CR401
IC600CP600
Memory
IC600CM552
IC6OOCM554
IC6OOCM544
IC600CM548
11-Slot
2K
4K
4K
8K
Logic/256 Registers
Logic/1K Registers
Logic
Logic
1.
Required for Expanded
2.
Parity checking is not available with this combination.
II functions.
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2-1
Physical Equipment Configuration
GEK-96602
--
CHAPTER 2
PHYSICAL EQUIPMENT CONFIGURATION
This chapter describes the components of a Series Six* Plus Programmable Logic
Controller. Included are descriptions of the Central Processing Unit, power supplies,
combined memory modules, racks, optional modules, system configuration, standard
rack-based l/O system, Genius* I/O subsystem and peripheral devices. For a complete
list of available hardware and software, refer to GEP-761, Products and Publications
Master Price List. For further information on any of the individual components described
in this chapter that are not part of the CPU, refer to the applicable manual.
PRODUCT STRUCTURE FOR THE SERIES SIX PLUS PLC
The product structure for the Series Six Plus PLC is such that many different
configurations, including combinations of l/O modules, may be contained in a single CPU
rack. The design is flexible to meet the user’s requirements. Figure 2.1 illustrates this
product structure, showing the location of modules in the rack.
a422 13
SLOT NUMBER +
f-
ill
IO
9
8
7
6
5
4
3
-
2
II
1
I
I
A
+I3"RACK HAS 8 SLOTS
WITHUP TO 4SLOTS
AVAILABLE FOR
I/O MODULES
‘:oco’
T 1
H C C
M
E C : :
: ;
C T
R
oc
ii
0
L
OL
r
!?I
L
IT---~
1
I/O MODULES 14OR 6 SLOTSIA
DISCRETE,ANALOG,APMlR,
ASCII/BASIC,I/O CCM,
l/O TRANSMITTER,HIGH SPEED
COUNTER,REHOTE l/o DRIVER,
GENIUSBUS CONTROLLER,
I/O LINK LOCAL
I/O OR AUXILIARY I/O l/O,AUXlLMRY l/O OR LOCAL
AREANETWORK
(LAN ISA2SLOTOPTIONl
1
1
1
1
)
-PROGRAMMING FUNCTION
1
)
lRE&JiRED
OPTIONI
ADVANCED,EXPANDED,OR
EXPANDED It
LAC (95-260 VACI
DC (20-32 VDC OR 100-150 VDCI
INCLUDED WITHBASIC
II
RACK
~LOGICiREGISTER MEMORY
REQUlRED OPTION)
- AUXILIARY I/O,COMMUNlCATlONS
CONTROLOR LOCALAREANETWORK
[LAN ISA2SLOTOPTION1
Figure 2.1 PRODUCT STRUCTURE FOR SERIES SIX PLUS PLC
Each of the modules shown in figure 2.1 is described on the following pages. The
descriptions include information relative to module location in the rack, and the function
of each module in the system. For installation instructions, refer to Chapter 3.
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Physical Equipment Conf igutation
2-2
GEK-96602
19 Inch CPU Rack Configuration
The 19 inch (483 millimeters) rack used to contain the Series Six Plus PLC modules is
designed for either 19 inch rack or panel mounting. Figure 2.2 is an iIlustration of the
rack. Each rack is supplied with reversible mounting brackets for mounting as required
by the user. With the brackets attached to the front of the rack as shown in figure 2.3,
the rack can be mounted in a standard 19 inch rack. By rotating the brackets 90 degrees and
,
mounting them on the rear of the rack, as shown in figure 2.4, the rack can then be either
wall or panel mounted.
Each rack has 11 slots to accommodate modules. For reference purposes these slots are
numbered from 1 through 11, beginning at the right slot (next to the power supply). The
slot number is printed on the rack backplane adjacent to the bottom board slot. Slots 6
through 11 can contain l/O modules. Any module in the I/O system can be placed in any
of these slots as long as their total power requirements, in addition to the power
requirements of the CPU modules, do not exceed the power output of the power supply,
which is 16.5 amps (275 units of load) for +5 V dc, 1.5 amps (60 units of load) for +12 V dc
and 1 .O amps for -12 V dc (40 units of load). A list of the power requirements, expressed
in units of load, for each I/O module is included in Chapter 3, Installation.
If an Auxiliary I/O module is added to a system, it can be placed in slot 5, 6 or 7. If the
GEnet Series Six Network Interface LAN (Local Area Network), which is a two-board
module, is required for a system those modules must be placed in slots 5 and 6, which
would then require the Auxiliary I/O module to be placed in slot 7. Slots 1 through 4 are
for the I/O Control, Logic Control, Arithmetic Control, and Combined Memory, in that
order. If a Communications Control module is selected, it is placed in slot 5.
13 Inch CPU Rack Configuration
The 13 inch (330 millimeters) rack is designed to be mounted several different ways,
including rack mount in a I0” deep rack (brackets on front), rack mount in a standard 19"
rack (wide brackets on front), panel mount (brackets on rear sides), and panel mount in a
NEMA 12 wide (30”) enclosure (brackets on rear top and bottom). When mounted in a
NEMA 12 enclosure, two CPUs can be mounted side-by-side. Each 13” rack has 8 slots
available to accommodate modules. The slots are numbered from 1 through 8, beginning
at the right slot, next to the power supply. All of the modules are located in the same
position in the slots as in the 19” rack with either 1 or 3 slots available for I/O modules.
The 13” rack requires the wide range ac power supply, catalog number IC600PM500.
Basic Unit Configuration
The Series Six Plus PLC basic CPU unit, as received from the factory, consists of a rack
with cable tray, a power supply, an I/O Control module, an Arithmetic Control module
and connecting ribbon cable (to the Logic Control module), a module extraction/insertion
tool, an I/O terminator plug, rack mounting brackets and hardware, and a Series Six Plus
User’s Manual. Any blank faceplates that are required must be ordered separately. The
Logic Control module must be ordered separately for the required level of functions,
either Advanced, Expanded, or Expanded II. One of six available Combined Memory
modules must also be selected and ordered separately. The required power supply for the
19” rack must be specified and can be either the wide range ac version or one of the two
dc versions (24 V dc or 125 V dc). The only power supply currently available for the 13”
rack is the wide range ac supply. The Expanded II functions require the IC600CB524
Arithmetic Control module, the IC600CB610 8-slot CPU rack, or a 19" CPU rack having a
date code later than 10/87, and one of the lC600LX logic memory modules (8K minimum
registers.
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Physical Equipment Configuration
2-3
GEK-96602
SLOT 11
11 SLOTS FOR MODULES
SLOT 1
a41058
Figure 2.2 BASIC CPU RACK CONFIGURATION FOR
THE SERIES SIX PLUS PLC
~6830 124
Figure 2.3 BRACKETS IN POSITION
FOR RACK MOUNTING
Figure 2.4 BRACKETS IN POSITION
FOR WALL OR PANEL MOUNTING
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Physical Equipment Configuration
2-4
GEK-96602
POWER SUPPLY FOR THE SERIES SIX PLUS PLC
The rack power supply is mounted at the extreme right of the rack as shown in the
illustration in figure 2.2. The power supply provides regulated +12, -12 and +5 V dc to the
rack backplane. It is used. to power the GE Fanuc supplied modules contained in the
rack. Input and Output field devices must be supplied with their own source of power at
the proper voltage levels. The power supply is a high-capacity supply and is available for
the 19” rack in three versions, wide range ac, 24 V dc, or 125 V dc. The 13” rack requires
the wide range ac supply. The current capacity of each power supply is 275 units of load.
Each unit of load corresponds to approximately 60 mA of current consumption.
The ac power supply (catalog number IC600PM500) is a wide range switching supply, that
will accept an ac input ranging from 95 to 260 V ac at 47 to 63 Hz. The two dc power
supplies that are available can be operated directly from a dc power source, such as
batteries or inverters, that provide dc power in the range of 20 to 32 V dc (catalog
number IC600PM541), or 100 to 150 v dc (catalog number lC6OOPM546). Each power
supply has several user items mounted on the faceplate. Figure 2.5 illustrates the power
supplies (ac version shown), identifying user items. AC and dc version faceplates are both
shown for reference.
s6830116/117
s6840224/244
-
1. Internal Terminal Strip
2. Chassis Ground Terminal
3. 18-Pin Connector: Connects signal
cable from rack backplane.
4. Front-Panel Connector Block
5.
6.
7.
8.
Power Switch/Circuit Breaker
CPU RUN/STOP Key Switch
MEMORY PROTECT Key Switch
POWER Light.
Figure 2.5 ILLUSTRATION OF POWER SUPPLIES
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2-5
Physical Equipment Configuration
GEK-96602
Each of the power supply user items shown in the preceding illustration is described
below. For detailed information on installation of a power supply, refer to the applicable
data sheet in the Data Sheet manual; wide range ac supply (GEK-83505), 24 V dc supply
(GEK-90761), or 125 V dc supply (GFK-0065).
Table 2.1 POWER SUPPLY USER ITEMS
USER ITEM
DESCRIPTION
LOGIC POWER
SWITCH
This switch is used to switch the ac or dc
power source to the supply ON and OFF.
CPU RUN/STOP
KEYSWITCH
This keyswitch is used to put the CPU in either
the RUN or STOP mode. With the CPU in the RUN
mode, normal scanning operation takes place and
outputs are activated. In the STOP mode, scanning
is halted and outputs are deactivated.
MEMORY
PROTECT/WRITE
KEYSWITCH
This keyswitch is used to allow user memory to be
written to (new program entered or existing program
edited) when in the WRITE position. When in the
MEMORY PROTECT position, the user memory can not be
This is a safeguard against unauthorized
accessed.
or inadvertent changing of the user program.
POWER
This is a visual indicator that the dc voltages
provided by the power supply are available and have
The LED is
reached their proper operating levels,
viewed through the translucent lens on the
faceplate.
LIGHT
ON
The voltage levels of the 3 dc outputs (+5,
+12 and -12 V dc) are available and are within
the specified tolerance.
OFF One or more of the 3 dc voltages is out of
tolerance.
TERMINAL
BLOCK
A terminal block is mounted at the bottom of the
power supply faceplate. Two groups of 7 screw
terminals are located on the block. These
terminals provide the connections for the source of
power, either ac or dc, 2 sets of alarm relay
contacts and an external auxiliary battery.
The
auxiliary battery is optional and is used to
provide battery back-up of the CMOS-RAM memory on
the combined memory module.
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Physical Equipment Configuration
2-6
GEK-96602
Terminal Block Connections
Figure 2.6 is an illustration of the terminal block. The 3 bottom terminals on the right
group of terminals are for connecting the input source of power, either ac or dc,
depending on whether an ac or dc power supply is selected. The 4 remaining terminals on
the right side have no internal connections to the power supply.
70tmpll
a41063
KY
CONTACTS
llSDLATEDl
LINE I ILII
LINE 2 tL21
k%
CONTACTS
fISOLATI
INOpCUT
2D ToD3R2 "OC
ID0 To Iso "'S
IASAPPLIC&8LEJ
Gf?OUND IGI
Figure 2.6 CPU TERMINAL BLOCK CONNECTIONS
The optional external auxiliary battery, if included in a system, is connected to the 2 top
terminals on the left group of terminals. The auxiliary battery voltage is routed through
a regulator in the power supply, which provides a regulated voltage to back-up the
CMOS-RAM memory circuitry in the event of a no power condition to the supply.
The remaining 5 terminals on the left group of terminals provide external signals when
certain internal faults are detected by the CPU. The minor alarm (terminals 1N0 and
1NC) faults are advisory in nature and do not affect the operation or reliability of the
PLC. The major alarm (terminals 2N0 and 2NC) faults are an indication that the CPU
has detected a fault affecting normal operation and has halted its scanning in order to
prevent unreliable or unpredictable operation of the PLC. If a fault does occur, status
indicators on various modules will point to the specific cause of the fault.
NOTE
During normal operation the alarm relays are energized. When an alarm
condition is detected, the contacts 1N0 and 2N0 open, and the contacts 1NC
and 2NC close.
The alarm relay logic is located on a terminal board in the power supply. The alarm relay
provides isolated outputs rated at 115 V ac or 28 V dc, 1 amp resistive load. The major
alarm causes the CPU status to be set to stop. The minor alarm causes an error
indication to be recorded, but the CPU status is not set to stop. Table 2.2 lists some of
the problems that can cause the alarm relays to switch.
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Physical Equipment Configuration
2-10
-
GEK-96602
I/O CONTROL MODULE
The purpose of the I/O Control module (catalog number lC6OOCB503) is to provide an
interface between the CPU backplane bus and the main I/O bus. It is also the interface
to and controls data transfers between the CPU and certain peripheral devices. Logic on
this module includes command, status, port select and data latches, a status multiplexer,
and control and timing circuitry. The I/O Control module must always be placed in slot 1,
which is adjacent to the power supply.
User Connections
There are two 37-pin connectors located on the front of the module. The programming
device for the Series Six Plus plugs into the top connector, which is labeled PP/DPU. The
bottom connector, labeled l/O, provides the connection to the main I/O chain. The l/O
Control module is connected through a parallel I/O cable to the top connector of an l/O
Receiver or Advanced I/O Receiver located in the first I/O rack in a CPU station or
Local I/O station. The last rack of a CPU l/O station can be located up to 50 feet from
the I/O Control module.
If a Redundant Processor Unit (RPU) is to be included in the control system, the bottom
connector of the I/O Control module is connected to the CPU1 or CPU2 connector on the
RPU’s CPU Switch module, depending on whether the CPU is the main or back-up CPU.
The main CPU connects to the CPU1 connector and the back-up CPU connects to the
CPU2 connector on the RPU. When an RPU is included in a system, the I/O chain (or
chains) connects to the I/O Switch module in the RPU, rather then to the l/O Control
module.
Status Indicators
There are 4 LED indicators on the front of the module, viewable through the lens on the
faceplate. The LED indicators provide system status and are an aid to troubleshooting,
should a problem occur.
Table 2.4 I/O CONTROL MODULE INDlCATORS
INDICATOR
CHAIN
OK
DEFINITION
ON when all stations in the main I/O chain have
continuity and have received good output parity.
PARITY
ON when Input data parity is good.
ENABLED
ON when the CPU is in the RUN mode with
outputs enabled.
DPU
ON when the optional Data Processor Unit
is connected and operating properly.
NOTE
With no I/O chain connected to the l/O Control module, the l/O Terminator
plug supplied with each CPU must be connected to the bottom connector in
order to terminate the I/O chain.
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2-12
Physical
Equipment
Configuration
GEK-96602
LOGIC CONTROL MODULE
The Logic Control module contains the CPU system clock, a microprogram sequencer,
and Programmable Read Only Memory (PROM). It provides timing and control signals to
the CPU backplane for use by other modules, and microprogram instructions to the
Arithmetic Control module through a ribbon cable. The time base for the timer functions
in the PLC are derived from a crystal clock on this module. PROM memory on the
module is programmed with an instruction set, which is accessed by the CPU when
executing the user programmed instructions. The Logic Control module also contains
circuitry which allows the CPU to access all 16K of Register memory.
Three versions of the Logic Control module are available, the difference being the level
of the instruction set contained in each one. The Advanced Logic Control module
(catalog number IC600CB525) contains instructions that are accessed by the CPU to allow
execution of the basic and advanced functions. The Expanded Logic Control module
(catalog number IC600CB526) contains instructions in PROM that are accessed by the
CPU in order to execute the basic, advanced and expanded functions.
The Expanded II Logic Control module (catalog number lC600CB515) contains all of the
instructions that are on the Expanded Logic control module. In addition it provides a
dynamic user program memory checksum calculation for enhanced memory checking, has
microcode changes to allow faster execution of ladder logic programs, contains new
instructions for accessing a new 1/O system to be available in the future, support of 64K
user program, and Auxiliary I/O overrides.
The Logic Control module must be placed in slot 2, immediately to the left of the t/O
Control module.
The Logic Control module works in conjunction with the Arithmetic Control module to
generate timing and control signals and must be next to it in the rack, since they are
linked together through a short length of ribbon cable. This short ribbon cable is included
with the basic CPU rack.
NOTE
Do not attempt to operate the system without the ribbon cable connected
between the Logic Control and Arithmetic Control modules. If the cable is not
connected, the CPU will operate unpredictably.
The Logic Control module has no status indicators or other user accessible items. Figure
2.10 is an illustration of a Logic Control module.
NOTE
The Expanded II Functions require the IC600CB524 Arithmetic Control
module, Logic Memory modules IC600LX (8K minimum registers), a 13” rack,
or a 19” CPU rack with a date code later than 10/87.
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Physical Equipment Configuration
2-14
GEK-96602
ARITHMETIC CONTROL MODULE
The Arithmetic Control module, catalog number lC600CB500, (IC600CB524 required with
Expanded II functions) contains circuitry that performs arithmetic and logical operations
on data and address lines. There are 4 hardware registers on the board. The continuity
and buffer registers are each 1 bit wide, while the accumulate and preset registers are
each 16 bits wide. These registers are operated on internally by the CPU and are not user
accessible registers.
The primary hardware for performing the arithmetic and logic functions on this module is
a 16 bit Arithmetic Logic Unit. The Arithmetic Logic Unit works in conjunction with the
Logic Control module to generate timing and control signals and must be next to it in the
rack, since they are linked together through a ribbon cable connector. The AM2903 is a 4
bit expandable bipolar microprocessor slice, which is especially useful for arithmetic
oriented processors. In addition, it provides a special set of instructions that ease the
implementation of multiplication, division, and other time consuming operations.
The Arithmetic Control module must be placed in slot 3 in the CPU rack, immediately to
the left of the Logic Control module.
Status Indicators
There are 2 LED status indicators, labeled RUN and CHECK, on the front of the board
which are viewable through the translucent lens on the faceplate. The executive routine
in the scan execution sequence contains a self-test that is executed once per scan. The
RUN LED, when ON, is an indication that the execution sequence is normal, the self-test
has passed, the I/O scan is completed at least once every 300 ms +/-50 ms, and the CPU is
in the RUN mode.
The CHECK LED is ON when the self-test has been completed successfully at least once
each l/O scan, the system clock is operating normally, or if the scan time is no longer
than 300 ms +/-50 ms.
Table 2.5 ARITHMETIC CONTROL MODULE STATUS INDICATORS
INDICATOR
RUN
DEFINITION
ON: Execution sequence proceeding normally,
self-test has passed, the I/Oscan is completed at
least once every 300 ms +/-50 ms and the CPU is in
the RUN mode.
OFF: CPU is in the STOP mode.
CHECK
ON: Execution sequence proceeding normally,
self-test has passed at least once each 300 ms
+/-50 ms.
CPU can be in RUN or STOP mode.
OFF: CPU self-test has not passed within
300 ms +/-50 ms, or user program takes longer than
300 ms to execute. CPU goes to STOP mode and I/O
chain is reset.
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Physical Equipment Configuration
2-17
GEK-96602
The status table stores bits representing the ON or OFF status of the 1000 inputs and
1000 outputs in the main I/O chain when in Normal mode. In the Expanded mode of
operation, the status table stores the status bits of the 1000 inputs and 1000 outputs in
the main I/O chain from a programming standpoint, but in Channel 0 from a real I/O
point-of-view. The transition table stores the logic state of the inputs to counters and
one-shots in the main I/O chain when in the Normal mode or for Channel 0, when in the
Expanded mode. The override table stores the status of overridden input or output bits in
both the Main and Auxiliary I/O chains in the Normal mode. An overridden bit in the
status table is not changed when the CPU reads inputs or solves outputs. The internal
memory is stored as 8 bits of data and 1 bit of parity.
Detection of Active Overrides in System
With the Expanded II functions, a means of detecting if there are any active overrides in
the system is available. Two bits in the Main status table are used for this purpose.
Output O1015 is defined as the Override Active in System Enable bit and O1016 is defined
as the Override Active in System Report bit. Once each sweep O1015 will be checked by
the CPU. tf the bit is not set to a 1, the CPU will skip the active Override search. If the
bit is set, the CPU will initiate a search of the Main and Auxiliary Override Tables in
search of an active override bit (bit that has been set to a "1"). The search will continue
until either an active override is found or the end of the override tables is reached. If an
active override is found, bit O1016 will be turned ON (the user can check O1016 for a “1”
or a “0” to determine if there are any active overrides in the system). If the end of the
override tables is reached without finding an active override, O1016 will be turned OFF.
If O1015 is turned OFF, then O1016 will not be modified.
Scratch Pad Items
The Scratch Pad storage area contains miscellaneous data pertaining to CPU operation.
The Scratch Pad display, as viewed on the Workmaster computer, includes these items
and the current status of each one. Some of the items can be changed by the user, others
are configured by the CPU and cannot be altered by the user.
Table 2.7 SCRATCH PAD STORAGE ITEMS
ITEM
DESCRIPTION
CPU ID
A number assigned to the CPU when there is more
than one CPU in a communications system
.
Number of words of logic memory in the CPU.
State of the Memory Protect key switch on the CPU.
Number of subroutines in the user’s program.
Current operating status of the CPU, either run
enabled, run disabled or stop.
Level of the instruction set resident
, in the CPU
either Advanced, Expanded, or Expanded II.
Length of current user program in 16-bit words.
Number of unused 16-bit words left in user memory.
N umber of 16-bit Register memory locations in CPU.
Revision level of the CPU software.
A group of 24 bits in Scratch Pad memory used by
the CPU to indicate the type and location of
faults detected by the CPU during its normal
operation or self checking.
MEMORY SIZE
CPUMEMORY
SUBROUTINES USED
CPU STATUS
FUNCTIONS
WORDS USED
WORDS AVAILABLE
REGISTERS
CPU VERSION
CPU ERROR FLAGS
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Physical Equipment Configuration
2-18
GEK-96602
Type of Memory Used
The Combined Memory modules use CMOS-RAM integrated circuit memory as the
storage devices. CMOS-RAM is an integrated circuit memory that uses low power.
CMOS-RAM memory is volatile, i.e, its contents are lost under no-power conditions. In
order to maintain the contents of memory when power fails or is turned off, a
Lithium-Manganese Dioxide battery (usually referred to as a Lithium battery) is provided
as a power back-up for these devices. The Lithium battery is located on the module,
along with circuitry to monitor the batteries voltage level.
Battery Status Indicator
The Lithium battery (catalog number IC600MA507) provides about 1 year of data
protection under no-power conditions. One of the 2 LEDs on the board is an indication of
the battery condition. This LED is labeled, BATTERY. With power applied to the CPU,
the LED w ilI be ON, if the battery condition is normal. The normal fully-charged voltage
of a Lithium battery is 2.95 V dc @ 1 .OO amp-hours.
If the battery voltage is low (between 2.55 V and 2.75 V), the LED will flash. When this
happens, the battery should be replaced as soon as possible. The CPU will continue
running if the battery voltage is low. If the CPU stops, it can be restarted. If the
battery voltage drops below 2.55 V, the LED will turn OFF. If the CPU stops, it cannot
be restarted under this condition. Instructions for replacing a defective battery can be
found in Chapter 5, System Maintenance.
Table 2.8 COMBINED MEMORY MODULE STATUS INDICATORS
INDICATOR
STATUS
DEFINITION
BATTERY
UN
Condition of Lithium backup battery is normal.
FLASHING
Battery voltage is low. CPU continues running.
Alarm 2 (Advisory) is activated. To protect the
memory contents, replace the battery as soon as
possible - before It fails.
OFF
Battery failed. CPU continues running, but will not
restart if stopped.
Alarm 2 remains activated.
Contents of memory wfll be lost if power Is turned
off or lost for any reason.
ON
Normal
OFF
Parity error detected in either Logic, Register, or
Internal memory. A bit will be set in the CPU Error
Flag and displayed on the Workmaster computer screen
in the Scratch Pad display An error message will be
displayed which will interpret the content of the
error flags. An address will be displayed in
Hexadecimal format to pinpoint the location of the
defective module.
PARITY
operation, no parity errors detected by CPU.
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2-19
Physical Equipment Configuration
GEK-96602
A jumper on the Combined Memory Module allows the user to use an external auxiliary
backup battery connected to the terminal block. With the external battery configuration,
the on-board battery need not be connected.
Location in Rack
The Combined Memory Module must be placed in slot 4, which is directly to the left of
the Arithmetic Control Module in the Series Six Plus CPU rack.
NOTE
Existing versions of the Series Six PLC Combined Memory module (catalog
numbers IC600CM552 and IC600CM554) can be used in a Series Six Plus CPU
rack. Additionally, all Series Six Plus PLC Combined Memory modules can be
used with a Series Six PLC model 60 CPU, however, there is no parity check
with this combination.
Precautions When Handling Memory Modules
When installing or removing a Combined Memory module, it is recommended that you use
the extraction/insertion tool (lC600MA504) provided with each CPU.
Relatively small amounts of excess charge can cause very intense
electrostatic fields in Metal-Oxide-Semiconductor (MOS) devices, damaging
their gate structure. Avoid handling the circuit board under conditions
favoring build-up of static electricity. Failure to observe this caution could
result in destruction of the CMOS-RAM devices in this module.
A bottom board cover provided with each Combined Memory module acts as an electrical
noise shield and helps protect the battery circuits from accidental discharge. This cover
should not be removed during operation or handling of the board.
Do not allow the bottom of the module to come in contact with a conductive
(metal) surface when the board cover is removed. Failure to observe this
caution could result in the discharge of the non-rechargeable lithium battery
and the loss of memory contents.
Memory
Protection
A two-position key switch located on the power supply is provided for protecting logic
and override memory that has been written into. The two positions are MEMORY
PROTECT and WRITE. In the WRITE position, the user can write into logic memory to
enter or change programs. When in the MEMORY PROTECT position, logic memory
cannot be written into, thereby protecting any user program previously entered from
being changed or destroyed. Once a program has been entered and debugged, it is
advisable to place the key switch in the MEMORY PROTECT position.
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Physical Equipment Configuration
2-21
GEK-96602
BUS CONTROLLER MODULE
The Bus Controller module is the required interface between a Series Six Plus PLC and
the Genius l/O blocks when they are included in the PLC’s I/O system. The Bus
Controller module can be placed in any I/O slot in the CPU or in a high-capacity I/O rack
located in a CPU station or local I/O station up to 2000 feet (600 meters) from the CPU.
Multiple Bus Controllers can be placed in one rack. Since each Bus Controller consumes
20 units of load, up to 5 modules can be placed in a CPU rack, or 10 modules in a high
capacity I/O rack.
A Bus Controller can be placed in an I/O rack in a Remote I/O station if the CPU scan
time is greater than 10 ms. However, because of the reduced capacity of the serial I/O
communications link, window commands would not be supported. Each Bus Controller can
interface up to 30 Genius I/O blocks to the Series Six Plus CPU by twisted pair
communications up to 2000 feet 6 0 0 meters). The only limit to the number of Bus
Controllers in any one PLC system is the I/O capacity of the Series Six Plus CPU. Each
Bus Controller, similar to any I/O module, has access to all I/O references on its I/O
chain.
A 4-segment DIP switch located on the module is used to enable channel selection for
Expanded I/O addressing. If Normal (non-expanded) addressing is used or if channel
selection is made through I/O Transmitter Modules, no switch setting is necessary.
The Genius l/O bus must be terminated at the Bus Controller by its characteristic
impedance. The enhanced version Bus Controller provides three selectable on-board
impedances, 100 150 or 750 Ohms Three jumpers (JP1, JP2, and JP3) on the module are
used to select one of the listed values, or to select no impedance.
Versions of Bus Controller
Two versions of the Bus Controller are available, they are:
1.
Catalog Number IC660CBB901 (lC660CBB903 has enhanced features). Interfaces
with the Genius l/O blocks and provides normal Genius I/O status information and
Hand Held Monitor support. It requires one byte of input address (8 references) for
transfer of its status to the CPU.
2,
Catalog Number lC660CBB900 (lC660CBB902 has enhanced features). Provides all
functions of the IC660CBB901 Bus Controller plus a wide range of diagnostic data
and system functions for the entire Genius I/O system. This Bus Controller requires
6 addresses for diagnostic input data (48 references) provided to the CPU and 4
addresses for command output data (32 references) received from the CPU.
Addresses are selected by the DIP switches at the rear of each I/O slot.
For detailed information on the Bus Controller modules, refer to the Genius I/O System
User’s Manual, GEK-90466.
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Physical Equipment Configuration
2-22
GEK-96602
COMMUNICATIONS CONTROL MODULES
The Communications Control Modules (CCM2, CCM3, I/O CCM, I/O Link local) provide a
serial interface between the Series Six Plus PLC and any intelligent device that can
initiate communications based on the CCM protocol and CCM electrical interface
requirements. A brief description of each of these modules is provided in this manual.
For detailed descriptions of these modules and pertinent data communications
information, refer to GEK-25364, which is the Series Six Data Communications Manual,
GEK-90505, which is the Supplement To The Data Communications Manual, and
GEK-90824, which is the data sheet for the Input/Output Communications Control
Module.
Communications Control Module, Type 2 (CCM2)
The CCM2 (catalog number IC600CB516) has 2 serial ports that provide RS-232 and
RS-422 electrical interface capability. RS-232 is normally used for direct connections at
a maximum distance of 50 feet (15 meters). The RS-422 interface allows direct
connection up to 4000 feet (1200 meters). The CCM2 can be connected directly to short
haul or telephone line modems through the RS-232 interface, if transmission distances
greater than the 4000 feet allowed by RS-422 are required. The CCM2 can operate at
speeds up to 38.4K baud, and can originate messages with control by the ladder diagram
logic, using the Serial Communications Request (SCREQ).
Examples of intelligent devices that can be interfaced to the CCM2 include:
-
Communications Control Module, Type 3 (CCM3)
-
A host computer or microprocessor based devices
-
Color-graphics terminals
-
GEnet
Factory LAN
The CCM2 also provides an interface to the following devices:
-
A S T R - L I N K IIA or STR-LINK III tape recorder. These recorders are used to
facilitate recording or loading of CPU user’s programs at the Series Six Plus PLC
location. The STR-LINK Ill tapes are interchangeable with PDT tapes.
-
A handheld Operator Interface Unit (OIU), which allows an operator to monitor
and modify the register contents of the CPU, monitor and modify timers and
counters, and monitor, modify, and override Input and Output (l/O) points.
-
A dumb terminal or printer
The CCM2 is capable of initiating data transfers to and from any Series Six Plus PLC
memory type, including register tables, input and output tables, override tables, scratch
pad, and user logic. When a Series Six Plus CPU is connected through a CCM2 to a host
computer or other device that is not a Series Six Plus PLC, the user must either write or
purchase the software necessary to communicate with the CCM2.
STR is a trademark of Electronic Processors, Inc.
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Physical Equipment Configuration
2-23
GEK-96602
System
Configuration
Three types of system configurations are supported by the CCM2: point-to-point,
multidrop, and GEnet . A point-to-point configuration allows only two elements to be
connected to the same communications line. Using this configuration, the CCM2 protocol
In the multi-drop
allows either peer-to-peer or master-slave communications.
configuration, one CCM2 or host device is configured as the master and one or more
CCM2s are configured as slaves; only the master-slave protocol can be used. The GEnet
Factory LAN (Local Area Network) is a Local Area Network through which many devices
can be connected. A Bus Interface Unit (BIU) allows Series Six Plus PLCs to access the
GEnet Factory LAN, and can support a maximum of 4 CCM2s. By using multiple BIUs, a
maximum of 254 Series Six Plus PLCs with CCM2s can be connected to the network.
User Items
The CCM2 requires 1 slot in the Series Six Plus PLC rack, and must be installed in slot 5.
At the top of the module are 2 switches used during communications with a STR-LINK
IIA or STR-LINK III tape recorder. The 2 connectors on the board are both capable of
RS-232 and RS-422 operation. J1 is a 25-pin "D” type female connector and J2 is a 9--pin
“D” type female connector. If a STR-LINK tape recorder is to be used, it must be
connected to the J1 connector. Four LEDs on the board, viewable through the faceplate
lens, are indicators of the operating state of the module. Table 2.9 is a description of the
indicators. Figure 2.14 is an illustration of the CCM2 module.
Table 2.9 CCM2 STATUS lNDlCATOR DEFINITIONS
INDICATOR
STATUS
DEFINITION
BOARD OK ON
Board has passed power-up
test and is operating
properly.
FLASHING Invalid configuration or CPU number.
OFF
Power-up test failed, indicating a hardware failure.
MATCH OK ON
OFF
Good compare between tape and CPU has been made.
Compare of tape with CPU Memory has failed. TAPE OK
Indicator also turns off.
DATA
OK
ON
FLASHING
OFF
Data transmission normal.
Data is being transferred.
Data incorrect because of parity, overrun or
framing errors, bad data block or the serial
link has timed out. A CCM2/CPU communications
failure will cause this light and the BOARD OK
light to turn off.
TAPE
OK
ON
OFF
Tape data transmission normal.
Data stream interruption caused by parity,
framing or overrun errors, unsuccessful tape
comparison or timeout on the tape link.
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Physical Equipment Configuration
2-25
GEK-96602
Communications Control Module, Type 3 (CCM3)
The CCM3 (catalog number IC600CB517) provides all of the functions of the CCM2 plus
the protocol required to communicate with selected process control systems. Physically,
the CCM3 is similar to the CCM2. Refer to the illustration, figure 2.14, on the preceding
page. Options for baud rate, protocol, turn-around-delay, and parity can be selected for
the CCM3 in the same manner as with the CCM2, by hardware, using DIP switches and by
software, using configuration registers. The primary difference between the two modules
is in the software, which for the CCM3 includes 2 modes of operation: CCM2 mode and
CCM3 Remote Terminal Unit (RTU) mode. Information on the installation, operation,
and protocol of the CCM3 can be found in GEK-90505, which is the Supplement To The
Data Communications Manual.
CCM2 Mode
When the CCM3 is in the CCM2 mode, the CCM3 operates the same as the CCM2 module,
except that the following protocol options of the CCM2 are not available to the CCM3:
- RS-422 with clock on port J1
- Test 1 on port J2
This is because the DIP switch settings and the bit pattern for the software configuration
registers, which are on the actual CCM2 are used to select the options listed above, are
reserved on the CCM3 to select RTU mode for ports J1 and J2 If any protocol selection
for a CCM3 port is made other than RTU, that port will operate as a CCM2. When
configuring the CCM3 in CCM2 mode, follow the directions found in Chapter 3,
Communications Control Module (CCM2) in GEK-25364, which is the Series Six Data
Communications Manual.
CCM3 Remote Terminal Unit (RTU) Mode
In RTU mode, the CCM3 is a slave device designed to be used on a link with a host
computer or other intelligent device capable of emulating RTU master protocol. When
using this mode, the CCM3 is capable of accessing the following Series Six Plus PLC
memory types: register tables, input and output tables, override tables, scratch pad and
user logic.
In addition, several Serial Communications REQuests which do not use RTU protocol, the
unformatted Write and Read Character String commands, can be initiated by application
programming when in RTU mode. These communications requests are included in CCM3
(RTU) software for application programming.
Dual Mode Usage
One CCM3 communications port can be configured in CCM2 mode at the same time that
the other port is configured in RTU mode. Restrictions regarding the use of two ports in
different modes are given in the section, Simultaneous Port Operations, in the CCM3
Supplement, GEK-90505.
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Physical Equipment Configuration
2-26
GEK-96602
I/O Communications Control Module (l/0 CCM)
The I/O CCM (catalog number IC600BF948) is a communications module for use as an
additional communications interface between the CPU in a Series Six Plus PLC and
external devices. The I/O CCM should be used when the primary communications module
(CCM2 or CCM3) has both ports committed and additional ports are required for an
appl icat ion.
The l/O CCM has two ports, labeled PORT 1 and PORT 2, for asynchronous serial
communication at data rates from 300 to 19.2K baud using CCM (master, slave, or peer)
or RTU (slave only) protocol. Unformatted read and write can also be used. Both ports
support RS-232 and RS-422. In addition, Port 1 also supports active or passive 20 mA
current loop. The two ports can be independently configured by module hardware.
The I/O CCM does not support STR-LINK tape recorders, the Operator Interface Unit, or
port configuration from registers. However, it can interface to most other devices and
perform the same tasks as the CCM2 and CCM3 modules. The l/O CCM must be inserted
in a high capacity I/O rack or an I/O slot in a Series Six Plus CPU rack.
Detailed information on the I/O CCM can be found in GEK-90824, which is the data sheet
for the Input/Output Communications Control Module. Figure 2.15 is an illustration of
the I/O CCM.
a40528
1.
2.
3.
4.
5.
6. J2 Connector: 25pin D-type female
LED Status Indicators.
connector (Communications Port 2).
Bank A DIP Switches.
7. J2 Communication selection DIP package:
Bank B DIP Switches.
RS-232 or RS-422 configuration. Read
Bank C DIP Switches.
from top of imprinted label.
J1 Connector: 25pin D-type
female connector (Communications 8. Faceplate.
Port 1).
Figure 2.15 ILLUSTRATION OF l/O CCM MODULE
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Physical Equipment Configuration
2-27
~~
GEK-96602
I/O Link Local Module
The l/O Link Local module (catalog number IC600BF947) provides a communication link
with diagnostics from a Series Six Plus PLC to a slave Series One PLC and Series Three
PLC input and output devices. The l/O_Link Local module can be connected to as many
as seven remote Series One or Series Three racks (or a combination of both) in a single
chain. It can access a maximum of 96 I/O points from a Series One rack and 224 l/O
points from each Series Three rack.
The I/O Link Local module can be inserted in the I/O portion of a Series Six Plus CPU
rack or in a Series Six high capacity I/O rack. The connection to the Series One or Series
Three I/O is made through the I/O Link Remote module in a Series One or Series Three
I/O rack.
A maximum of 4 I/O Link Local modules can be installed in the I/O portion of the CPU
rack. With this configuration, no other l/O modules can be resident in the CPU rack.
This is because of the power consumption (in units of load) of the I/O Link Local
modules. A maximum of 5 I/O Link Local module can be installed in a high capacity I/O
rack. In this configuration, there are 175 units of load remaining for I/O modules with +5
V dc power only.
The actual physical connection between the I/O Link Local module and the remote Series
One or Three racks is a 2-wire (plus ground) RS-422 multidrop. The maximum distance
between the I/O Link Local module and the last remote rack in the chain is 3300 ft (1 km).
The I/O Link Local module must be configured for each application by setting DIP
switches located on the module. The DIP switches determine the starting address of a
configuration table in the CPU.
For detailed information on the use and configuration of an I/O system using the l/O Link
Local module and Series One or Three l/O, refer to GEK-90825, which is the Series Six
PLC I/O Link Local User’s Manual. Figure 2.16 is an illustration of a typical I/O
communications link between a Series Six Plus PLC and Series One and Three I/O.
a42084
n
Figure 2.16 I/O LINK LOCAL MODULE TO SERIES ONE
OR SERIES THREE REMOTE I/O RACKS
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Physical Equipment Configuration
2-28
GEK-96602
Figure 2.17 is an illustration of the physical layout of the l/O Link Local module.
a4047 7
1 LINK
ICAL
IARD
<
‘l-l
MM
ic 1
7E-i
ic 2
SSOR
LED
BATTERY NOT REQUIRED BOARD OKCPU
COMMUNICATIONS
NOT
USED
-
RECEIVE 1 TRANSMIT
1 -
RECEIVE 2 TRANSMIT 2 -
lANs
8
CONFIGURATiON
TABLE ADDRESS p
D I P SWtTCHES f
C
‘DRT 1
.:*.
::*
9::9:*
0.
00
I
PORT NOT USED
-[
L
i
I
;
i
I
8
Figure 2.17 I/O LINK LOCAL MODULE
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/
2-29
Physical Equipment Configuration
GEK-96602
I/O STRUCTURE FOR THE SERIES SIX PLUS PLC
The I/O structure for the Series Six Plus PLC provides the user with many options of
system configurations and a large variety of discrete and special I/O modules designed to
fit the needs of virtually any application. Any of the rack-based Series Six l/O modules
can be used in a Series Six Plus PLC system and can be placed anywhere within the I/O
structure, except that devices such as the ASCII/BASIC module requiring windows from
the CPU cannot be used in Remote I/O stations. The 19” CPU rack has 6 slots in which
I/O modules may be placed and the 13” rack has 3 slots for I/O modules. When an
application requires more l/O than can be contained in the CPU rack, an optional I/O rack
or racks can be added. This allows a system to use the maximum I/O points available in a
configuration.
I/O RACKS
All I/O modules, other than those in the CPU rack, are housed in an I/O rack. The l/O
rack uses the same mechanical packaging as the CPU rack and is available in both 13” and
19” racks. The l/O racks can be mounted in the same manner as the CPU racks and can
be either rack or panel mounted. Two 13” racks can be mounted side-by side in a NEMA
12 wide rack. Each rack is supplied with reversible mounting brackets for mounting as
required by the user. With the brackets attached to the front of the rack, it can be
mounted in a standard 19” or 13” rack, as applicable. By rotating the brackets 90” and
mounting them on the rear of the rack, the rack can then be wall or panel mounted.
81pc51
1.
2.
3.
4.
7 Position DIP Switch (10 Per Rack).
41-Pin Connector (11 Per Rack).
Logic Power On/Off Circuit Breaker.
Power On Indicator.
5.
6.
7.
8.
I/O Power Supply.
Terminal Board
Tray For Containing Field Wiring.
Cardguide (11 Per Rack).
Figure 2.18 TYPICAL I/O RACK
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Physical Equipment Configuration
2-30
GEK-96602
Each I/O rack provides regulated dc power and backplane signals from the power supply
for I/O modules, and is available in three versions: ac standard and ac or dc high-capacity
(13” rack requires the high-capacity ac supply). The difference being the total current
supplied from the power supply. A standard I/O rack provides adequate current for
modules for most applications.
When an application requires I/O modules that
collectively would draw more than 6.1 amps, a high-capacity rack must be used.
Table 2.10 I/O RACK AND POWER SUPPLY SPECIFICATIONS
Rack Dimensions (19", 11 slots)
Rack Mount
Panel
Mount
Weight (Empty)
Rack Dimensions (13", 8 slots)
Rack Mount
x 14.0(H) x 10.3(D) inches
(483 x 356 x 261 millimeters
20.0(W) x 14.0(H) x 10.3(D) inches
508 x 356 x 261 millimeters
30 Pounds (13 Kg)
19.0(W)
16.0(W) x 13.25(H) x 9.3(D) inches
406 x 337 x 236 millimeters
Rack Mount with Brackets for
standard 19" Rack
19.0(W) x 13.25(D) x 9.3(D) inches
483 x 337 x 236 millimeters
Panel Mount (Brackets on sides)
16.0(W) x 13.25(H) x 9.3(D) inches
Panel Mount (Brackets on Top and
Bottom, Side-By-Side Mount
13.25(W) x 16.1(H) x 9.3(D) inches
337 x 410 x 236 millimeters
Power Supply Input Requirements
AC - Standard, IC600YR501
Frequency
Voltage
Maximum load
- High Capacity, IC600YR511
Voltage and Maximum Load
DC - High Capacity, IC600YR514
Voltage and Maximum Load
DC - High Capacity, IC600YR546
Voltage and Maximum Load
Power Supply Voltages to Rack
Standard (100 Units of Load) (1)
High Capacity (275 Units of Load)
AC
Allowable Power Interruptions
Operating Temp. (Outside of Rack)
Storage Temperature
Humidity (Non-Condensing)
Noise Immunity
Altitude
(1) 1 unit of load = 60 mA.
47 to 63 Hz
95 - 132 V ac
190 - 269 V ac >
80 VA
Jumper
Selectable
9 5 - 260 V ac (Wide Range), 250 VA
20 to 32 V dc, 180 VA
100 to 150 V dc, 180 VA
+5 V dc, 6.1 A (maximum)
+5 V dc, 16.5 A (maximum)
+12 V dc, 1.5 A (maximum)
-12 V dc, 1.0 A (maximum)
AC: 33 mSec (min) - 115 V ac line
DC: 10 mSec (min) - 20 V dc line
4 mSec (min) - 100 V dc line
0 to 60°C (32F to 140" F)
-20 to + 8 O C (-4 to 176°F)
5% to 95%
Meets requirements of NEMA
ICS 2-230 and ANSI C37.90A
Up to 10,000 Feet (3000 meters)
above Sea Level
Calculations based on worst case, all inputs or outputs on.
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Physical Equipment Configuration
2-33
GEK-96602
Normal Mode I/O Addressing
The Series Six Plus PLC allows I/O to be configured in either the Normal I/O mode or the
Expanded I/O mode. Selection of the mode is made through the Configuration Menu
screen, using Logicmaster 6 software. In the Normal I/O mode, one I/O chain per CPU is
permitted (this is the factory default setting). In this mode, available I/O is 1000
Inputs/l000 Outputs in the Main I/O chain, plus an additional 1000 Inputs/l000 Outputs in
the Auxiliary l/O chain, if an Auxiliary l/O module is included in the system.
The ON or OFF state of the 1 K Inputs and 1 K Outputs in the main I/O chain is maintained
in the I/O Status Table. The ON or OFF states of I/O points in the Auxiliary I/O chain
are maintained in the Auxiliary I/O Status Table which is mapped into the first 128 words
of Register memory. ROOOI to R0064 contains the Auxiliary Output Table, and R0065 to
R0128 contains the Auxiliary Input table.
Expanded Mode l/O Addressing
When the Expanded I/Omode is selected, a total of 8K Inputs and 8K Outputs in the Main
I/O chain are available to the user. In addition, if the Auxiliary I/O chain is selected
(requires an Auxiliary I/O module) 8K Inputs and 8K Outputs are available in the Auxiliary
chain. The total real I/O available through the use of both chains is 16K Inputs and 16K
Outputs (32K total points). I/O points in the Expanded mode are selected in 1K (1 K tnputs
and 1 K outputs) increments, referred to as channels.
An I/O Transmitter module is required for each channel of l/O, with the exception that if
channels 0 and 8 are the only Expanded mode channels selected, an I/O Transmitter is not
needed since the I/O is scanned the same as the Main and Auxiliary I/O chains in the
Normal mode. If more than two channels are to be used, I/O Transmitters are required.
A jumper on each l/O Transmitter module must be configured for either Normal mode or
Expanded mode. The CPU scans only those channels that have been selected. The
channel number to be associated with each l/O Transmitter is selected by setting the first
3 switches (switches 1,2, 3) on the DIP switch package on the backplane adjacent to the
module.
Channel Reference Numbering
The channels are numbered from 0 to F; the Main I/O chain channels are referenced 0
through 7 and the Auxiliary I/O chain channels are referenced 8 through F.
The format for addressing I/O in the Expanded mode must include a channel number,
either I or O, a real I/O state (+) or internal discrete status (-) reference identifier and
the l/O number. The exception to this is for channel 0 and 8; channel 0 programming
references are O0001 - O1024 and I0001 - I1024, channel 8 programming references are
AO0001 - AO1024 and Al0001 - Al1024). References O0+000l to O0+1024, I0+0001 to
I0+1024 (if Auxiliary Inputs and Outputs are not being used) and O8+0001to O8+1024,
I8+0001 to I8+1024 cannot be used as real I/O references, but are available for use as
discrete programming references.
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Physical Equipment Configuration
2-34
GEK-96602
Thus, the format for real I/O points for channel 3 in the Main I/O chain is (for example)
I3+0001 to I3+1024 for Inputs and O3+0001 to O3+1024 for Outputs. Each IK channel
requires 64 words of memory (64 words x 16 bits = 1024 l/O). Note that although 1024
bits are available in each channel, 0001 to 1000 are used for actual l/O points. 1001 to
1024 are reserved for special use.
Real I/O Memory Allocation
In the Expanded mode, the real I/O points for Channel 0 are scanned on the Main I/O
chain (references 10001 - I1024 and O0001 - O1024) and their status is maintained in the
Main I/O status table. Channel 8, which is the first Auxiliary I/O channel in Expanded
mode, is scanned on the Auxiliary I/O chain (references Al0001 - AI1024 and AO0001 AO1024) and its I/O status is maintained in Registers R0001 through R0128, which is the
Auxiliary I/O status table. Channels 1 through 7 of real I/O are mapped into Registers
R0129 through R0961 and the Auxiliary channel real I/O, Channels 9 through F are
mapped into Registers R1153 through R2048. This mapping scheme is valid for systems
having either 8K or 16K words of register memory. For mapping of 1K or 256 register
systems, refer to Chapter 4. There you will find illustrations of memory allocation for
each register configuration.
The override tables are associated only with the I, Al, O, and AO references. The
transition tables, which are required for operation of one-shot and counter functions, are
associated only with the O and AO references.
Internal Discrete Reference Memory Allocation
The internal discrete references (I/O states) for Channels 0 through 7, which can be used
for program references, but are not available to real world inputs or outputs, are mapped
into Registers R2049 through R3072. The internal discrete references for Auxiliary
channels 8 through F are mapped into Registers R3073 through R4097 for systems having
8K or 16K of registers.
Expanded Mode I/O References
Table 2.11 is a list of Expanded Mode I/O point references for each channel and their
memory location. There is a total of 66K of discrete references supported by the Series
Six Plus PC. These references include 4K in the Main and Auxiliary I/O chain (I, O, Al,
AO), 30K of real I/O, and 32K of internal references when in the Expanded mode. Any
reference that is not used as a real I/O point can be used for internal reference or
retentive data storage (registers).
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Physical Equipment Configuration
2-36
GEK-96602
I/O SYSTEM CONFIGURATION
A Series Six Plus PLC I/O system can be configured as 3 types of interconnected l/O
groupings of racks referred to as stations. The 3 systems (stations) are described in the
following pages. I/O racks are connected by interface modules located in the CPU or I/O
racks. Interfacing is through the parallel bus channel using a 16-pair shielded cable for
CPU I/O stations and Local l/O stations. Interfacing to the Remote l/O station is through
a serial communication channel using a 2-pair shielded cable or an RS-232 modem link.
The number of I/O racks and modules in a system is determined by the number of I/O
points required by the application. The maximum number of I/O points in a system is
determined by the mode of operation, either NORMAL or EXPANDED, and the number of
selected channels in the system. Each I/O rack contains a power supply, an interface
module and up to 10 additional modules. The station configuration will be shown in detail
in the illustration included in this section for each l/O station.
I/O Rack Interconnections
l/O racks are interconnected in a system by using combinations of I/O Receivers,
Advanced I/O Receivers, l/O Transmitters, Remote I/O Drivers or Remote I/O Receivers,
depending on the number of l/O points required, the grouping, and location of the racks.
Racks are grouped together in either a CPU station, a Local I/O station or a Remote I/O
station depending on their physical location and distance from the CPU and from other
I/O racks.
Each I/O rack requires a receiver which isolates the I/O data cable from the backplane
bus and performs error checking. A receiver does not require an address and is normally
inserted in the left slot; however, a receiver can be placed in any l/O slot. Two
connectors are mounted on each receiver, the top one is for incoming data and the
bottom one is used to forward datato a receiver in the next rack of an I/O chain. This
method of linking l/O racks together in a station is referred to as a daisy chain. A group
of I/O racks in a daisy chain can have no more than 50 feet (15 meters) separating the
first rack from the last and there can be a maximum of ten I/O racks in the chain.
The last rack in a daisy chain requires termination of the I/O signals. This is done by
configuring the DIP shunts and jumper pack on the last I/O Receiver module in the daisy
chain. Optionally, the Workmaster computer can be connected to the bottom connector
of the last rack in a CPU station or Local I/O station.
I/O racks separated by no more than 500 feet (150 meters) can be connected from an I/O
Transmitter, through a 16 pair cable to an I/O Receiver or Advanced l/O Receiver in the
first I/O rack of a chain of no more than ten racks. A total of four Local I/O stations can
be connected in this manner; however, the last Receiver can be no more than 2000 cable
feet (600 meters) from the originating CPU.
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Physical Equipment Configuration
2-37
GEK-96602
A Remote I/O system allows l/O racks to be located up to 10,000 feet (3 km) from any
rack in a CPU station or a Local l/O station by direct cable connection. A Remote I/O
Driver placed in a slot in a CPU station or Local station is connected through a two
twisted pair serial cable to a Remote I/O Receiver located in the left slot of a remote
station. Any number of Remote I/O Drivers and Remote l/O Receivers can be used in a
system. Up to 243 inputs and 248 outputs can be located in a Remote l/O station.
Additionally a CPU station or Local station can be connected to a remote station at
distances greater than 10,000 feet (3 Km) by using a communications fink consisting of
RS-232 modems.
CPU I/O Station
The CPU I/O station, as illustrated in figure 2.21, consists of a Series Six Plus CPU with
up to 10 I/O racks. The racks are daisy chained on the parallel I/O bus (to the l/O Control
module) with the last I/O rack located physically no more than 50 feet from the CPU.
Each I/O rack in the chain includes a Power Supply module (standard ac or high-capacity
ac or dc in a 19” rack, or high-capacity ac in a 13” rack), an I/O Receiver or Advanced
I/O Receiver module and up to 10 additional modules in a 19” rack or up to 7 additional
modules in a 13” rack, The modules in the I/O rack are determined by the system
configuration required. The modules can be a combination of the following modules:
Input modules, Output modules, I/O Transmitter module and Remote I/O Driver module.
Each I/O rack must have one, (and only one) l/O Receiver or Advanced I/O Receiver.
If more than 10 I/O racks are required in a system, one or any of the I/O racks in the CPU
station may contain any combination of l/O Transmitter or Remote I/O Driver modules
for connection to additional I/O racks.
A Workmaster or Cimstar I computer, or PDT can be plugged into the l/O Control module
at the CPU, an I/O Receiver or Advanced I/O Receiver in the last I/O rack in a CPU l/O
station or a Local I/O station. The Workmaster or Cimstar I computer can also be
plugged into an I/O Transmitter in a CPU station or Local I/O station. When connected
to an I/O Transmitter, the Workmaster or Cimstar I computer can be connected through
the 100, 200 or 500 foot lengths of I/O cable. The PDT can only be used in the Normal
mode and only with the Advanced functions.
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Physical Equipment Configuration
2-40
GEK-96602
Remote I/O Station
A Remote I/O station consists of I/O racks connected in a daisy chain through the parallel
I/O bus. A combination of l/O modules with a total of either 120 inputs and 120 outputs
or 248 inputs and 248 outputs (jumper selectable) can be located in a Remote l/O station.
The first and last rack in a Remote I/O station daisy chain can be separated by no more
than 50 feet (15 meters) of cable.
In addition to the racks on the daisy chain an I/O Transmitter located in a rack in the
Remote I/O station can be the first in a link of l/O Transmitters connecting to additional
groupings of racks. An I/O Transmitter can be connected to the first rack in a group of
racks by a 16-pair parallel cable with a length up to 500 feet (150 meters). Up to four
links can be connected in this manner, thereby extending the Remote l/O station an
additional 2000 feet (600 meters).
NOTE
The total number of l/O points assigned to a Remote I/O station (either
120/120 I/O or 248/248 I/O) cannot be exceeded regardless of the rack
configuration.
A Remote l/O station connects to an upstream I/O rack in either a CPU station, Local
I/O station or to an l/O slot in a CPU rack. The connection is made through a serial
communication channel by a two-twisted pair shielded cable or through an RS-232
compatible modem Iink. The system interface module in the CPU rack, the CPU l/O
station or Local I/O station is a Remote I/O Driver and the system interface module in
the Remote I/O station is a Remote I/O Receiver.
The serial communications link to the Remote I/O station can be up to 10,000 feet (3 Km)
using a two-twisted pair cable. With an RS-232 modem link, the distance between local
and remote I/O is virtually unlimited.
NOTE
A Remote I/O Driver module cannot be installed in a Remote I/O station. A
Workmaster or Cimstar I computer, or PDT cannot be connected to a Remote
l/O stat ion.
Figure 2.23 illustrates a typical configuration for a Remote l/O station. The illustration
shows how a Remote I/O station can be extended an additional 2000 feet (600 meters) by
using l/O Transmitters to connect additional racks to the parallel bus.
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Physical Equipment Configuration
2-44
The I/O Receiver module receives signals through the parallel bus link, modifies the
signals to update the status of inputs and outputs, then relays those signals to the next
rack in a chain. Racks can be connected when they are more than 50 feet (15 meters)
from a CPU by connecting an I/O Receiver in the first rack of the distant grouping to an
I/O Transmitter through a 16-pair twisted cable on the parallel bus. The length of this
cable can not exceed 500 feet (150 meters). This distant grouping of racks at the end of a
parallel bus cable is referred to as a Local I/O station. Again, up to 10 I/O racks can be
daisy-chained in a Local I/O station with no more than 50 feet (15 meters) of cable
separating the first and the last rack.
The maximum distance an I/O Receiver can be located from the originating I/O Control
or Auxiliary l/O Control module is 2000 cable feet (600 meters). In a Remote I/O station,
an I/O Receiver is used when connecting racks on the daisy chain in the station if more
than one I/O rack is required in the station.
An l/O Receiver is normally installed in the leftmost slot of an l/O rack; however, it
could be inserted into any I/O slot in an l/O rack if required. An I/O Receiver can be
installed in any I/O rack except the first I/O rack in a Remote l/O station, this rack
requires a Remote l/O Receiver.
I/O Chain Signal Continuation or Termination
Before installation of an I/O Receiver in an I/O rack, it must be determined if the module
is to be in the last rack of an I/O station daisy chain or in a rack within the chain. An l/O
Receiver, as received from the factory, is configured to continue the I/O chain signals
through the module toward the next I/O Receiver in the chain. If the module is to be the
last I/O Receiver in the daisy chain a jumper pack must be removed from its socket at
location D1 and DIP shunts inserted into the sockets at locations C1 and D1. When
installed in these locations, the DIP shunts wiII cause the I/O chain signals to terminate.
Figure 2.25 shows the location of these jumpers.
~6840114
L
Cl EMPTY
I
I
Factory Setting
(Cont inues l/O Chain Signals)
c
Last l/O Rack in Daisy Chain
(Terminates l/O Chain Signals)
Figure 2.25 l/O RECEIVER DIP SHUNT/JUMPER RACK CONFIGURATION
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Physical Equipment Configuration
2-45
GEK-96602
If an I/O Receiver should be removed from the last rack in a daisy chain and moved to a
rack upstream, the jumper pack and DIP shunts must be reconfigured to continue the I/O
chain signals. Conversely, if an I/O Receiver is moved from a rack within the chain to
the last rack in the chain, the jumper pack and DIP shunts must be reconfigured to
terminate the I/O chain signals.
When a jumper pack is not inserted in location D1 or the DIP shunts are not installed in
locations Cl and D1, they should be inserted in spare sockets located at the bottom of the
printed circuit board. These spare sockets are in board locations F2 and F3.
Module Connections
Two 37 pin D-type connectors are mounted on the front edge of the module. The bottom
connector connects to downstream l/O racks. The top connector connects to the next
upstream l/O rack, to an I/O Transmitter at the opposite end of a parallel bus cable, or to
an I/O Control module in’ a CPU rack.
Status Indicators
There are three edge-mounted LEDs which provide a visual status of certain fault
indications on the I/O chain. The LEDs are viewed through the lens on the faceplate.
Table 2.13 defines the status provided by each LED.
Table 2.13 l/O RECEIVER STATUS INDICATORS
INDICATOR
DEFINITION
POWER
ON
ON when station power is present, continuity is
present and all stations downstream are OK.
CHAIN
PARITY
ON when all downstream statlons have received good
parity.
LOCAL
PARITY
ON when the I/O Receiver has received good output
parity.
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Physical Equipment Configuration
2-46
GEK-96602
Advanced l/O Receiver
The Advanced I/O Receiver module allows the I/O connected to a Series Six Plus CPU to
be more versatile in how I/O failures are detected and enables the Series Six Plus CPU to
respond to these faults. When using this module, all levels of Series Six Plus software can
be programmed using relay logic to respond to l/O faults, such as a power supply failure
or a break in the I/O cable. When this module is used with CPU software level 105 or
above, relay logic can also be used to address the problems of input and output parity
errors.
If any of the advanced diagnostics are to be used, an Input and Output address must be
selected by setting two sets of DIP switches located on the board. The Inputs provide
status information to the CPU relative to the Advanced I/O Receiver. The state of the
output data is controlled by CPU relay logic programmed by the user. Any valid I/O
address can be selected. The Input and Output addresses do not have to be the same;
however, identical addresses can be selected.
In many applications it is desirable to allow the user program to decide whether the CPU
should stop on an I/O system error or continue to run under controlled conditions. This
module allows that decision to be made. A decision can also be made to select a
particular I/O chain (usually the chain that contains the fault) to be shut down while
allowing the balance of the system to continue to run.
The Advanced l/O Receiver module provides status information accessible to the CPU
user program indicating where in the I/O system an error occurred, and what type of
error it was. Using this information the CP U can be programmed to respond in a
controlled manner based upon the type of error detected. Errors sensed by this module
include input and output parity, power supply faiI ure, and I/O cable failures.
Module
Connections
The Advanced I/O Receiver module has two 37-pin connectors available through the
faceplate, The top connector receives an I/O cable that is connected to an upstream I/O
rack or directly to the CPU. If coming from another upstream I/O rack, it may be
connected to a standard or Advanced I/O Receiver module, or to a Local I/O Transmitter
module. The bottom connector can be left unconnected, connected to a standard or
Advanced l/O Receiver module, or be connected to a Workmaster computer or Program
Development Terminal. Any of the modules mentioned above can be connected and
intermixed to meet the requirements of a given application.
On both the standard and Advanced l/O Receivers, the top and bottom connectors are
connected together internally, thus, data signals can pass through them even though the
I/O rack may be non-functional. In the Advanced module, data can also pass through
even if the power supply is turned off.
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2-47
Physical Equipment Configuration
GEK-96602
~-
I/O Signal Continuation or Termination
Located on the Advanced I/O Receiver module are two identical DIP resistor pacs. The
location of these DIP pacs determines if the module is used in an intermediate l/O rack or
used in the last rack of an I/O chain. The module is configured for use in an intermediate
rack when the DIP resistor pacs are located in sockets U7 and US (default positions).
When configured as the last rack in an I/O chain, the resistor pacs must be located in
sockets U12 and U50 The resistor pacs are identical and thus can be interchanged.
Figure 2.26 is an illustration of the Advanced I/O Receiver, showing the location of user
items.
a40205
1. D-type 37-pin connector to
2.
3.
4.
5.
upstream modules.
D-type 37-pin connector to
downstream modules.
Resistor pac locations for last I/O
rack in chain.
Resistor pac locations for
intermediate I/O rack in chain.
Dip switch for selection of module
options.
6. Dip switch for selection of Input
address.
7. Dip switch for selection of Output
address,
8. Location of 12 LED diagnostic
indicators.
9. Location of external Reset
pushbutton.
Figure 2.26 LOCATION OF USER ITEMS
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Physical Equipment Configuration
2-48
GEK-96602
Status and Diagnostic Indicators
Twelve LED diagnostic indicators, visible through the faceplate, are mounted on the
Advanced I/O Receiver module. These LED's are used to indicate status and the results
of diagnostic routines executed by the module. The last six indicators are latched-in (or
turned off) when a fault is sensed as some faults may be transitory or intermittent.
These latched-in fault indications can be reset (if the fault is cleared) by depressing the
RESET pushbutton that is accessible through the faceplate, or by CPU logic sending a
latch reset signal through the I/O chain. This signal is read by the module via the I/O
addresses that have been previously set and enabled. Cycling the power of the rack that
contains the module will also reset the LED indicators. Note that the power supply OK
LED indicator will be latched off when this is done. The following table describes the
function of each diagnostic indicator.
Table 2.14 STATUS AND DIAGNOSTIC INDICATOR DEFINITIONS
CHN OK
CHAIN OKAY, ON if power is okay in all downstream racks, and if cable
continuity is okay to all downstream racks; OFF if one of the above
conditions is not met.
CHNPAR
CHAIN PARITY, ON 1f Output Parity is okay on rack backplane; OFF if
Output Parity Error is sensed from a Local Transmitter or Remote I/O
Driver in this rack.
LOCPAR
LOCAL PARITY, ON if Output Parity 1s okay in this rack; OFF if this
module has detected an Output Parity Error entering from an upstream
rack.
BLANK
The state of this LED is controlled by CPU logic and transmitted to
the module via its I/O address. The default state of this LED is ON.
ADDPAR
ADDRESS PARITY, ON if no error 1s detected in the I/O address
transmitted from the CPU through the I/O chain; OFF if a Parity Error
is detected in the I/O address transmitted from the CPU. Successful
retransmission of the address will clear the Parity Error.
DATPAR
DATA PARITY, ON if no error is detected in the I/0 data transmitted
from the CPU through the I/O chain; OFF if a Parity Error is detected
in the I/O data transmitted from the CPU. Successful retransmission
of data will clear Parity Error.
XMITOK
TRANSMIT OKAY, ON if power is okay and cable continuity is okay to
all downstream racks connected to a Local Transmitter or Remote I/O
Driver module that is located in this rack; latched OFF if the above
conditions are not met in one or more of the connected racks.
CHN OK
CHAIN OKAY, ON if power and cable continuity is okay to all
downstream racks directly connected to this Advanced I/O Receiver;
latched OFF if the above conditions are not met in one or more of the
connected racks.
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Physical Equipment Configuration
2-49
GEK-96602
Table 2.14 STATUS AND DlAGNOSTIC INDICATOR DEFINITIONS (Continued)
POWER SUPPLY OKAY, ON If power supply in this rack is within
tolerance; latched OFF if power supply should fall out of tolerance.
LED will-be latched off when power is applied to power supply.
PS OK
IN PAR INPUT PARITY, the source of Input Parity Error is determined by the
settings of SW6 and SW7 of the diagnostic dip switch; the LED is ON
if no Input Parity Error is sensed; latched OFF if an Input Parity
Error is sensed from either a Local I/O Transmitter or Remote I/O
Driver module mounted In this rack, or from any downstream I/O rack
that may be connected directly to the Advanced I/O Receiver module in
this rack.
W DOG
WATCH DOG TIMER, ON when communications to CPU is okay; latched OFF
if the module has not communicated to the CPU within the last one
second.
OUTPAR
OUTPUT PARITY, ON if no Parity Error is detected in either the I/O
address or I/O data transmitted from the CPU; latched OFF if a Parity
Error is detected. This is a latch for ADDPAR and DATPAR indicators
previously discussed.
For detailed information on
be
found
in
the
Series
Six
operation of the Advanced I/O Receiver,
Data
Sheet
Manual,
refer to GEK-90771, which can
GEK-25367.
I/O Transmitter
The I/O Transmitter module (figure 2.27) provides an interface between the rack
backplane signals and the I/O bus to a downstream Local I/O station. In addition, the
mode of operation, either NORMAL or EXPANDED, must be specified by jumper
configuration.
In the NORMAL mode, there is 1 Main and 1 Auxiliary I/O chain
(maximum of 2000 Inputs/2000 Outputs) per CPU. In the EXPANDED mode, there are up
to 8 I/O chains (16 with Auxiliary I/O) per CPU. In this configuration, up to 16K Inputs
and 16K Outputs (including Auxiliary I/O), are allowed per system. In the EXPANDED
mode, if only Channels 0 and 8 are selected, an I/O Transmitter is not required to drive
those channels. However, if more than 2 channels are selected, each channel must be
driven by an I/O Transmitter* Any l/O Transmitters located downstream from the first
one in a link must be configured to the N0RMAL mode of operation.
In other words, if an
I/O Transmitter in the CPU rack or the first I/O rack has been configured for
E X P A N D E D m o d e , a n y o t h e r I/O T r a n s m i t t e r s o n t h a t l i n k m u s t b e c o n f i g u r e d f o r
NORMAL mode. Likewise, when the first l/O Transmitter in a link is configured to the
NORMAL mode, all other II0 Transmitters downstream must also be configured to the
NORMAL mode.
An I/O Transmitter must be used to interface to a Local I/O station if l/O racks are
required beyond the capacity of a CPU station (10 I/O racks), an existing Local I/O
station or a Series Six Plus CPU rack. Any number of I/O Transmitters can be installed in
a rack as long as the l/O load for the rack and the distance limitations are not exceeded.
An I/O Transmitter can be installed in a Remote I/O station and linked to additional l/O
Transmitters up to 2000 feet 6OO meters), thereby extending the Remote I/O capability
by that distance. Each I/O Transmitter link cannot exceed 500 feet (150 meters). No
more than four I/O Transmitter links can be used with the 2000 foot limitation on the
parallel I/O chain.
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Physical Equipment Configuration
2-50
GEK-96602
Data received at the CPU from each I/O Transmitter is placed in the input status table for
input bits IX+1017 through IX+1024 for the addressed channel. The data in this status byte
is: bits 1-3, channel number; bit 4, card present; bits 5 and 6, set to 0; bit 7, fault trap
enable; bit 8, fault present. If the I/O Transmitter does not respond when addressed,
nothing will be written to the input locations for that channel. The channel will be
scanned regardless of whether the module responded or not.
When the I/O Transmitter receives its address in the output data (to address 127 (I/O
points 1017-1024)) during the l/O scan it connects its channel, as selected by DIP switch
setting, to the CPU’s I/O chain, thereby enabling its I/O channel. When the data to
address 127 is changed to a value other than the DIP switch setting, the I/O Transmitter
disconnects its l/O channel from the CPU’s I/O chain. When the value 80H (Hexadecimal)
is written to address 127 by the CPU, it is interpreted as a command to all of the I/O
Transmitters to connect their channels to the CPU’s l/O chain (but will not cause them to
send input data to the CPU).
a40757
1 D-Type 37-Pin Connector to I/O
Receiver or Advanced I/O
Receiver in Downstream Local
I /O station.
2 CHAIN OK Light:
3 CHAIN PARITY Light:
4 ISOLATED POWER Light:
5 FAULT ENABLE Li ght:
6
CHAIN ACTIVE LIGHT:
Not visible with faceplate in
place, for use in system set up
only.
ON for EXPANDED I/O MODE.
7 FAULT ENABLE/DISABLE Selector:
8
NORMAL/EXPANDED I/O SELECTOR:
a.
P l a c e t h e j u m p e r (JP2) o v e r
pins 1-2 for NORMAL I/O.
One nonselectabl e I/O chain.
b.
Place the jumper (JP2) over
pins 2-3 for EXPANDED I/O
Selectable 1 to 8 chains.
Figure 2.27 I/O TRANSMITTER MODULE
Isolation Circuitry
The l/O Transmitter translates the I/O rack backplane signals into isolated, balanced
signals at a level suitable for transmission up to 500 feet (150 meters) and with sufficient
power to drive up to 10 l/O Receivers. Optocouplers on the module isolate signals passing
through the module and a DC to DC converter provides a +5V dc isolated supply voltage
to those circuits connected to the parallel l/O bus. This method of isolation ensures that
all Local I/O stations are electrically isolated from each other and from the CPU station.
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Physical Equipment Configuration
2-51
GEK-96602
Location in Rack and I/O Channel Addressing
An l/O Transmitter can be installed in any card slot in an I/O rack except the leftmost
slot which is normally reserved for an I/O Receiver. The seven segment DIP switch on
the backplane adjacent to the selected slot for the module does not need to be set for an
I/O address, since an I/O Transmitter does not require an I/O address. However, the first
3 (1, 2, and 3) switches on the DIP switch package must be set to select an I/O channel
number, when required by system configuration.
Status
Indicators
A monitor circuit checks the output level of the isolated +5V dc supply. If the output is
not within its specified tolerance, the monitor circuit causes the I/O Transmitter to shut
down. An LED indicator (ISOLATED POWER) is on when the voltage is within tolerance.
The status of other LED indicators are defined in table 2.15.
Table 2.15 I/O TRANSMITTER STATUS INDICATOR DEFlNlTlONS
INDICATOR
DEFINITION
CHAIN
OK
ON when station power is OK and continuity is
present to all downstream stations.
CHAIN PARITY
ON when output parity is OK at all downstream
stations.
ISOLATED
POWER
ON when the output voltage of the +5V dc
isolated power supply is within tolerance.
.
FAULT
ENABLE
ON when the module has been configured to stop
the system for a local fault condition.
CHAIN
ACTIVE
This LED is not visible through the faceplate.
Used for set up only. When ON, indicates that the
EXPANDED I/O chain is active.
Configuration
Jumpers
Two items are configurable by placing a jumper plug over the desired set of pins. By
configuring JP1, the user can select to enable the system stop for a local fault or not to
stop the system on a local fault. The second jumper plug, JP2, is used to select the I/O
mode of operation for this module, either NORMAL I/O (one non-selectable I/O chain) or
EXPANDED I/O (1 to 8 selectable l/O channels).
Connector
One 37 pin D-type connector is mounted on the bottom front edge of the circuit board. A
16-pair parallel cable plugged into this connector in a Series Six Plus CPU, a CPU station
or a Local I/O station connects to the first I/O Receiver or Advanced I/O Receiver in a
local I/O station at a distance not to exceed 500 feet (150 meters).
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Physical Equipment Configuration
2-52
GEK-96602
REMOTE I/O SYSTEM
A Remote I/O system allows a Series Six Plus system to have an I/O capability that
extends beyond the limit of the 2000 feet (600 meters) maximum distance allowed with
the parallel l/O bus. A Remote I/O system can be located a maximum of 10,000 feet (3
Kilometers) from a CPU, a CPU station, or a Local I/O station when using a two
twisted-pair serial cable. In addition a Remote I/O system can be transmitted over voice
grade telephone lines through RS-232 or RS-422 compatible modems to a location a great
distance from the originating l/O station.
System
Connections
A Remote I/O system consists of a Remote I/O Driver, a two twisted-pair serial cable or
modems and a Remote I/O Receiver. The Remote I/O Driver is installed in an I/O slot in
a CPU, a CPU station or a Local I/O station. The Remote I/O Driver is then connected
by cable or a modem link to a Remote l/O Receiver in the first slot of the first I/O rack
in a Remote l/O station.
If the Remote I/O Driver and Remote I/O Receiver are to communicate over a modem
link, the Remote Receiver module must be installed in a High Capacity l/O rack and the
Remote Driver must be in either a High Capacity I/O rack or a CPU I/O slot, since a 12 V
dc source must be available to conform to RS-232 specifications. Figure 2.28 illustrates
the two methods of system configuration described above.
b4106fi
*When connecting to a Remote I/O station through modems (RS-232 interface) the
Remote I/O Driver and Remote I/O Receiver must be installed in High-Capacity I/O
racks.
Figure 2.28 TYPICAL REMOTE I/O SYSTEM CONNECTIONS
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2-53
Physical Equipment Configuration
GEK-96602
Remote System Response Time
The response time of a Remote I/O system is slightly delayed because of the distance
when using up to the 10,000 foot (3Km) maximum cable length. The response time is
delayed further when connection to the Remote I/O is made through the communications
link using modems. Part of the delay is due to the fact that the Remote l/O Driver stores
output and input data and provides this data when needed to the Remote I/O Receiver and
the CPU. This store and forward technique results in a one sweep delay.
NOTE
A one sweep delay for inputs can be avoided if a DO I/O instruction is executed
for the Remote l/O prior to executing any logic using remote inputs.
System response times to the Remote I/O for each of the valid baud rates are
summarized in table 2.16. The times as listed are approximate maximum response times
and may vary slightly from system to system. These response times are due to hardware
considerations related to communications between a Remote I/O Driver and a Remote
I/O Receiver (component tolerance, cable length, etc.).
Table 2.16 TYPICAL SYSTEM RESPONSE TIMES TO REMOTE I/O
Quantity of
I/O in Block
120 I/O
Output Delay
Input Delay
248
Output
I/O
Delay
Input Delay
.6 sec
10 sec
1 1200
I
2 sec
.5 s e c
.9 sec
4 sec
11 sec
18 sec
4 sec
110
300
2 sec
1 sec
1.6 sec
2400
57.6K
.25 sec
0 . 5 sec
.5 sec
.9 sec
20 ms
25 ms
.14 sec
.2 sec
75 ms
.l
sec
30 sm
46 ms
I
(1)
+l sweep for all baud rates
(2)
+2
sweeps for all baud rates
REMOTE I/O ADDRESSING
A Remote I/O system normally responds to a block of 128 inputs and 128 outputs or 256
inputs and 256 outputs. However, eight inputs and eight outputs are used by the Remote
I/O Driver for system status information, thus allowing a total of either 120 inputs and
outputs or 248 inputs and outputs. The block of either 120 I/O or 248 l/O is selected by
positioning of a jumper on the Remote I/O Driver module.
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Physical Equipment Configuration
2-54
GEK-96602
The unique I/O points (addresses) for each module in a Remote I/O station are selected by
setting the seven segment DIP switch on the backplane adjacent to each slot in the I/O
rack. However, all I/O points selected must be within the block selected for the Remote
l/O station. The I/O points in a remote system must be within one of the blocks as listed
in table 2.17.
Table 2.17 I/O POINT RANGES IN REMOTE I/O STATIONS
120 Inputs/l20 Outputs
1
129
257
385
513
641
769
897
-
128
256
384
512
640
768
896
1000
248 Inputs/ 248 Outputs
1
257
513
769
-
256
512
768
1000
(2)
(1)
(1) This block selected allows 96 inputs and 96 outputs.
(2) This block selected allows 224 inputs and 224 outputs.
The address selected for the Remote I/O Driver can fall anywhere within the range of I/O
points in a block. All I/O modules in a Remote l/O station (including the Remote l/O
Driver) must have switches 5, 6 and 7 (120 l/O) or 6 and 7 (248 I/O) set the same. By
doing this all modules in a Remote station are thus tied to that particular Remote I/O
Driver. More than one Remote I/O station can be programmed to the same l/O block;
however, each Remote Driver must have its own unique address. Each Input module must
also have a unique address; output module addresses can be duplicated. Unused l/O points
in a Remote I/O station can be used by another Remote I/O station, a Local l/O station, a
CPU station or a CPU I/O slot.
Printed Circuit Board Jumpers
There are several printed circuit board jumper plugs which must be properly configured
for operation of a Remote I/O system. Jumper plugs are located on both the Remote l/O
Driver and the Remote l/O Receiver. Factory configuration of these jumpers is set for
the following options.
a
?
?
?
a
0
120 Inputs and 120 Outputs
Connection up to 10,000 feet (3Km) using two twisted pair serial cable
Baud rate - 57.6Kb
Halt CPU on communications failure or Remote I/O parity error.
Turn all outputs off on communications failure
Odd serial parity
If a block of 248 Inputs and 248 Outputs, or the Remote I/O system is to be linked with
RS-232 compatible modems, or any of the other options are to be changed, the printed
circuit board jumper plugs must be reconfigured. Refer to the applicable data sheet in
the Series Six Data Sheet manual, GEK-25367, for board jumper configuration.
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Physical Equipment Configuration
2-55
GEK-96602
Remote I/O Driver
The Remote I/O Driver module provides control and data signals to a Remote l/O
stat ion. Circuitry on this module converts output data from parallel to serial and input
data from serial to parallel, Specifically, a Remote I/O Driver connects the l/O structure
in a CPU, a CPU station or a Local l/O station to a Remote I/O station through a serial
communications channel by direct connection with a two twisted-pair cable or a
communications link using RS-232 compatible modems.
With two twisted-pair cable, the Remote I/O station can be located up to a maximum of
10,000 feet (3 km) from the Remote I/O Driver. A communications link using modems
allows connection over a much greater distance. An I/O Transmitter located in a rack in
the Remote l/O station can be the first of a link of up to four 500 foot (150 meters) links
using f/O Transmitters, thereby extending the remote capability an additional 2000 feet
(600 meters).
a41069
CONNECTOR TO
REMOTE I 0
RECELVER ORRS-232CM O D E M
Figure 2.29 REMOTE I/O DRIVER MODULE
The Remote I/O Driver can drive up to 248 Inputs and 248 Outputs. A Remote l/O Driver
module can be installed in any unused l/O slot in a CPU station, a Local I/O station or a
CPU (except the left most slot in an I/O rack which is reserved for a Receiver module).
If connection to the Remote I/O station is to be made through a modem link, the Remote
I/O Driver must be installed in a high capacity l/O rack. This is necessary since the
RS-232 specification requires +I2 and -12 V dc for operation.
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Physical Equipment Configuration
2-56
GEK-96602
Remote I/O Driver Addressing
A block of addresses for the Remote I/O station is established by setting the seven
segment DIP switch adjacent to the slot selected for the Remote l/O Driver. For a block
of 120 I/O, switches 5, 6, and 7 are set to select the block and for 248 I/O, switches 6 and
7 are set to select the block of I/O addresses. All I/O modules in the Remote I/O station
connected to a Remote l/O Driver must then have the corresponding DIP switch segments
set in the same configuration as the Remote I/O Driver. In all cases switches 1 to 4 or 1
to 5 (in addition to 5, 6, 7 or 6, 7) are configured to set a unique address for each module
in the Remote I/O station; i.e. 1-8, 249-256, 673-680, etc.
A unique I/O reference (address) must also be set for the Remote l/O Driver and can be
the first of any group of eight consecutive valid I/O references within the selected block.
The eight input references provide status information which can be monitored on the
programmer by observing the byte in the applicable Input Status Table (Normal mode or
Channel 0) or Register location associated with the I/O channel in the EXPANDED mode.
The eight output references are for future use.
Table 2.18 REMOTE I/O DRIVER STATUS BYTE
INPUT
I/O REFERENCE
INFORMATION PROVIDED
1
10297 (1)
Input toggles every time new input data
is transferred to the CPU.
2
3
IO298
10299
Reserved
Reserved
4
10300
Remote Parity
0= Parity error in Remote I/O station.
1 = Remote parity good.
5
10301
Remote OK
0=
Fault in Remote System
(Power supply failure, parity error, etc.)
1 = Normal operation, Remote I/O OK.
6
10302
Link OK
0= Error detected with communications
between Remote I/O Driver and Receiver.
1 = Communications link good.
7
10303
Local OK
0 = Fault in Remote I/O Driver module.
1 = Remote I/O Driver operation normal.
8
100304
Heartbeat
This input cycles from 0 to 1 (O/1/O/l, etc.),
changing with each I/O scan when Remote I/O is
operating normally. If any input status (4-7)
is set to zero, cycling stops and the status will
contain the last valid data received (0 or 1).
(1) I/O references shown are typical, and are only used as an example.
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2-57
Physical Equipment Configuration
GEK-96602
Status Indicators
There are four LED status indicators viewed through the faceplate lens. The four LEDs
display the same status information as that indicated by the state of Inputs 4 through 7 in
table 2.18. These indicators and their meanings are listed below in table 2.19 in the same
order as they appear on the module faceplate.
Table 2.19 REMOTE I/O DRIVER STATUS INDICATORS
INDICATOR
LOCAL
OK
DEFINITION
Remote I/O Driver module operating normally.
ON
OFF Fault in Remote I/O Driver.
LINK
ON
OK
Of
REMOTE
OK
ON
Remote system is operating normally.
OFF Fault exists in Remote I/O system. (Power supply
failure, cable loose, module not seated properly, etc.
REMOTE
PARITY
ON
Remote system has no parity errors, operation normal,
OFF Parity error detected in Remote I/O system, CPU will
stop unless option, jumper on this module is set for
CPU to RUN when error detected.
Communications link between this module and Remote
Receiver good.
Communications error between this module and Remote
Receiver.
Option Jumpers
Several jumpers located on this module are used for configuration of various options
necessary for system and module operation. Table 2.20 lists the factory and alternate
settings for the Remote I/O Driver options.
Table 2.20 REMOTE I/O DRIVER OPTION SETTINGS
OPTION
FACTORY
SETTING
Block Size
120
Baud Rate
57.6 Kb
Serial
Yes/Odd
Yes/Even or No
CPU Status on
Communications
Failure
STOP CPU
Allow CPU to RUN
Remote I/O
Parity Error
STOP CPU
Allow CPU to RUN
Communications
Link
Two Twisted Pair To
10,000 feet (3 Km)
RS-232 Modem Link
Inputs/l20
OPTIONAL SETTING
Outputs
248
Inputs/248
Outputs
UserSelected
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Physical Equipment Configuration
2-58
GEK-96602
Remote I/O Receiver
The Remote I/O Receiver module is the interface to the serial communications link for a
Remote I/O station. It is physically located in the first rack in a Remote I/O station,
normally in the left slot since the Remote l/O Receiver does not require an I/O address
(there is no DIP switch on backplane adjacent to the left slot).
A Remote I/O Receiver connected to a Remote I/O Driver through a two twisted pair
cable can be installed in any I/O rack. If connection to the Remote I/O station is to be
through a communications link using RS-232 compatible modems, then the Remote I/O
Receiver must be installed in a high capacity I/O rack.
a41067
TO-
REMOTE
I/O DRIVER
OR
R S;-232C MODEM
TO-
c IOWNSTREAM
I/O RECEIVER
OR REMOTE
I/O RECEIVER
Figure 2.30 REMOTE l/O RECEIVER MODULE
Circuitry on this module converts output data from serial to parallel and converts input
data from a parallel to a serial format: The Remote I/O Receiver also isolates the serial
data cable from the backplane bus and provides error checking circuitry. If more than
one I/O rack is required in a Remote l/O station, the additional racks are daisy chained to
the Remote I/O Receiver through I/O Receivers or Advanced I/O Receivers.
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Physical Equipment Configuration
2-59
GEK-96602
Connectors
A Remote I/O Receiver has two edge mounted D-type connectors. The top connector (25
pin) connects to a Remote I/O Driver at the opposite end of the serial communications
link using a two twisted-pair cable or to a modem located no more than 50 feet (15
meters) from the Remote I/O Receiver.
The lower connector (37 pin) provides a connection through a 16-pair parallel bus cable to
an l/O Receiver or Advanced l/O Receiver module located in the next downstream rack in
a Remote I/O station. If no connection is to be made to the lower connector, the I/O
chain signals must be terminated. This is done by reconfiguring three jumper plugs on the
printed circuit board which performs the same function as reconfiguring the jumper pack
and DIP shunts on an l/O Receiver or Advanced t/O Receiver module.
Status Indicators
The Remote I/O Receiver has four LED indicators visible through the faceplate lens. The
legends on the faceplate lens are the same as those on the Remote I/O Driver.
Table 2.21 REMOTE I/O RECEIVER STATUS lNDlCATOR DEFlNlTlONS
I
DEFINITION
INDICATOR
LOCAL
OK
ON
OFF
Remote I/O Driver module operating normally.
Communications fallure or addressing difference
between Local and Remote Stations.
LINK
OK
ON
Communications link between this module and Remote I/O
Driver established and valid.
Communicat!ons failure between this module and
Remote I/O Driver.
OFF
REMOTE
OK
ON
OFF
Remote system Is operating normally.
Fault in Remote I/O system. (Illegal address block,
loose connection, power supply failure)
REMOTE
PARITY
ON
OFF
Remote system operating normally with no parity errors.
Parity error detected 1n Remote I/O system.
Option Jumpers
There are several circuit board jumpers on this module which are used for option
selection and 1/O chain signal termination. Jumpers are factory set prior to shipment and
must agree with the Remote l/O Driver to which the Remote I/O receiver is connected.
Table 2.22 lists the factory and alternate settings for the Remote I/O Receiver options.
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Physical Equipment Configuration
2-60
GEK-96602
Table 2.22 REMOTE l/O RECEIVER OPTtONS
OPTION
FACTORY
SETTING
CHOICES
Baud Rate
57.6 Kb
Parity
Yes/Odd
Yes/even or no
Communications
Failure at
Remote I/O
Turn all
outputs Off
Hold all outputs
at last state
I/O Chain Signals
I/O Chain Signals have I Terminate I/O chain
continuity through this
Signals at this module
module.
User
selected
Instructions for reconfiguring any of the circuit board jumpers to change options can be
found in the applicable data sheet (see GEK-25367, Series Six Data Sheet manual) for this
module. Jumper options are required when selecting the RS-232 option and are listed in
the chapter on installation in this manual. In addition, there are jumpers reserved for
future expansion or production testing and should not be changed.
AUXILIARY I/O SYSTEM
The Auxiliary I/O system allows the total number of I/O points in a Series Six Plus PLC
system to be doubled. If an Auxiliary t/O module is inserted into slot 6 or 7 of a CPU
rack, an l/O system functionally identical to the main I/O system can be originated at the
CPU. The Auxiliary l/O chain is scanned in parallel with the Main I/O chain. The
Auxiliary I/O chain does not increase the total CPU scan time.
The structure of the Auxiliary l/O system provides the Series Six Plus CPU with an
additional 1000 inputs and 1000 outputs when operating in the NORMAL I/O mode of
operation. Thus, the total I/O capacity of the Series Six Plus PLC when in the NORMAL
I/O mode, with the Auxiliary l/O system selected is 20 00 inputs and 2000 outputs.
If the Auxiliary I/O module and the EXPANDED I/O mode of operation have been
selected, an additional 8000 Inputs and 8000 Outputs are available to the PLC system.
This~-~
configuration provides a total I/O capacity of 16,000 real inputs and 16,000 real
outputs.
The Auxiliary I/O module can be used in either a Series Six Plus CPU rack, or in a Series
Six model 6000 CPU rack. When used with the Series Six model 6000 CPU, the maximum
I/O is 2000 Inputs and 2000 Outputs. A group of 4 DIP shunts must be inserted in one of
two locations, determined by which CPU the module is to be used with, either Series Six
Plus or Series Six model 6000.
All information pertaining to use of Input and Output modules, I/O interface modules,
cable type and distance allowed between racks and stations is applicable when configuring
an Auxiliary I/O system. Inputs and Outputs in the Auxiliary I/O chain can be overridden
as in the Main I/O chain, (with the Expanded II instruction set), when in the Normal
mode. When in Expanded l/O mode, only Channel 8 (AI/A O) has overrides.
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Physical Equipment Configuration
2-61
GEK-96602
A standard I/O cable, catalog number IC600WDXXX (where XXX is a 3 digit number
corresponding to the selected cable length), provides the connection to the Auxiliary I/O
chain and is made to a connector located at the bottom of the faceplate of the module.
The cable is connected from the Auxiliary I/O module, through the l/O cable, to the top
connector on the l/O Receiver or Advanced I/O Receiver in the first l/O rack in the
Auxiliary I/O chain.
b40762
SEFHES
@ SIX
PLUS
0IIi::
i:
II
?
??
??
??
1. D-Type 37 pin Connector to
Auxiliary I/O Chain connects to I/O
Receiver or Advanced I/O Receiver
in nearest I/O rack in auxiliary
chain.
2. CHAIN OK LED
On: Continuity, power, and output
data parity are OK at all I/O
stations in the auxiliary chain.
Off: A continuity, power problem
or output data parity error
exists at one or more
auxiliary chain I/O station(s).
3. PARITY LED
On: Input data parity is OK at the
Auxiliary l/O module.
Off: Input data parity error exists.
4. ENABLED LED
On: The outputs are enabled. CPU is
operating in the RUN ENABLED
mode.
Off: The outputs are disabled. CPU in
the RUN DISABLED or the STOP
mode.
5. Shunt location A (Factory installed
locat ion)
6. Shunt location B
Figure 2.31 AUXILIARY I/O MODULE BOARD LAYOUT
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Physical Equipment Configuration
2-62
GEK-96602
WORKMASTER COMPUTER TO SERIES SIX PLUS PLC CONNECTIONS
The Workmaster computer can communicate with a Series Six Plus PLC using either a
parallel or serial version of the Logicmaster 6 software. The methods of connection from
the Workmaster computer to the Series Six Plus PLC are described in the following
paragraphs.
Workmaster to Series Six Interface Adaptor Boards
This is a two-board option which provides high speed parallel communications between
the Series Six Plus PLC and the Workmaster computer through the Logicmaster 6
software. One board is the WorkmasterISeries Six Interface board (IC640BSS303) which
contains the circuitry necessary to format and transfer data between a Workmaster
computer and a Series Six Plus PLC. This board requires a long slot for instaflation.
The other board in the set is the Workmaster/Series Six Terminator board (IC640BLD304),
which contains the circuitry to terminate and protect data lines between the Series Six
Plus PLC and the Workmaster computer. This board requires a short slot for installation.
There are two DIP rocker switches on the board which must be configured as described
below.
These two boards are connected together inside of the Workmaster computer by a
34-wire ribbon cable. The boards can-be installed in any 2 unused slots in the Workmaster
computer with the requirements that the full-size board must be installed in a long slot
and the half-size card be installed close enough for the ribbon cable to reach. These
boards should be installed as instructed in the Workmaster Guide to Operations Manual,
GEK-25373.
Connection to I/O Control or I/O Receiver Modules
The factory setting for the DIP switches on the Terminator board is ALL of the switches
set to the OFF (open) position. This is the correct setting for connecting a Workmaster
computer to the I/O Control module in the CPU rack or to an I/O Receiver or Advanced
I/O Receiver in a CPU station or Local I/O station. The maximum distance for this type
of connection is 10 feet (3 meters).
Connection to an I/O Transmitter Module
When ALL of the switches are set to the ON (closed) position, the parallel l/O bus is
properly terminated for long distance communications through an l/O Transmitter module
up to 500 feet (150 meters) away. With this configuration, the l/O Transmitter module
must be dedicated to communicating with the Workmaster computer.
All of the DIP switches on the Terminator Board must be set properly as
described above. Failure to do so may result in the Series Six Plus CPU
stopping in an incorrect state or incorrect operation of the I/O bus which may
cause the outputs to be directed to an incorrect state.
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2-63
Physical Equipment Configuration
GEK-96602
The valid connections for the Workmaster computer to the parallel I/O chain are
illustrated in figure 2.32.
a41085
1
p-‘-‘.-1
.
%?
1
r -I------- -:
ONLYONEWORKMASTER
CAN ;#tth$TED
WCMKMASTER
.
f
f
I
i
t ----------I
THE CABLE CONNECTING
WORKMASTER TO THE
SERIES SIX FLUS IS A
STANDARD l/D CABLE
I/o CONTROL
d,ff--j- t/O TRANSMITTER
ADVANCED I/O RECEIVER
OR I/o RECEIVER
r1
- C~J STATION
-i 5Kl*
WORKUASTER k-------wem-u-w-11
ADVANCED I/o RECEIVER
OR I/O RECEIVER
?
f
1
I
I
I
500 FT.
r
IL
- m - -MAX.
/-----------I
--: WORKMASTER 'I
I
---------s-d i
LOCAL I/O STATION
WORKbfASTER
Figure 2.32 WORKMASTER COMPUTER CONNECTIONS TO THE SERIES SIX PLUS PLC
Connecting Cable
The cable to be used for connecting the Workmaster computer to a Series Six Plus PLC is
a standard parallel I/O bus cable. Following is a list of catalog numbers for these cables.
CATALOG
IC600WD002
IC600WD005
IC600WD0l0
IC600WD025
IC600CJD050
IC600WDl00
IC600WDZ00
IC600CJD500
CABLE
NUMBER
(1)
(1)
(1)
2
5
10
25
50
100
200
500
LENGTH
feet
(0.6
feet
(1.5
feet
(3.0
feet
(7.5
(15.0
feet
feet
(30.0
feet
(60.0
feet (150,O
meters)
meters)
meters)
meters)
meters)
meters)
meters)
meters)
(1) To be used only for direct connection to a dedicated I/O Transmitter module in a
Series Six Plus PLC system.
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Physical Equipment Configuration
2-64
GEK-96602
Connections Using the Serial Version of Logicmaster 6
The Workmaster computer can also communicate with a Series Six Plus PLC using the
serial version of Logicmaster 6 software. The Workmaster computer must be connected
to the CCM2 in the Series Six Plus CPU rack or to a CCM3 operating in the CCM2 mode.
The CCM3 catalog number must be IC6OOCB517C or later.
The CCM2 must be configured for Workmaster protocol. Cable connection to the CCM2
is to the COM1 port on the Workmaster computer. The location of the COM1 port is
determined by the type of communication to be used.
When point-to-point communications over distances less than 50 feet (15.0 meters) is
used, connection at the Workmaster computer is made to the 9-pin connector on the
Combination Adapter card.
If point-to-point communications over distances greater than 50 feet or multidrop
communications are used, the Asynchronous/Joystick card must be used in the
Workmaster computer. When this configuration is used, the Combination Adapter card
must be configured as COM2, and the Asynchronous/Joystick card configured as COM1.
For more detailed information on installation and configuration of the above cards, refer
to the Logicmaster 6 User’s Manual, GEK-25379.
USING THE CIMSTAR I COMPUTER WITH A SERIES SIX PLUS PLC
The CIMSTAR I computer can also be used as the programming device with a Series Six
Plus PLC. It can run either the parallel or serial version of the Logicmaster 6 software.
The serial version does not require any additional equipment added to the CIMSTAR I
computer. The parallel version requires installation of an additional board set. Both
versions require GE-DOS version 1 or later, which is equivalent to MS-DOS version 3.2.
This version of DOS is supplied with the computer. Refer to GEK-25379, the
Logicmaster 6 Programming and Documentation Software User’s manual, Chapter 2 and
Appendix A, and GEK-90527, the CIMSTAR I Industrial Computer Reference Manual,
for further information on the CIMSTAR I computer hardware requirements and use.
Parallel Version of Logicmaster 6 Software
The parallel version communicates with a Series Six Plus PLC through a standard l/O
interface cable, as with the Workmaster computer. The following board set must be
installed in the CIMSTAR I computer for parallel communications with a Series Six Plus
PLC:
-
A Workmaster/Series
Six interface board (IC640BSS303)
-
A Workmaster/Series
Six Terminator board (IC640BLD304)
This board set was previously described under “Workmaster to Series Six Interface
Adapter Boards”.
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Physical Equipment Configuration
2-65
GEK-96602
Serial Version of Loqicmaster 6 Software
The serial version, when installed in a ClMSTAR I computer, communicates with a Series
Six Plus PLC over a serial communications channel to a CCM module in the Series Six
Plus PLC. Communication is possible over a long distance using a wide range of baud
rates, either with or without modems. The system can communicate with a single CCM
module and CPU, or be used in a multi-drop configuration having up to eight CCM
modules and CPUs.
PROGRAMMING A SERIES SIX PLUS PLC WITH AN IBM PC
The IBM PC version of the Logicmaster 6 software can be used to program a Series Six
Plus PLC when installed in an IBM PC, IBM PC-XT, or IBM PC-AT computer that meets
the following requirements:
- 640K of RAM memory
-
PC-DOS version 2.1 or later for the IBM PC and PC-XT. PC-DOS version 3.1 or
later for the IBM PC-AT.
- Either a color or monographics monitor adapter card. The software will also
support the Enhanced Graphics Adaptor (EGA) card.
The Logicmaster 6 software for the IBM PC version is available as a set of three 5.25 inch
360K diskettes. Performance of the software with other versions of DOS or on other IBM
PC-compatible computers is not guaranteed. The system supports the IBM monochrome
adaptor board and the asynchronous communications adaptor board. It does not support
serial communications adaptors based on the 8250 UART.
An IBM PC-based Logicmaster 6 system communicates with a Series Six Plus PLC
through the serial ports, to a CCM module in the Series Six Plus CPU rack. The IBM PC
version of Logicmaster 6 software communicates and functions in the same way as does
the serial version for the Workmaster computer.
REDUNDANT PROCESSOR UNIT
The Redundant Processor Unit (RPU) monitors the CPU and I/O. When the RPU detects a
failure of the CPU or I/O, it switches to a backup CPU and (optionally) to a backup I/O
chain. For more information about the module, refer to the Redundant Processor Manual
(GEK-25366).
I/O Addressinq for the RPU
Originally, the RPU used pre-assigned inputs and outputs in the Main I/O Status Tables.
These inputs and outputs could not be changed. The upgraded version of the RPU uses
hardware-selectable I/O addresses.
IBM is a registered trademark of International Business Machines Incorporated
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Physical Equipment Configuration
2-66
GEK-96602
The older type of RPU should not be used in a system with Expanded I/O addressing. The
older RPU uses 8 outputs (O1017 through O1024) to control its operations. Setting O1017
in the Master will cause transfer to the Back-up CPU (if it is available). lf O1022 is set,
outputs from the Main I/O Status Tables and the Override Table are transferred from the
Master to the Back-up. If O1023 is set, register R0254 is transferred from the Back-up
to the main CPU. If O1024 is set, a block of registers starting at the address specified by
the value in register R0255, and ending at the value in register R0256 will be transferred
from the Master to the Back-up. The 8 inputs (I1017 through I1024) and 8 outputs O1017
through O1024) are always mapped into the Main I/O Status Table. Of the 8 inputs, only
input 1024 is used. It is set to “1” if the associated CPU is the backup.
Only the upgraded model RPU should be used in an Expanded I/O system. In Expanded
addressing, an l/O Transmitter Module in either channel 0 or channel 1 will write data
into the references formerly assigned only to the RPU. For example, for channel 0, the
status of the l/O Transmitter module maps into Main I/O at addresses I1017 through
I1024. However, I1024 is the input normally used by the RPU to specify the end of the
register block to be transferred from the Main CPU to the Back-up CPU. The upgraded
model RPU features jumper-selectable addressing. This allows greater memory access,
and permits assignment of non-conflicting I/O addresses to the RPU.
Proqram References for the I/O Transmitter Module
If the Expanded mode is enabled, the module uses the references listed below. If
Expanded mode is disabled, the module operates without the additional diagnostics, and
does not use any I/O references.
Channel Return Status Memory Locations
MAIN I/O CHAIN
Location
5
6
7
I1017-I1024
R256 (high byte)
R384
R512
R640
R768
R896
R1024
AUXILIARY I/O CHAIN
ChanneI
Location
R128 (high byte)
R1280
R1408
R1536
R1664
R1792
R1920
R2048
Expanded Addressing for a System with an RPU
Formerly, the Redundant Processor Unit was required to use input I1024, outputs O1017,
O1022, O1023, and O1024, and registers R254-256. Referring to the list above, you can
see that there is a conflict with the channel status return memory locations for channels
1 and 2. Using channel 0 or 1 results in information from the I/O Transmitter module on
that channel being written into references assigned to the RPU. To avoid this conflict, a
system with Expanded I/O addressing should use the enhanced version of the RPU.
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Installation Instructions
3-1
GEK-96602
CHAPTER 3
INSTALLATION INSTRUCTIONS FOR THE SERIES SIX’” PLUS
PROGRAMMABLE LOGIC CONTROLLER
INTRODUCTiON
This chapter contains information which will aid in installing the Series Six Plus
Programmable Logic Controller and preparing the system for use, Included are
instructions for unpacking/packing, inspecting, installing in a rack or panel, setting
internal switches, and connecting cables. A t t h e e n d o f t h i s c h a p t e r i s a s t a r t - u p
procedure for the Series Six Plus CPU to be followed when bringing up a new CPU for the
first time.
QUALITY CONTROL
Each Series Six Plus PLC undergoes a thorough quality control inspection and extensive
system testing before being shipped. Each part of a system undergoes environmental and
operational tests before leaving the factory.
PACKAGING
The method of packing and shipping the components of a Series Six Plus PLC system are
outlined in this section.
CPU racks are shipped to include the following modules and other components: Power
Supply, I/O Control, and Arithmetic Control modules, I/O Terminator plug, board
extraction/insertion tool, and rack mounting brackets and screws. The power supply,
I/O Control module and Arithmetic Control modules are seated in their proper slots in
the rack. The ribbon cable for connecting the Arithmetic Control to the Logic
Control modules is connected to the Arithmetic Control module. Blank faceplates
must be ordered separately for the remaining slots and are shipped separately.
The CPU rack is inserted into 2 halves of foam plastic sections. This is then placed in
an antistatic plastic bag along with the rack mounting brackets, hardware for
mounting the brackets, a printed circuit board extraction/insertion tool, an I/O
Terminator plug and the Series Six Plus User’s Manual. This package is then placed in
a shipping container.
The Combined Memory, Logic Control and any optional modules are shipped in a
separate container. Each module is placed in the bottom of a two-section foam
plastic package. Two inserts are provided, one for the printed circuit board and one
for its faceplate. The top section is added and this package is inserted into a sleeve.
Either 2, 5 or 10 module packages are then placed in a shipping container.
l/O racks are shipped with only the power supply in place. The I/O racks and I/O
modules are packaged the same as the CPU rack and modules.
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Installation
3-2
Instructions
GEK-96602
The Workmaster or Cimstar I industrial computer is packed in a separate shipping
container. It is recommended that the shipping containers and all packing material be
saved in the event that it becomes necessary to transport or ship any part of the system.
VISUAL INSPECTION
Upon receiving your Series Six Plus PLC system, carefully inspect all shipping containers
for damage during shipping. If any part of the system is damaged, notify the carrier
immediately. The damaged shipping container should be saved as evidence for inspection
by the carrier.
It is the responsibility of the consignee to register a claim with the carrier for damage
incurred during shipment. However, GE Fanuc - NA will fully cooperate with the
customer should such an action be necessary.
PREINSTALLATION CHECK
After unpacking the Series Six Plus CPU and I/O racks, all modules, the Workmaster
computer, and any peripherals that have been ordered as part of a system, it is
recommended that serial numbers of the CPU, Workmaster computer, and any peripherals
be recorded. The serial numbers are required if Product Service should need to be
contacted for any reason during the warranty period of the equipment.
Verify that all components of the system have been received and that they agree with
your order, If the system received does not agree with your order call your PtC
Distributor or GE Fanuc - NA sales representative for further instructions.
RACK INSTALLATION
The Series Six Plus CPU can be rack, panel or wall mounted. A set of mounting brackets
is included with each rack and can be mounted on either the front or rear of each rack.
The method for mounting the brackets is determined by the system mounting
configuration. Dimensions and placement of the mounting brackets for racks are
shown in figures 3.1 and 3.2.
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Installation Instructions
3-4
CEK-96602
EXTRACTION/INSERTION
TOOL
The printed circuit board extraction/insertion tool (board puller), Catalog No.
IC600MA504 included with your Series Six Plus CPU should always be used when installing
or removing a module. The boards in the CPU require an insertion force of about 50 Ibs.
(22.68 Kg) and the l/O boards require about 25 Ibs. (11.34 Kg). Use of the
extraction/insertion tool should alleviate any problems of possible board damage which
could be caused by hand insertion or removal. Refer to figure 3.3 for identifying features
of this tool.
a41115
BOARD PULLER
LOGIC RACK NOTCH
BOARD SEATING
BOARD PULLER
LcK;IC RACK NOTCH
‘p&i
BOARD PULLER
tIxx;IC RACK FLANGE
tTcm
BOARD PULLER
BTIJDS
Figure 3.3 EXTRACTION/INSERTION
IJLLER
LLK;IC RACK FLANGE
00=-f)
TOOL
NOTE
It is recommended that power to any rack be turned off before attempting to
install or remove any printed circuit board.
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Installation
Instructions
3-5
GEK-96602
Inserting a Printed Circuit Board
The following instructions should be followed when inserting a printed circuit board into
its slot in a rack.
-
Grasp the board firmly with your hand and insert it into the cardguide.
-
Align the board with the connector(s) on the rack backplane and slide it towards the
connector(s) untiI it has started to seat.
-
insert the board puller Logic Rack Notch (Top) into the short siot beside the top of the
solder side of the board. lnsert the Logic Rack Notch (Bottom) into the short slot
beside the bottom of the solder side of the board. See figure 3.4 for proper toof
positioning for insertion of a board.
-
Grasp the handle area of the board puller with either hand and squeeze it until you
feel the board seat. Visually inspect the board to be sure it has seated properly.
Remove the tool.
a42067
Figure 3.4 POSITION OF EXTRACTION/INSERTION TOOL FOR BOARD INSERTION
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Installation
3-6
Instructions
GEK-96602
Removing a Printed circuit Board
The following instructions should be followed for proper removal of a printed circuit
board from its slot.
-
Insert the board puller studs into the printed circuit board from the solder side of the
board. Ensure that the board puller surface is flat against the printed circuit board.
The board puller is now 180 degrees reversed from the position for inserting a board. See
figure 3.5 which shows proper positioning of the tool.
-
Grasp the handle area with either hand and squeeze it. The board should break loose
from the connectors and set loose in the cardguides.
-
Remove the board puller and slide the board out of its slot. Handle the board
carefully.
a41080
Figure 3.5 POSITIONING THE EXTRACTION/INSERTION TOOL
FOR BOARD REMOVAL
MODULE INSTALLATION
The modules for your system should now be installed in their proper slots in the CPU and
I/O racks. Before installation some of the modules may require configuration of switches
or jumpers. Figure 3.6 is provided as a guide to proper module location in the CPU rack.
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Installation
3-7
Instructions
GEK-96602
00000000
--------
0
LOGG
AAlTti
AOGC
---m
“O GE Fanuc
13” CPU RACK
19” CPU RACK
Figure 3.6 CPU MODULE LOCATION GUIDE
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3-8
Installation Instructions
GEK-96602
Combined Memory Module
The Combined Memory module for the Series Six Plus PLC combines the functions of
internal memory, register memory and logic memory on one module. The Combined
Memory module, should be unpacked and removed from its sleeve. Remove the blank
faceplate (if in place) from the slot where the module is to be installed. The Combined
Memory module should then be inserted into slot 4, which is immediately to the left of
the Arithmetic Control module. After installing the module, install the faceplate, which
is imprinted with the legend LOGIC MEMORY. The Combined Memory module is a
required option, and is available in 6 different versions as shown below in table 3.1. The
Combined Memory modules used in the Series Six model 60 PLC (IC600CM552 and
IC600CM554) can also be used in a Series Six Plus PLC, but do not provide parity
checking.
Table 3.1 COMBINED MEMORY MODULES
I
CATALOG
NUMBER
IC6OOlX605
IC600LX612
IC600LX616
IC600LX624
IC600LX648
IC600LX680
I
~ LOGIC
I
4
4
8
16
32
64
MEMORY TYPE
REGISTER
1
8
8
8
16
16
TOTAL
MEMORY
5
12
16
24
48
80
Battery lnstallation
Before installing a memory module in a CPU rack, the Lithium-Manganese Dioxide
battery must be connected unless an external auxiliary back-up battery is to be used.
These modules are shipped from the factory with the battery connector disconnected
from the battery. When connecting a battery, the following procedure is recommended.
Refer to figure 3.7, which shows a mounted, connected battery.
-
The battery mounting location is located at the bottom front of the memory module
on the component side of the module.
-
If the battery is not mounted, firmly place it in its mounting clip with the cable end
facing toward the battery connectors.
-
Connect the battery cable to one of the battery connectors.
-
The memory module is now ready for installation into the CPU rack.
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Installation
Instructions
3-9
GEK-96602
External Auxiliary Battery Selection
If an auxiliary back-up battery is to be used with your system, a jumper on the board
must be properly configured. This jumper is JP6 and is located next to the Lithium
battery. Factory default is - no auxiliary battery present (JP6 over pins 1 and 2). To
change the selection to auxiliary battery present, place JP6 over pins 2 and 3. In order to
use this feature, the user must supply a battery with the proper voltage (6 to 28 V dc)
connected to the auxiliary battery terminals on the power supply terminal block.
a42221
m
EXTERNAL AUXILIARY
BATTERY SELECT
r
Figure 3.7 MEMORY BOARD BATTERY CONNECTiON
Relatively small amounts of excess charge can cause very intense
electrostatic fields in metal-oxide-semiconductor (MOS) devices, damaging
their gate structure. Avoid handling the circuit board under conditions
favoring the buildup of static electricity. Failure to observe this caution could
result in the destruction of the CMOS RAM devices in this module.
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Installation
3-10
Instructions
GEK-96602
Do not allow the bottom of a module to come into contact with a
conductive (metal) surface when the board cover is removed.
Failure to observe this caution could result in the discharge of the
non-rechargeable lithium battery and the loss of memory contents.
When installing a Combined Memory module or any module, position the component side
of the board to your right (towards the CPU power supply). Figure 3.8 shows proper
orientation of a printed circuit board.
a41136
.
--a-------
.I
P
-
I
I
m
n
i
L
“1
4
I
:
aI
.
z
21
I
L
NOTE
Proper orientation of printed circuit boards is with component side
towards the power supply.
Figure 3.8 PRlNTED CIRCUIT BOARD ORIENTATION IN A RACK
Install the faceplate by placing the faceplate in the proper position and while pushing in,
turn the quarter-turn thumbscrew clockwise until it feels secure.
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Installation Instructions
3-11
GEK-96602
Arithmetic Control Module
Logic Control Module - Advanced, Expanded, or Expanded II
None of these modules have any devices needing user configuration. The selected Logic
Control module should be installed in slot 2, which is the second slot to the left of the
power supply.
The Arithmetic Control module should be installed in slot 3, immediately to the left of
the Logic Control module.
A short length of ribbon cable is used to interconnect these two modules through sockets
on the lower front edge of each printed-circuit board. Refer to figure 3.9. Ensure that
this cable is in place and that the connectors are seated properly.
NOTE
Operation of the system without the ribbon cable connected
between the Arithmetic Control and Logic Control modules will
result in unpredictable operation by the CPU.
a41079
figure 3.9 LOGIC CONTROL TO ARlTHMETlC CONTROL RIBBON CABLE
NOTE
To prevent unpredictable operation of your Series Six Plus CPU, the
CPU should be powered-down before installing or removing either
module or the connector.
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Installation Instructions
3-12
GEK-96602
I/O Control Module
The I/O Control module should be inserted in slot 1, immediately to the left of the power
supply. The I/O Control module contains three labeled jumper terminals, which are for
selection of board options. These jumpers are located on the lower right of the
component side of the printed circuit board (with component side towards you and LEDs
and connectors to the left).
The jumper configuration and definitions are indicated in the following table. To change
a configuration, move the jumper plug to the correct pins. Jumpers should be configured
to conform to the requirements for a particular application.
Table 3.2 I/O CONTROL OPTION JUMPERS
DEFINITION
DPU Present
DPU Not Present
E
D-E
DPU Fault Trips Alarm No. 1 and
Alarm No. 2. CPU Stops
E
E-F
DPU Fault Trips Alarm No. 2. Provides
an Advisory Indication.
H
G-H
Communications Control Fault Trips Alarm
No. 1 and Alarm No. 2. CPU Stops.
H
H-J
Communications Control Fault Trips Alarm
No. 2. Provides an Advisory Indication.
The I/O Control connects to an I/O Receiver or Advanced I/O Receiver in the first l/O
rack in a CPU I/O station through a 16 pair parallel cable. Location of the 3 jumpers on
the lower part of the board is shown below.
a41076
tI0
Xl14
V.-l
JUMPERS
Figure 3.10 I/O CONTROL MODULE JUMPER LOCATION
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3-13
Installation Instructions
GEK-96602
Auxiliary 1/O Module
The Auxiliary I/O module is available as an option and is required if an Auxiliary I/O
chain is to be included in a Series Six Plus PLC system. The Auxiliary I/O module can be
used in either a Series Six Plus CPU rack, or in a Series Six model 6000 CPU rack.
When used with the Series Six Plus PLC in the Expanded mode of operation, up to 8000
Inputs and 8000 Outputs are available on the Auxiliary I/O chain (in addition to the 8000
Inputs and 8000 Outputs on the Main l/O chain). When used with the Series Six model
6000 CPU, the maximum available I/O is 2000 Inputs and 2000 Outputs.
A group of 4 DIP shunts must be inserted in one of two locations, determined by which
CPU the module is to be used with, either Series Six Plus or Series Six model 6000.
The Auxiliary I/O module can be installed in slot 5, 6 or 7 depending on whether or not
the GEnet Factory LAN Series Six Network Interface 2-slot option is selected. If the
LAN communications option is not selected, install the Auxiliary I/O module in slot 5.
The Auxiliary I/O module connects to the first I/O rack in a CPU I/O station in the
Auxiliary I/O chain through a standard 16-pair parallel bus cable.
Communication Control Modules
If a Communications Control Module, either CCM2 or CCM3, has been selected as an
option, it should be installed in slot 5, immediately to the left of the Combined Memory
module.
There are jumpers or DIP switches on the Communications Control Modules which should
be configured to set operating parameters for the module. For complete details on
configuration of any of the communications modules, refer to the applicable manual as
listed below.
- CCM2
GEK-25364
Series Six Data Communications Manual
- CCM3
GEK-90505
Supplement to the Series Six Data Communications Manual
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Installation
3-14
Instructions
GEK-96602
CPU Power Supply
The CPU power supply, which is installed at the factory, has 2 terminal boards located on
the lower part of the faceplate. Refer to figure 3.11 which is an illustration of the
terminal boards and their connections. Remove the protective cover and make the
following connect ions.
7Otmpll
a41063
i%z
CONTACTS
(ISOLATEDI
LlNE I ILlI
LINE 2 IL21
GROUND lG1
AC POWER SUPPLY
E
CONTACTS
(ISOLATED1
INDkT
tl
@ GROUND 1GL
20 ToDi* VDC
100 TO IS0 "DC
(A!5 APPLiCABLEI
DC POWER SUPPLY
Figure 3.11 CPU POWER SUPPLY CONNECTIONS
-
Provide the required power source for your system, either 95V to 260 V ac for the
wide range ac power supply, 20 to 32 V dc, or 100 to 150 V dc for the dc power supply.
- AC power supply COnnections: connect a 3-wire AC power cord to the 3 lower
terminals of the terminal board on the right. The power cord plug should have the
proper pin configuration for either 115 V ac or 230 V ac.
If the same ac power source is used to provide ac power to other racks in a
Series Six Plus PLC system, ensure that all ac input connections are identical
at each rack. Do not cross line 1 (L1) and line 2 (L2). A resulting difference
in potential can cause damage to equipment.
DC power supply connections: connect 3 wires from the DC power source to the proper
terminals on the power supply. These terminals are labeled POS, NEG, and GND. Ensure
that these wires are of the correct polarity before applying power.
Connect the alarm relay contacts to external alarm devices as required by
system configuration. (Optional)
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Installation
Instructions
3-15
GEK-96602
The user devices connected to each set of alarm terminals on the power
supply module should present a resistive load drawing no more than one amp
of current at 115 V ac or 28 V dc. Failure to observe this caution may result
in damage to the circuit board.
-
Connect the + and - Auxiliary Battery contacts to an external battery having a
voltage from 6 to 28 V dc. This is an option that will provide a back-up to the
memory back-up battery mounted on each memory module.
If a memory auxiliary battery is used, the circuit connecting it to the power
supply module should be isolated from the rest of the system. If this caution
is not observed, the battery could be short-circuited.
After these connections have been completed the protective cover plate should be
carefully reinstal led.
1 WARNI NG |
Ensure that the protective cover is installed over the terminal boards. During
normal operation either 115 V ac or 230 V ac is present on the ac Power
supply, or 20 to 32 V dc or 100 to 150 V dc on the dc power supply. The cover
protects against accidental shorting of terminals which could cause damage to
the machine or injury to the operator or maintenance personnel.
SYSTEM GROUNDING PROCEDURES
All components of a programmable control system and the devices it is controlling should
be properly grounded. This is particularly important for two reasons as stated below.
1. SAFETY CONSIDERATIONS - A low resistance path from all parts of a system to
earth minimizes exposure to shock in the event of short circuits or equipment
malfunction.
2. PROPER EQUIPMENT OPERATION - Some components of the Series Six Plus PLC
system require a common ground connection between racks to guarantee correct
operation.
Recommended Grounding Practices
The following grounding practices are recommended to ensure proper operator safety and
correct equipment operation when installing and using a PLC system.
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3-16
Installation Instructions
~ ~. -...
GEK-96602
Ground Conductors
1. Ground conductors should be connected in a tree fashion with branches routed to a
central earth ground point. This ensures that no ground conductor carries current
from any other branch. This method is shown in figure 3.12.
a41055
r
SERJES SIX PLUS
PC
MOTOR DRIVES
AND OTHER
ELECTRICAL
CONTROL EQUIPMENT
MACHINERY
?
?
?
POINT
5 EARTH GROUND
Figure 3.12 PLC SYSTEM GROUNDING
2. Ground conductors should be as short and as large in size as possible. Braided straps
or welding cables (AWG No. 8 or larger) can be used to minimize resistance.
Conductors must always be large enough to carry the maximum short circuit current
of the path being considered.
Series Six Plus PLC Equipment Grounding
Rack Grounding - There are 2 important requirements for grounding Series Six Plus CPU,
I/O and associated peripheral racks.
1. Safetv Ground. This connection should be made from the GND terminal or the rack
powe; supply directly to system earth ground. The purpose of this connection is to
provide a guaranteed current path to ground in case a malfunction occurs within the
rack or the rack is incorrectly wired. Figure 3.1 3 illustrates recommended wiring for
the rack safety ground.
a41 056
CONNECT A SHORT
AND DIRECT SAFETY
GROUND WIRE FROM
THE G (GROUND)
TERMINAL TO
GROUNDED PANEL OR
CABINET
c SCREW OR
%OLT
Figure 3.13 RACK SAFETY GROUND WIRING
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Installation Instructions
3-17
-
GEK-96602
2. Signal Ground - All racks that are grouped together as a CPU I/O station or a Local
I/O station MUST have a common ground connection. This is especially important for
racks in the same I/O station which are not mounted in the same control cabinet, If
this situation exists, the control cabinets MUST be tied together using the shortest
possible connect ions.
If racks in a CPU or Local l/O station are distributed among several
control cabinets that cannot be directly tied together, it is
recommended that
I/O Transmitter modules be used to
communicate between these cabinets.
The GND terminal of the rack power supply should not be used as the Signal Ground
connection between racks. The best way to provide Signal Ground connections is to
ensure that the Series Six Plus PLC rack metal frames are directly connected to the
control panels or racks in which the racks are mounted. This can be accomplished by
connecting a ground strap from one of the ground lugs on the rack plate on either side
of the rack to the control panel or cabinet. These Signal Ground methods are
illustrated in figures 3.14 and 3.15.
a4 1054
I
GROUNDED PANEL OR CABINET
1 STAR WASHERS UNDER
RAIL MOUNTING BOLTS
OR
,2. GROUND STRAP FROM
GREEN GROUNDING SCREW
IN CENTER OF RACK SIDE
PLATE TO PANEL
-SERIES SIX PLUS
RACK
1
I
SAFETY GROU
GROUND 7
Figure 3.14 SERIES SIX PLUS PLC RACK SIGNAL GROUND CONNECTIONS
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3-18
InstaIlation Instructions
GEK-96602
I/O
FROM
TRANSMITTER
CONTROL CABINET
a41052
a
GROUND CONNECTIONS
AT EACH RACK
/
CONTROL CAB&JETS MUST IBE TlED TOGET
AND HAVE A COMMON EARTH GROUND
Figure 3.15 I/Q STATION GROUNDING
3. Programming Device Grounding - For proper operation, the programming device,
(Workmaster computer, CMSTAR I computer, or a Program Development Terminal)
must have a ground connection in common with the CPU or VO rack to which the PDT
or Workmaster computer interface cable is connected. Normally, this common ground
connection is provided by ensuring that the programmer’s power cord is connected to
the same power source (with the same ground reference point) as the CPU or I/O rack
as shown in figure 3.16.
GRWNMD
NOTE
PANEL OR CABMET
??? ?????? ?????
POWER SUPPLY ts A
DC VERSK)N. THE OUTLET
wxms A SEPARATE
AC POWER SOURCE
v o NrmFACL
CABLE
-GROUND CONNECT+DNS
AT EACH RACK
H
ND
Figure 3.16 PROGRAMMING DEVtCE GROUND CONNECTION
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a41053
*
Installation
Instructions
3-19
GEK-96602
I/O SYSTEM CONFIGURATION
l/O rack(s) should be rack, panel or wall mounted in the same manner as the CPU rack.
When mounting multiple racks at the same location, enough space should be allowed
between racks, both horizontally and vertically, to allow sufficient air flow between
racks (minimum of 6 inches vertically), with the exception that the 13” rack can be
mounted side-by-side.
I/O Interface modules should be available for installation in racks. The types of I/O
interface modules are determined by the number of I/O points required and the location
of the racks in a system. Refer to Chapter 2 for a discussion of the 3 types of stations in
an I/O system (CPU, Local and Remote). The type of l/O station will determine whether
your I/O racks will contain l/O Receivers, Advanced I/O Receivers, l/O Transmitters,
Remote I/O Drivers, Remote I/O Receivers or combinations of these modules. Figure
3.17 is an example of a typical l/O rack.
To prevent accidental mating of an I/O module with a faceplate not compatible with that
module, all of the l/O printed circuit boards are keyed to match the corresponding
faceplates.
¶
oI
c3-
II
o-
1.
2.
3.
4.
5.
I/O power supply
Power source terminal block
DC Power Indicator
Logic Power Switch/Circuit Breaker
Module Slot 1
6. Module Slot 11
7. I/O System Interface Module
8. Connector to l/O Control, upstream I/O
Receiver, Advanced I/O Receiver, l/O
Transmitter or Remote I/O Receiver.
9. Connector to a downstream I/O
Receiver.
10. Tray to contain field wiring.
Figure 3.17 TYPICAL I/O RACK
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3-20
Installation
Instructions
GEK-96602
I/O Power Supply
The I/O power supply is shipped from the factory installed in the I/O rack. 5 V dc at 6.1 A
is provided for the standard I/O rack or 5 V dc at 16.5A, +I2 V dc at 1.5A and -12 V dc at
1.OA for the high capacity I/O rack (13” rack requires a high-capacity power supply).
There is one terminal board located on the lower part of the faceplate. Remove the
protective cover plate and make the required connections as shown in figure 3.18.
6830122
6830114
a41060
SELECT JUMPER (1) FOR
115 OR 230VAC OPERATION
8 m m--m, ;,l 1 WAC
0- .--.-,/ ‘>230VAC
8c
0 NO CONNECTION
a
0 WUNEI
8 (i-2) LtNE 2
0 GND) G R O U N D I
0
8
0
8
8
0
8
Standard
Power Supply
High Capacity
Power Supply
r
s-w-/
QWNE 1
fL2IWE2
1
AC INPUT
95 TO 260 VAC
(GND) GROUND
115/230 V ac CONNECTIONS
0
8
0
8
8
0
8
POS
DC INPUT
20 TO 32 VDC
OR
100 TO 1 5 0 V D C
NEG
GND
.
24 or 125 V dc CONNECTIONS
Figure 3.18 l/O POWER SUPPLY CONNECTIONS
AC Power Source Connections
-
-
Remove the plastic cover protecting the terminal board.
Select 115 V ac or 230 V ac input by configuring the jumper to the proper terminals
as shown (for a standard power supply). The jumper will be configured for 115 V ac
when shipped from the factory. The high capacity power supply does not require
jumper configuration, since it is a wide range supply and will accept an ac input
voltage from 95 to 260 V ac.
Connect a 3-wire AC power cord to the 3 lower terminals.
When connecting multiple I/O racks to the same ac power source, ensure that
all ac input connections are identical at each rack. Do not cross line 1(L1)
and line 2 (L2). A resulting difference in potential can cause damage to
equipment.
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3-21
lnstallation Instructions
GEK-96602
DC Power Source Connections
-
Remove the plastic cover protecting the terminal board.
-
Connect a DC power source (20 to 32 V dc or 700 to 150 V dc as required) to the
proper terminals on the terminal board (POS, NEG, or GND).
After completing the ac or dc connections as required, the protective plastic cover should
be reinstalled.
Ensure that the protective cover is installed over the terminal board. During
normal operation either 115 V ac, 230 V ac, 24 V dc, or 125 V dc is present.
The cover protects against accidental shorting of terminals which could cause
damage to the machine or injury to the operator or maintenance personnel.
I/O System Interface Modules
The I/O system interface modules are the I/O Receiver, Advanced l/O Receiver, l/O
Transmitter, Remote I/O Driver, and Remote I/O Receiver. Individual functions of these
modules are described in Chapter 2, Installation instructions for each of these modules
can be found in the individual data sheets for each module. Data sheets for all I/O
system interface modules are included in the Series Six Data Sheet manual, GEK-25367.
In addition, individual data sheets are included with each module shipped from the factory.
For reference, the data sheet numbers for each of the I/O system interface module are
Iisted below.
I/O INTERFACE MODULE
I/O Receiver
Advanced I/O Receiver
I/O Transmitter
Remote I/O Driver
Remote I/O Receiver
PUBLlCATlON
NUMBER
GEK-83512
GEK-90771
GEK-83515
GEK-83537
GEK-83537
A summary of installation requirements for the l/O system interface modules is included
on the following pages.
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Installation
3-22
Instructions
GEK-96602
I/O Receiver or Advanced I/O Receiver
Either an I/O Receiver or an Advanced l/O Receiver module must be installed in slot 11
in a 19” rack or in slot 8 in a 13” rack, which is the leftmost slot in an l/O rack. An I/O
address DIP switch is not required for this module (or for any I/O communication
modules). The top connector on the I/O Receiver or Advanced I/O Receiver in a daisy
chain of racks connects to an I/O Control module in the main I/O chain, to an Auxiliary
l/O module in an auxiliary I/O chain, to the next upstream I/O rack, or to an I/O
Transmitter in a CPU, Local or Remote l/O station. The bottom connector connects to
the next rack downstream, if additional racks are in the system. The I/O Receiver and
Advanced I/O Receiver modules have 2 DIP shunts and a jumper pack that must be
configured to specify whether the module is to pass the I/O chain signals through to the
next rack or if it is the last rack in the chain. A 16-pair parallel l/O chain cable of the
required length (see table 3.4) connects the I/O Receiver or Advanced I/O Receiver to
other modules on the chain.
l/O Transmitter
An I/O Transmitter module can be installed in any slot in an I/O rack or in an I/O slot in a
Series Six Plus CPU rack or in a Series Six model 60 CPU rack. Connect a parallel l/O
chain cable from the connector on an I/O Transmitter to the first I/O Receiver or
Advanced I/O Receiver in the next downstream I/O station.
Jumper JP1 must be configured to stop or not stop the system on a system fault.
Enable system stop for a local fault
System does not stop for a local fault
Jumper over pins 2 - 3
Jumper over pins 1 - 2
A jumper (JP2) must be configured to select the I/O mode of operation, either NORMAL
or EXPANDED as shown below.
NORMAL I/O Mode
EXPANDED I/O Mode
Place jumper over pins 1 - 2
Place jumper over pins 2 - 3
When in the EXPANDED I/O mode, one I/O Transmitter is required to originate each
channel of Expanded I/O. The exception to this, is if only Expanded I/O channels 0 and 8
are to be used. In this case an I/O Transmitter is not required. If more than two channels
of Expanded I/O are to be used, an I/O Transmitter module must be used for each
channel. Any l/O Transmitters downstream from the originating one must be configured
for the Normal mode.
The first 3 positions (1,2,3) of the DIP switch on the backplane adjacent to each I/O
Transmitter must be configured to select the Expanded I/O channel that it is driving. The
switch settings are shown below in table 3.3.
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3-23
Instat lation lnstntctions
GEK-96602
Table 3.3 EXPANDED I/O CHANNEL SELECTION
CHAN EL NUMBER
AUXILIARY
MAIN
CHAIN
CHAIN
0
8
DIP SWITCH POSITION
3
2 1
Remote I/O Driver
A Remote I/O Driver can be installed in any l/O slot (except the left slot) in an l/O rack
located in a CPU I/O station, a Local l/O station, a Series Six Plus CPU l/O slot or a
model 60 CPU I/O slot. Before installing this module, the seven segment DIP switch on
the backplane adjacent to the selected I/O slot for the module must be configured to
select the group of I/O references for the Remote I/O station.
NOTE
Both the Remote l/O Driver and the Remote I/O Receiver must be
placed in high capacity I/O racks to operate with RS-232 devices.
Either a standard or high capacity I/O rack can be used when the
link connections are with twisted-pair cable.
Switches 5,6, and 7 are used to establish the I/O references for groups of 120 Inputs and
120 outputs. If the option is selected for 248 Inputs and 248 Outputs, then switches 6 and
7 will establish the l/O references. The remaining switches, either 1, 2, 3 and 4 or 1, 2
and 3 respectively, are used to select a unique address for the Remote I/O Driver. The
unique address will assign 8 consecutive I/O points to the Driver which will be used to
provide status data to the CPU for the Remote I/O station.
A group of jumper plugs must also be configured for proper system operation. These
items configured by the jumpers include the following:
Quantity of l/O (120/120 or 2481248)
Remote I/O Parity Error Effect on the CPU (STOP or Continue to RUN)
Communications Failure Effect on the CPU (STOP or Continue to RUN)
Even or Odd Parity
Specify Parity Check (Yes or No)
Baud Rate (Selectable from 110 baud to 57.6K baud)
Carrier Detect (No or Yes)
Clear To Send (No or Yes)
Output Mode (Twisted Pair or RS-232)
Input Mode (Twisted Pair or RS-232)
Sensitivity (Medium or Minimum)
For detailed instructions on jumper configuration for a Remote I/O Driver module, refer
to the Remote I/O module data sheet, GEK-83537.
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Installation Instructions
3-24
GEK-96602
Remote l/O Receiver
A Remote I/O Receiver must be installed in the left slot (slot 11 in a 19” rack or slot 8 in
a 13” rack) of the first I/O rack in a Remote I/O station. The Remote Receiver does not
require an I/O address. Before installing a Remote Receiver module, several jumper
plugs on the printed circuit board must be configured to be compatible with the Remote
I/O Driver to which it is connected. The jumper locations are arranged on the board in
groups of three pins and are identified by the center pin.
If direct connection to the Remote I/O Driver is to be through a serial two twisted-pair
cable at a distance up to 10,000 feet (3Km), the end of this cable at the Remote I/O
station should be connected to the top connector. If connection is to be through an
RS-232 modem link, a cable, not to exceed 50 feet (15 meters) in length should be
connected from the top connector to the modem in the Remote l/O station.
If there is to be more than one l/O rack in the Remote l/O station, the next downstream
rack in the daisy chain will connect to the bottom connector using a 16 pair parallel I/O
chain cable. This cable wilI in turn connect to an I/O Receiver in the next rack. If the
rack containing the Remote Receiver is the only rack in a Remote Station, terminate the
I/O chain signals by configuration of jumpers on the Remote Receiver printed circuit
board.
For detailed information on jumper configuration, refer to the Remote I/O module data
sheet, GEK-83537.
Parallel I/O Chain Cables
Cables may be ordered in standard lengths for interconnection between racks on the
parallel I/O chain. The maximum cable lengths in a system configuration are determined
by the type of I/O station used. For cable limitations refer to Chapter 2 in this manual.
Table 3.4 lists the standard length I/O cables available.
Table 3.4 PARALLEL i/O CHAIN CABLE CATALOG NUMBERS
Lenqth
Feet
Meters
2
5
10
25
50
100
200
300
400
500
0.6
1.5
3.0
7.5
15.0
30.0
60.0
90.0
120.0
150.0
Catalog
Number
IC600WD002A
IC600WD005A
lC6OOWD010A
IC600WD025A
IC600WD050A
IC600WD100A
IC600WD200A
IC600WD300A
IC600WD400A
IC600WD500A
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3-25
Installation Instructions
GEK-96602
Parallel I/O Cable Conf iguration
Figure 3.19 is an illustration of the Parallel l/O Chain cable used to connect a CPU to I/0
rack or to connect racks in a daisy chain in a CPU I/O station, a Local I/O station or I/O
racks within a Remote I/O station.
2 IN. TUBING OVER SHIELD
\
NOUWTtl MMOWME I2 tEl4 WINECTOR~
WIRE TMLE FOR ALL C&LE LEtifffi
PLUG
RI WlRE
TnBLE
PM #I N
PIY
O
#2 B L U E - W I T
P I N #3 WT-BLU
PIN
#4 1 mu-WIT
Pltdf5
WT-ORN
P I N #6 BRN-W-T
PLUC#2
P L U G #I
WIRE TABLE
Pl# #20 WY-RED
SOCKEtdI
COMNECTIOU
PIW # 21 RED-6RY
$CtUET#2I
SOCKEt#3
PIN
SOCKET#22
1 SOCKEf#4
SOCUETRS
]
1
# 22 BLU-BLX
PM #23 BLK-BLU
PIN # 24 DRN -BFK
SOCKET#23
fOCKET#24
SOCKET#25
SOCKETt6
PJlt
#2’S BLK-ORY
WIT-&tN
j SOCKETkt7
PM
#26
PM
Wtr-WIT
1 SDCKEtlC8
PIW #I4
ORn -RED
SOCKET# I4
PIW#lSA
RED-oaw
5oCKET#C6
r
SOCKEf#20
!iOCXETWZ
PIY #?
It8
P L U G #2
MN-BLK
SOCKETb26
1 PIW #27 1 BLK-6RN
i SOCKEl#Z271
1 PIN #32 1 BLU-YEL
I socKn#3zl
1 PIN #37j
SHIELD
LEI
FEET
rt4
YETERS
2
S
0.6
I5
30.0
lcGwwoIooA
CO.0
K6wwD2w~
lo
3.0
7.5
SOD
moomlaoA
2s
l20.0
l-#oA
so
IS.0
150.0
lc6oom5ooA
NOTE
Minimum conduit size for running this cable (with the hoods in place) should be
no less than 2 inches.
Figure 3.19 PARALLEL I/O CHAIN CABLE
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70126
Installation Instructions
3-26
GEK-96602
Serial Link Cable To Remote I/O System
The following data is provided as an aid to the user for assembling and wiring a
twisted-pair cable for connecting a Local l/O system to a Remote l/O system over a
serial Iink.
70110
SHIELD
RECEIVED +
DATA
_
C
SHIELD
15
/-\ PAIR #2
3
1!I1
IW
REo”RStX&O
9
' IO
t> TRDAANTSAUIT
REMOTEMl
RECEIVER
CABLE SPECIFICATIONS
Length, Maximum - 10,000 Feet (3 Kilometers)
Two Individual Shielded,Twisted pairs
22 AWG, Minimum
15 pf/foot, Maximum
Cable Type - National Electric Cable Co. 22P1SLCBT or equivalent
Connector (Driver and Receiver End) - D-Subminiature Type, Cannon DBC25P with
207908-7 Hood or equivalent connector and hood
Figure 3.20 REMOTE l/O TWISTED PAIR CABLE
DATA
TERMINAL
TRANSMIT DATA
RECEIVE DATA
SIGNAL GROUND
CLEAR TO SEND
CARRIER DETECT
UARK
SPACE
REMOTE I/D
DR IVER OR RECEIVER
70111
II
I
MODEM
CABLE SPECIFICATIONS
Length, Maximum - 50 feet (15 Meters)
Overall Shield
24 AWG, Minimum
Connector, Driver or Receiver End - D-Subminiature Type, Cannon DBC25P with
207908-7 Hood or equivalent
Connector, Modem - User selected
Figure 3.21 REMOTE I/O CABLE FOR RS-232 MODEMS
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Installation
Instructions
3-27
GEK-96602
I/O POINT SELECTION
After I/O racks have been installed, cables run, and AC or DC power cables connected,
the racks are ready for installation of l/O modules. The I/O module starting l/O point
reference numbers should now be programmed by setting the DIP switches on the rack
backplane adjacent to the connectors. Refer to figure 3.22, as a guide to configuration of
the DIP switches for 8 circuit modules. The I/O point number selected is the first of
eight consecutive I/O points (one l/O address) starting with that number. For modules
requiring different switch settings, such as High Density or Analog modules, refer to the
installation instructions on the applicable data sheet for each module for proper DIP
switch configuration.
After configuring the DIP switches, install the I/O modules in their respective slots as
determined by your program. The actual I/O reference used for each I/O point in your
program depends on whether the I/O system is in the Normal or Expanded I/O mode. If
the Expanded l/O mode is selected, the applicable channel number is added before the
reference number as described previously.
NOTE
There are limitations on the combination of types of I/O modules which may be
instal I ed in an I/O rack. This is determined by the load placed on the power
supplyr by the various modules.
,
Al
IAl
1
1
AIA
I
111111
Figure 3.22 DIP SWITCH SETTINGS FOR I/O POINT SELECTION
FOR 8 CIRCUIT MODULES
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70.97
Installation instructions
3-28
GEK-96602
POWER SUPPLY LOAD CAPACITY
The load capacity of the power supply in a Series Six Plus CPU rack is the sum of the
internal loads placed on it by each of the CPU modules as well as the l/O modules and is
expressed as units of load, with 1 unit of load being equal to 300 milliwatts of power.
Each unit of load of 300 milliwatts can also be expressed in terms of current as follows:
+5 Vdc = 60 mA of current
+12 V dc = 25 mA of current
-12 V dc = 25 mA of current
Load Capacity for a Series Six Plus CPU Rack
The power supply in a Series Six Plus CPU rack is a high capacity supply with 3 outputs
having capacities as follows:
Table 3.5 CPU RACK POWER SUPPLY CAPACITIES
I
VOLTAGE & CURRENT
UNITS OF LOAD
+5 V dc at 16.5 Amps
+12 V dc at 13 Amps
-12 V dc at 1.0 Amps
275 units of load
60 units of load
40 units of load
I
I
I
I
NOTE
In addition to the units of load listed for each voltage type, the total load on all
outputs of the supply must not exceed 300 units of load (90 watts of total
power.
The number of I/O modules that can be used in a rack is determined by adding up the
loads of all CPU modules and subtracting that load from the total load capacity. The
remaining capacity in a Series Six Plus CPU rack usually allows up to 100 units of load for
I/O modules to be contained in the rack. The total load of those I/O modules must not
exceed the remaining current capacity.
Do not exceed any of the following limits:
1. The total current capacity (units of load) of each supply (+5, +I 2 and -12 V
dc).
2. The sum of units of load for all supplies must not exceed 300 units.
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Installation Instructions
3-29
The available units of load for each module to be located in the CPU rack are listed in
Table 3.6.
Table 3.6 SUMMARY OF UNITS OF LOAD FOR CPU RACK MODULES
CATALOG
NUMBER
MODULE
DESCRIPTION
IC600CB524
Arithmetic
IC600CB525
IC600CB526
IC600CB515
Logic Control (Advanced)
Logic Control (Expanded)
Logic Control (Expanded II)
12
12
12
IC600CB503
IC600CB513
I/O Control
Auxiliary I/O
17
9
IC6OOLX605
IC6OOLX612
IC6OOLX616
IC6OOLX624
IC6OOLX648
IC6OOLX680
Logic
Logic
Logic
Logic
Logic
Logic
IC600CB516
IC600CB517
Communications Control (CCM2)
Communications Control (CCM3)
17
17
4
4
4
4
IC650AELOOO
IC650AEMOlO
LAN Interface Controller Board
LAN Interface Modem Board
20
17
2
16
1
2
(1)
UNITS OF LOAD (1)
+5 v
+12 v
-12 v
Control
Control
Memory
Memory
Memory
Memory
Memory
Memory
30
24
24
24
24
24
24
For +5 V dc, 1 unit of load = 60 mA (300 mw of power)
For +12 V dc, 1 unit of load = 25 mA (300 mw of power)
For -12 V dc, 1 unit of load = 25 mA (300 mw of power)
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Installation
3-30
Instructions
GEK-96602
Load Capacity for an I/O Rack
The power supply in a standard I/O rack can supply 100 units of load while the power
supply load capacity in the high capacity I/O rack is the same as the load capacity for a
Series Six Plus CPU rack (275 units of load for +5 V dc, 60 units of load for +12 V dc, and
40 units of load for -12 V dc). The total load on all outputs for the high capacity supply
must not exceed 300 units of load (90 watts of total power). The types of l/O racks
(standard or high capacity) to be used in a system are determined by the combination of
modules to be installed in the racks. Table 3.7 is a list of the I/O modules and their units
of load.
Table 3.7 SUMMARY Of UNITS OF LOAD FOR f/O MODULES
T
CATALOG
NUMBER
IC600BF800
IC600BF801
IC600BF802
IC600BF804
IC600BF805
IC600BF806
IC600BF808
IC600BF810
IC600BF813
IC600BF814
IC600BF875
IC600BF816
IC600BF817
IC600BF818
IC600BF819
IC600BF827
IC600BF830
IC600BF831
IC600BF841
IC600BF842
IC600BF843
IC600BF900
IC600BF901
IC600BF902
IC600BF903
IC600BF904
IC600BF905
IC600BF906
IC600BF907
T
MODULE
DESCRIPTION
UNIT
+5 v
I/O Receiver
Remote I/O Receiver
24 to 48 V dc Input
115 V ac/dc Input
230
V ac/dc
Input
12 V ac/dc Input
Interrupt Input
115 V ac/dc Isolated Input
Type J Thermocouple Input
Type K+ Thermocouple Input
Type S Thermocouple Input
Type T Thermocouple Input
Type B Thermocouple Input
Type E Thermocouple Input
Type R Thermocouple Input
High Speed Counter
Advanced I/O Receiver
High Density Input
0 to 10 V dc Analog Input
+/-10 V dc Analog Input
4 to 20 mA Analog Input
I/O Transmitter
Remote I/O Driver
24 V dc Sink Output
48 V dc Sink Output
115 V ac Output
230 V ac Output
12 V dc Sink Output
12 V dc Source Output
9
42
2
2
2
2
3
2
29
29
29
29
29
29
29
19
12
4
29
29
29
34
38
7
7
9
9
7
7
OF LOA
+12 v
10
10
10 (2)
(I).
For +5 V dc, 1 unit of load equals 60 mA (300 mw of power).
For +12 and -12 V dc, 1 unit of load equals 25 mA (300 mw of power).
(2).
+I2 V and -12 V current is less than 1 unit of load if RS-232 mode is not used.
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Installation
3-31
Instructions
GEK-96602
Table 3.7 SUMMARY OF UNITS OF LOAD FOR l/O MODULES (Continued)
CATALOG
NUMBER
MODULE
DESCRIPTION
IC600BF908
IC600BF909
IC600BF910
24 V dc Source Output
48 V dc Source Output
115 V ac Isolated Output
230 V ac Isolated Output
Reed relay output
Axis Positioning Module, Type 1
Axis Positioning Module, Type 2
5 V TTL Output
10 to 50 V dc Sink Output
120 V dc Output
10 to 50 V dc Source output
115 V ac Protected Output
0 to 10 V dc Analog Output
+/-10 V dc Analog Output
4 to 20 mA Analog Output
ASCII/BASIC Module (12K)
ASCII/BASIC Module (28K)
Loop Management Module
I/O Link Loccal
I/O CCM
I/O CCM4
Genius Bus Controller
Genius Bus Controller w/Diag.
Genius Bus Controller
Genius Bus Control1 wo/Diaq.
IC6OOBF912
IC600BF914
IC6OOBF915
IC600BF917
IC600BF921
IC6OOBF923
IC6OOBF924
IC6OOBF929
IC600BF930
IC600BF941
IC6OOBF942
IC600BF943
IC6OOBF944
IC600BF949
IC600BF946
IC600BF947
IC6OOBF948
IC600BF950
IC660CBB900
IC660CB902
IC660CBB901
IC66OCB903
(7)
UNITS OF LOAD (1)
+5 v
+12 v 1 -12 v
7
7
8
8
13
23
21
3
3
5
3
8
29
29
29
20
20
20
20
20
20
20
20
20
20
-
7
11
-
3
6
-
I
-
1
-
12
12
12
12
12
12
2
2
2
2
-
For +5 V dc, 1 unit of load equals 60 mA (300 mw of power).
For +12 and -12 V dc, 1 unit of load equals 25 mA (300 mw of power).
**R*~**R*~xx*R*x***
IMPORTANT INFORMATION RRX*RRRR***~*******
After you have completed the installation procedures for all of your hardware and have
installed the Logicmaster 6 software on your Workmaster industrial computer, CIMSTAR
I industrial computer, or IBM PLC, PC-XT, or PC-AT Personal Computer, you should
proceed to the following START-UP instructions for a new Series Six CPU.
INITIAL START-UP INSTRUCTIONS FOR A NEW SERIES SIX CPU
Any new memory board will usually power-up with a parity error. The reason this
happens is that when the lithium battery is first plugged into the board, the RAM memory
devices power-up in an unknown state. These parity errors must be cleared before proper
CPU operation can be expected. The CPU should be cleared even though it appears to
run properly when it is first powered-up. The following procedures, when followed, will
clear any parity errors present in the CPU memory when starting up a CPU for the first
time.
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Installation
3-32
Instructions
GM-96602
Unpredictable operation of the CPU may occur if the CPU is in the RUN mode
with an uninitialized memory board. Always place the CPU in the STOP mode
when installing a new memory board.
1.
Install lithium battery on the Logic Memory module.
Before installing a memory module in a CPU rack, the Lithium-Manganese Dioxide
battery must be connected. These modules are shipped from the factory with the
battery connector disconnected from the battery.
following procedure is recommended.
When connecting a battery, the
-
The battery mounting location is at the bottom front of the memory module on the
component side of the module.
-
If the battery is not mounted, firmly place it in the mounting clip with the cable end
facing toward the battery connectors.
-
Connect the battery cable to one of the battery connectors.
-
The memory module is now ready for installation into the CPU rack.
1 CAUTION 1
Relatively small amounts of excess charge can cause very intense
electrostatic fields in metal-oxide-semiconductor (MOS) devices, damaging
their gate structure. Avoid handling the circuit boards under conditions
favoring the buildup of static electricity. Failure to observe this caution could
result in the destruction of the CMOS RAM devices in this module.
-
Be sure that the board covers provided with the Logic Memory module are in place
before installing the module.
1 CAUTION 1
Do not allow the bottom of a module to come into contact with a conductive
(metal) surface when the board cover is removed. Failure to observe this
caution could result in the discharge of the non-rechargeable lithium battery
and the loss of memory contents.
-
When installing a Logic Memory module or any module, position the component side of
the board to your right (towards the CPU power supply) as shown in figure 3.8.
NOTE
Proper orientation of printed circuit boards is with component side towards the
power supply.
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3-33
lnstal lation Instructions
GEK-96602
Install the faceplate by placing the faceplate in the proper position and while pushing
in, turn the quarter-turn thumbscrew clockwise until it feels secure.
2. Remove any l/O modules from the backplane of the CPU. Disconnect any expansion
racks from the CPU rack and plug the I/O Terminator Plug supplied with the CPU
rack into either port of the I/O Control module,
3. Turn the RUN/STOP keyswitch to the STOP position and the MEMORY PROTECT
keyswitch to the WRITE position.
4. Apply power to the CPU rack and turn on the power switch.
5. The CHECK light on the Arithmetic Control module should be on at this time before
proceeding to the next step. If it is not on, power-down, reseat the CPU boards and
power-up again.
NOTE
If at any time when the CPU is switched to the RUN mode, it drops out of RUN
on a memory parity error, most likely the communication ports are locked out.
To reset the ports, turn the RUN/STOP keyswitch to STOP, power-down the
CPU and power-up again.
If you are using a Workmaster computer with the parallel version of Logicmaster 6
software, proceed with the following steps:
1. Boot up the Workmaster computer. Display the SUPERVISOR MENU.
2. Turn the keyswitch to OFFLINE, and connect the cable from the Workmaster
computer to the CPU.
3. Select the US/V function with the F6 key and clear the Logicmaster memory
while in that function by selecting the F5 (CLEAR) key.
4. Return to the SUPERVISOR MENU and go to the Scratch Pad by selecting the
F4 key. Set the Scratch Pad values for Logic Memory and Register memory size
to match the memory actually installed in the CPU.
5. Again go to the L/S/V function and store the blank program (nothing in memory)
to the CPU by selecting the F2 key and following the instructions on the screen.
6.
Return to the Supervisor menu and select the UTILITY FUNCTION Menu by
selecting the F8 key. From this menu, select the CLEAR PARITY function with
the F7 key and follow the screen instructions.
7. Turn the CPU RUN/STOP keyswitch to RUN. The CPU should be cleared of any
memory parity errors at this time.
If you are using a programming devicee other than the Workmaster industrial
computer,
start-up procedures are similar.
Refer to the Logicmaster 6
Programming and Software User’s manual for detailed instructions for start-up with
those devices.
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Installation Instructions
3-34
GEK-96602
RUNNING EXPANDED I/O ON THE SERIES SIX PLUS PLC
As Internal Coils Only
Simply type "1” or “0” then CNTL-channel number, followed by the /lO point number.
The I/O is mapped into its corresponding register tables. No [SERIES SIX CONFIGURATION
DATA] command is needed. Channels do not have to be enabled in the CPU Config Menu.
To Be Solved To Real World I/O Points
Program the [SERIES SIX CONFIGURATION DATA] command in rung 1 and then set the
number of channels to be scanned in the CPU CONFlG MENU, then transfer to the CPU.
How It Works
When running expanded I/O channels, the CPU generates a code for a particular channel
number then does a full I/O scan as it normally does. The channels are scanned in order
from the lowest to the highest enabled channel. Each one takes 6-7 ms. Auxiliary
channels are automatically scanned with their corresponding main channel. For example,
enabling channels 0-3 also enables channel 8-B.
An l/O Transmitter (lC600YB900C or later) capable of decoding I/O channels must be
used to separate the real I/O channels. One and only one transmitter should be set to
decode each channel. These transmitters have a jumper to allow them to run in expanded
or normal mode. In expanded mode, they turn on only when their channel is called for.
The channel number is set by the first three dip switches on the rack backplane. In this
way, the I/O data for each channel stays separated. No l/O cards, Remote I/O Drivers, or
phase A Bus Controller may be installed in any I/O slot that is not downstream of a
decoding transmitter. Any such device would receive data from all enabled channels.
Outputs would respond to all enabled channels, and inputs would report back to all
channels that scanned that address.
Phase B Genius Bus Controllers also have the capability of decoding I/O channels and
could be placed in a non-decoded slot. Once downstream of a transmitter with a channel
selected, all normal rules apply for cable length, number of racks, chain termination,
etc. Any other Y8900C transmitters downstream should be set to normal I/O mode.
Also, no other transmitters could decode any other channel. For example, a transmitter
in channel 0 could not be set for channel 1. The data for channel 1 is not present in
channel 0.
Examples of correct and incorrect configurations for expanded l/O are shown in the
following examples.
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Installation
Instructions
3-35
GEK-96602
a42208
#’
* = l/O
XMIT
SERIES SIX PLUS CPU
SETTO
EXPANDED
hh3DE CHO
SET TO
EXPANDED
MOOE CHl
I CHO
SET TO
l/O MODE
I
C’ll
I/O
Figure 3.23 EXAMPLE 1 - CORRECT
L
I “‘l”““‘i’ ’
L
Y
J
CHl
I/O
CONFIGURATION
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Installation instructions
3-36
GEK-96602
SERIES SIX PLUS CPU
N O I/0
CARDS
=
IN
THESE
SLOTS
a42209
* = I/O XMIT
I CHO
+CHl
1
CH2
I/O
YBQOOC
I/O
TRANSMI-I-I
- SETTO
CH2
I/O
Y
J
CHO
I/O
YBQOOA
l/O
TRANSMITTER
Figure 3.24 EXAMPLE 2 - CORRECT CONFIGURATION
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Installation
3-37
Instructions
GEK-96602
a42210
SERIES SIX PLUS CPU
* EXPANDED CHO
2 EXPANDED CH1
, CHO
I/O
CHO
I/O
J
--
CL
I/O
THESE RACKS WOULD
NEVER SEE CHI DATA
Figure 3.25 EXAMPLE 3 - INCORRECT CONFIGURATION
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3-38
Installation Instructions
GEK-96602
a4221 1
* = EXPANDED MODE CH1
SERIES SIX PLUS CPU
t/O IN THESE RACKS RECEIVE
DATA FROM ALL ENABLED
CHO
CHANNELS. OUTPUTS APPEAR
ERRATIC, INPUTS APPEAR IN ALL I/O ’
CHANNELS. EACH CHANNEL MUST
HAVE ITS OWN TRANSMITTER.
Figure 3.26 EXAMPLE 4 - INCORRECT CONFIGURATION
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Installation
Instructions
3-39
GEK-96602
System Design Considerations
When programming expanded I/O, use regular l/O references for the primary I/O. Do not
use a channel 0 reference in the program. This actually maps into the auxiliary table and
should be avoided. Channel 8 maps into user registers starting at 1025. This will never
be solved to real I/O, but could be used as internal points.
The WINDOW command allows you to specify a channel number from 0 - F. The
communications window that is opened as a result of executing this command is directed
to only one of the Expanded I/O channels on one or the other of the I/O chains (Main or
Auxiliary). In other words, a WINDOW command to channel BH (Hexadecimal) does not
affect any window devices downstream from Expanded Parallel I/O Transmitters which
are set for channels 0 - 7 in the Main chain or channels 0 - 2 and 4 - 7 in the Auxiliary
chain. Window devices include the ASCII/BASIC Module, I/O CCM, LMM, and Series Six
I/O link local module. The Genius bus controller is also a window device if window
commands are issued to it. If no window commands are used, bus controllers may be used
in the same address in main and auxiliary channels without conflict.
The ASClI/BASIC Module and its derivatives (LMM, I/O CCM, etc.) always report their
status bytes back to the main input table, regardless of what channel they are in. An
ASCII/BASIC Module at address 257 in channel E will report its 8 bits of status to main
channel address 1257. Care should be taken not to address any inputs in the main channel
to the same address as any of these devices in the system.
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Expanded CPU Operation
4-1
GEK-96602
CHAPTER 4
EXPANDED CPU OPERATION
INTRODUCTION
The Series Six* Plus Programmable Logic Controller operates in one of two user
selectable modes, either Normal or Expanded. Selection of the desired mode is made on
the Configuration Menu screen on a Workmaster* computer using Logicmaster* 6
software. This chapter describes the Expanded functions as they are used with the Series
Six Plus PLC. For detailed information on programming the Expanded functions, refer to
the Logicmaster 6 Programming and Documentation Software User’s Manual, GEK-25379.
All existing features, functions, l/O modules, programming devices and peripheral devices
currently available for the Series Six PLCs can be fully used by the Series Six Plus PLC.
NORMAL MODE OF OPERATION
In the Normal mode of operation, the Series Six Plus CPU scans the Main I/O chain and
the Auxiliary I/O chain in the same manner as in Series Six PLCs. In the Normal mode,
the maximum number of I/O points available is 4000; 1 0 0 0 Inputs and 1000 Outputs in the
Main I/O chain and 1000 Inputs and 1000 Outputs in the optional Auxiliary I/O chain.
Additionally, direct addressing of all 16K words of Register memory with all Advanced
functions is supported.
EXPANDED
FUNCTIONS
With the Expanded functions option, the Series Six Plus PLC has access to and can
perform many additional functions when compared to the Series Six PLCs. These
functions are:
1.
Expanded I/O. Up to 16 channels (8 on Main I/O chain, 8 on Auxiliary I/O chain) of
I/O can be configured within a range of stop and start addresses configured by the
user with a Workmaster computer using Logicmaster 6 software. Each channel has
1 0 0 Inputs and 1000 Outputs. The I/O scanning is done exactly as in the Series Six
PLC with the Auxiliary I/O chain scanned in parallel with the Main I/O chain. I/O
scanning takes 7 ms for each pair (0 and 8, 1 and 9, etc.) of channels that have been
enabled through the Configuration Menu. In the Expanded I/O mode, only the
Expanded I/O channels that have been enabled will be scanned.
2.
In addition to the existing 4K of discrete references supported by the Series Six PLC
(I, 0, Al, AO), an additional 62K of discrete expanded I/O references are supported
(30K real I/O, 32K internal I/O).
3.
Configurable features. Through Logicmaster 6 software, release 3.01 and later, the
user can enable configurable features, including the Expanded I/O, Genius I/O/O
diagnostics, expanded time reference and the computer mail box.
4. Seven function floating point arithmetic which includes floating point addition,
floating point subtraction, floating point multiplication, floating point division,
floating point compare, integer to floating point conversion and floating point to
integer conversion.
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Expanded CPU Operation
4-2
GEK-96602
5.
Genius l/O diagnostics. Through user configuration, the CPU maintains a fault
status image of the Genius I/O system. Faults are reported and logged in the CPU,
then interpreted by Logicmaster 6 software.
6.
A computer mail box is provided for communications with Genius I/O Bus Controllers
and intelligent modules.
7.
Window function. An enhanced DPREQ function allows the user specification of
channel, address and COMM block.
8.
The DO I/O function has been expanded to include the channel number for the start
and end addresses.
9.
Time Reference. This is a real-time clock maintained by the CPU which uses three
consecutive registers to keep track of days, hours, minutes, seconds and tenth of
seconds. It is used by the CPU to keep track of fault occurrences.
In addition, when the Expanded II functions option is selected, a faster scan rate is
provided, instructions are available for accessing an alternate I/O system to be available
in the future, a dynamic user program memory checksum provides more data integrity by
detecting certain types of errors not caught by memory parity checking, and a way to
detect if there are any overrides active in the system is provided.
SERIES SIX PLC I/O DIAGNOSTICS FOR SERIES SIX PLUS PLCs
All of the I/O diagnostic features used with earlier models of Series Six PlCs are valid
for use with Series Six Plus PLCs. The address recorded for parity errors includes a
channel number for Expanded l/O systems. The channel number is stored in the Scratch
Pad in location SP(10). If a parity error is detected while the Expanded I/O mode is not
selected or while channel 0 or 8 are being scanned, the value in SP(10) will be set to 80H
(Hexadeci mal).
I/O Transmitter Diagnostic Feature
Data received at the CPU from each I/O Transmitter is placed in the input status table
for input bits I1017 through 11024 for channel 0, AI1017 through Al1024 for channel 8 and
IX+1017 through IX+1024 for channels 1-7 and 9-F. The data in this status byte is: bits
1-3, channel number; bit 4, card present; bits 5 and 6, set to 0; bit 7, fault trap enable;
bit 8, fault present. If the I/O Transmitter does not respond when addressed, nothing will
be written to the input locations for that channel. The channel w i IlI be scanned regardless
of whether the module responded or not. Through user logic, this byte can be cleared
each sweep to determine if the I/O Transmitter responded when addressed.
INTERRUPT MODULE LOCATION
A maximum of two Interrupt Input modules can be used (1 in the Main I/O chain and 1 in
the Auxiliary I/O chain) in an Expanded l/O system. The Interrupt Input module for each
chain can be placed in any channel in each of the chains. The l/O Transmitter modules
pass the interrupt signal through to the CPU at all times. The interrupt input data is
placed in the Main Input status table in bits I1001 through I1008 for the Main I/O chain
and AI1001 through AI-1008 for the Auxiliary chain.
I/O
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4-3
Expanded CPU Operation
GEK-96602
NORMAL MODE I/O ADDRESSING
The Series Six Plus PLC allows l/O to be configured in either the Normal mode or the
Expanded I/O mode. Selection of the l/O mode is made through the Configuration Menu
using Logicmaster 6 software. In the Normal mode, one l/O chain per CPU is permitted
(this is the factory default setting). In this mode, available I/O is 1000 Inputs/1000
Outputs in the Main I/O chain, plus an additional 1000 Inputs/1000 Outputs in the
Auxiliary I/O chain, if an Auxiliary I/O module is included in the system. It should be
noted that each chain actually has 1024 inputs and Outputs, however, only the first 1000
are available for I/O. References 1001 through 1024 are reserved for special use.
The ON or OFF state of the 1K Inputs and 1K Outputs in the main I/O chain are
maintained in the I/O Status Table. The ON or OFF states of I/O points in the Auxiliary
I/O chain are maintained in the Auxiliary I/O Status Table which is mapped into the first
128 words of Register memory. R0001 to R0064 contains the Auxiliary Output Table, and
R0065 to R0128 contains the Auxiliary Input table.
EXPANDED MODE l/O ADDRESSING
When the Expanded I/O mode is selected through the Configuration Menu (a jumper must
also be configured on each l/O Transmitter that is to drive a chain), a total of 8K Inputs
and 8K Outputs in the Main I/O chain are available to the user. In addition, if the
Auxiliary I/O chain is selected (requires an Auxiliary I/O module) 8K Inputs and 8K
Outputs are available in the Auxiliary chain. The total real I/O available through the use
of both chains is therefore 16K Inputs and 16K outputs (32K total points). The l/O
references O0001 - O1024, I0001 - I1024 are used as real I/O references for channel 0 and
AO0001 - AO1024 and Al0001 - Al1024 are used as real I/O references for channel 8.
These references, in addition to channel 1 through 7 and 9 through F references for real
world l/O and 32K of internal references available in the Expanded mode provide an
additional 64K of discrete references in a Series Six Plus PLC.
I/O Channels
I/O points in the Expanded mode are selected in 1 K increments, referred to as channels.
An I/O Transmitter module (configured for Expanded Mode) is required to originate each
channel of I/O, with the exception that if channels 0 and 8 are the only Expanded mode
channels selected, an l/O Transmitter is not needed for channel origination, since the l/O
is scanned in the same manner as the Main and Auxiliary f/O chains when in the Normal
mode. If more than two channels are to be used, I/O Transmitters are required. The CPU
scans only those channels that have been selected. Any downstream l/O Transmitters in a
chain must be configured for the Normal Mode.
Expanded Modes of operation.
This is true for both the Normal and
A maximum of eight l/O Transmitters are required for channel origination in each of the
two chains. If the maximum of 16 I/O Transmitters is used (8 in each chain), 16K Inputs
and 16K Outputs are available to the user. The channel number to be associated with
each I/O Transmitter is selected by setting the first 3 switches (switches 1, 2, 3) on the
DIP switch package on the backplane adjacent to the module as shown in figure 4.1. The
total number of l/O Transmitters is determined by the number required for channel
origination plus any downstream l/O Transmitters used in each channel, as determined by
the system configuration.
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Expanded CPU Operation
4-4
GEK-96602
CHANNEL NUMBER
1 DIP SWITCH
A dot indicates that a switch is in the OPEN position (depressed to the left). All other
switch segments should be in the CLOSED position (depressed to the right).
Figure 4.1 l/O TRANSMITTER DIP SWITCH SETTINGS
FOR EXPANDED t/O CHANNEL SELECTION
Channel Reference
Numbering
The individual channels are numbered from 0 to F; the Main I/O chain channels are 0
through 7 and the Auxiliary I/O chain channels are 8 through F.
The format for addressing I/O in the Expanded mode must include either the prefix I or O,
a channel number (except for channel 0 and 8; for channel 0 programming references use
OXXXX and IXXXX, for channel 8 programming references use AOXXXX and AIXXXX),
a real I/O (+) or internal I/O (-) reference identifier and the l/O reference number. This
format is shown in figure 4.2.
I
C
+
0025
I
I-
I = Input
0 = Output
Channel Number (0 - F)-
I/O Reference Number
+= I/O Reference State (Real I/O)
-r I/O Reference Status (Internal I/O)
Figure 4.2 EXPANDED I/O REFERENCE FORMAT
Thus, for example, the format for real world I/O points for channel 3 in the Main I/O
chain is I3+0001 to I3+1024 for Inputs and O3+0001 to O3+1024 for Outputs. Each 1K
channel requires 64 words of memory (64 words x 16 bits = 1024 I/O). Note that although
1024 bits are available in each channel, 0001 to 1000 are used for actual I/O points. 1001
to IO24 are reserved for special use.
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4-5
Expanded CPU Operation
GEK-96602
NOTE
Ensure that when referencing an I/O point in a program, a prefix is added to
properly address the applicable I/O chain. Normal mode references address the
Main and Auxiliary l/O chains, for example I0234, O0346, AI0222, AO0456,
etc. Expanded mode references for channels 1 through 7 and 9 through F
include the channel number, for example, I3+0101, O3+0101, lB+0234, OB+0567,
etc. The individual module DIP switch settings for I/O points 1 to 1000 are the
same for each chain or channel, only the prefix is different.
Real I/O Mapping
In the Expanded mode, the "real world” I/O points for Channel 0 are scanned on the Main
I/O chain and their status is maintained in the Main I/O status table. Channel 8, which is
the first Auxiliary l/O channel in Expanded mode, is scanned on the Auxiliary I/O chain
with its I/O status maintained in Registers R0001 through R0128, which is the same as
the Auxiliary I/O status table for the Normal mode Auxiliary I/O chain. Channels 1
through 7 of real I/O are mapped into Registers R0129 through R1024 and the Auxiliary
channel real I/O, Channels 9 through F are mapped into Registers R1153 through R2048.
Internal Mapping of Discrete References
The internal discrete references for Channels 0 through 7, which can be used for program
references to control real inputs or outputs or Genius fault status, are mapped-into
Registers R2049 through R3072. The internal references for Auxiliary channels 8 through
F are mapped into Registers R3073 through R4096. The Register Memory, located on the
Combined Memory module is a 16-bit user accessible storage area of memory used for
data storage and for data (bit) manipulation by many mnemonic functions. Many of these
registers have special significance to system operation.
Register Memory Size
The maximum register storage available in a system is determined by the Combined
Memory module selected. The user must also verify the maximum registers in a system
by making a selection on the Configuration Menu with Logicmaster 6 software. The
selections available are 256, 1 K, 8K and 16K registers. Note that if the smaller register
sizes are selected, the register use should be such that if a larger register size is later
used, the registers used are compatible. Figures 4.3, and 4.4 illustrate register memory
use for each of the register sizes.
NOTE
The 256 word register memory option is not currently compatible with Genius
I/O diagnostics and should not be selected for that use.
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Expanded CPU Operation
4-6
CEK-96602
REGISTER RANGE
16K
8K
ROOOl
REGISTER
CONTENTS
ROOOl
1K OUTPUTS (A00001 - A01024) (1, 3)
1K INPUTS (AI0001 - AI1024)
R0128
ROl28
R0129
R0129
RI024
Rl025
R1024
R1025
R1152
R1153
R1152
Rll53
R2048
R2049
R2048
R2049
R4096
R4097
R4096
R4097
R4112
R4113
R4112
R4113
R4116
R4117
R4116
R4117
R4119
R4119
R4120
R4120
R4121
R4121
RXXXX
RXXXX
RXXXX
RXXXX
R8222
R8123
R16314
R16315
R8192
R16384
7K OUTPUTS (Ol+OOOl to 07+1024)
7K INPUTS (Il+OOOl to I7+1024)
USER
(3)
REGISTERS
7K OUTPUTS (09+0001 - OF+1024) (3)
7K INPUTS (I9+0001 - IF+1024)
STATUS BITS FOR 32K I/O (or internal
References), (00-0001 to IF-10241
BUS CONTROLLER STATUS - BIT MAP
USER REGISTERS
CLOCK
POINTER FOR FAULT TABLE
FAULT
TABLE
ENTRIES
USER REGISTERS (4)
COMPUTER MAIL BOX
(1) Channel 8 real I/O is mapped into Registers 1 through 128 (references AO0001
- AO1024
and
AI0001 - AIl024).
(2) Channel 0 real I/O is scanned on Main I/O chain (references O0001 - O1024 and I0001 - I1024).
(3) Expanded discrete references AO0001 through AO1024, AI0001 through AI1024 and Ol+OOOl
through OF+1024,
(4)
and
Il+OOOl
through
IF+1024
are
overlaid
on
the
Register
table.
These
registers are available for general use if the above references are not used.
The number of registers available for general use depends on the quantity of Genius I/O
fault
tables
selected.
Figure 4.3 MEMORY MAP FOR 8K AND 16K REGISTERS
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4-7
Expanded CPU Operation
GEK-96602
1K REGISTER
RANGE
REGISTER
CONTENTS
ROOO 1
1K OUTPUTS (AO0001 - AO1024) (1)
1K INPUTS (AI0001 - AI1024)
R0128
R0129
1K OUTPUTS (Ol+OOOl - 01+1024) (1)
1K INPUTS (Il+OOOl - Il+lO24)
R0256
BUS CONTROLLER STATUS - BIT MAP
R0257
R0258
USER
R0266
R0267
CLOCK
R0269
POINTER FOR FAULT TABLE
R0270
R0271
FAULT TABLE ENTRIES
RXXXX
RXXXX
USER REGISTERS (3)
R0954
R0955
COMPUTER MAIL BOX
R1024
(1)
REGISTERS
Expanded discrete
references
through
01+1024,
Il+OOOl
registers
are
available
for
AO0001
through
general
through
11+1024
use
if
the
(2)
Channel 0 I/O is scanned on the Main I/O chain.
(31
The number of registers available for general
fault
tables
AO1024,
are
AI0001
overlaid
above
on
references
through
the
are
AI1024
Register
not
and
table.
Ol+OOOl
These
used.
use depends on the quantity of Genius I/O
selected.
F i g u r e 4 . 4 M E M O R Y M A P F O R 1K R E G I S T E R S
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Expanded CPU Operation
4-11
GEK-96602
DYNAMIC USER MEMORY CHECKSUM
The Expanded II function set is provided through selection of the Logic Control module
option, IC600CB515. An important feature of this function set is the user program
memory checksum. The purpose of this checksum is to provide more data integrity within
the user program memory. This user program checksum will trap certain types of data
errors not caught by memory parity checking. Specifically, the error conditions to be
caught through this checksum are; an even number of bits changed in memory and stuck
address Ilines.
Memory Checksum Calculation
During normal operation, the CPU can detect when the logic memory has been altered by
an external device (such as Logicmaster 6, etc.). When it has sensed that the memory has
been changed, the CPU will begin to calculate a checksum by starting at memory location
00000 and working its way through all logic memory. The checksum is the 16 bit sum of
all the words of logic memory in the CPU.
Each time that the internal executive routine is run in the CPU, 64 words of memory are
summed. Since there can be a maximum of 64K words of logic memory, it is not possible
to complete the entire checksum in one scan. Therefore, the checksum will take a
maximum of 1024 scans to be calculated. When the CPU completes the calculation it
stores the checksum in the Scratch Pad. It will then recalculate the checksum, and when
once again completed, the resulting calculation is compared with the previously stored
checksum. If this calculated number disagrees with the number stored in the Scratch
Pad, the CPU will STOP (if it is running) and de-energize Alarm 1. It will also set error
flags in the Scratch Pad.
The checksum calculation continues while the CPU is in the STOP mode. The calculation
adds about 150 us to the CPU’s executive routine. The total time for the checksum
calculation for the maximum 64K words of memory with a 150 ms sweep is 153 seconds.
Logicmaster 6 Display of Checksum Error
The checksum is displayed on the Scratch Pad screen display if Logicmaster 6 is in the
on-line or monitor mode. It is not displayed when Logicmaster 6 is in the off-line mode.
If a checksum error is detected, the message LOGIC MEMORY CHECKSUM ERROR is displayed
below the CPU ERROR FLAGS line at the bottom of the Scratch Pad display.
Restarting a CPU Stopped by a Checksum Error
The CPU also recalculates the checksum when the CPU is powered-up or switched from
STOP to RUN if the memory protect switch is set to the WRITE position. If the key
switch is set to the PROTECT position, the checksum error fault indication will remain in
the Scratch Pad and the CPU will not be able to be restarted unless either the keyswitch
is switched to WRITE or the fault indication in Scratch Pad locations SP (07) and (09) are
cleared by an external device.
A recalculation of
board is replaced
PROTECT which
occurred while the
the checksum when the CPU is restarted is desired if a Logic Memory
and the CPU is then restarted. Normally, the CPU should be left in
allows the checksum feature to catch any memory changes that
CPU was powered down.
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4-12
Expanded CPU Operation
GEK-96602
CONFIGURATION OF EXPANDED FUNCTIONS THROUGH
LOGICMASTER 6 SOFTWARE
In order to configure the Expanded Functions, a Workmaster computer, CIMSTAR I
computer, or an IBM-PC, PC-XT, or PC-AT Personal Computer with Logicmaster 6
applications software, version 3.01 or greater is required for programming. This is
required to enable configurable features, which include expanded I/O, Genius
diagnostics, expand ed time reference and the computer mail box. Each of these
configurable features can be selectively enabled and configured for its range of
operation. The required configuration is automatically entered into the first 24 words of
the CPU user memory as it is selected and entered from a configuration menu. The first
word of memory (location 0000) must be programmed by the user with the [SERIES SIX
CONFIGURATION DATA] instruction.
Standard features included with the expanded functions that do not require configuration
include expanded discrete and register references, the Window function and floating point
arithmetic. An improved basic compare instruction has been added which allows any
reference A to be compared to any reference B. The previous form of this instruction
only allowed registers to be compared.
EXPANDED FUNCTIONS MENU
In order to access the configuration menu, the Expanded Functions screen must first be
selected from the Supervisor menu. When the Expanded Functions (F7) key is pressed
from the Supervisor menu, the Expanded Functions screen appears as shown below.
L O G I C M A S T E R ( T M ) 6
E X P A N D E D F U N C T I O N S
~
KEY #
Fl F’; :; -
FUNCTION
C P U CONFIG . . .
I/O Faults . . .
COMM S ET UP. .
MSD FUNC . . . .
SUPERV MENU . .
CPU
1CONFIG
2FAULTS
. . . . Display/Modify CPU Configuration
. . . . .Display/Clear Genius I/O Faults
. . .D i s p l a y / M o d i f y C o m m u n i c a t i o n s S e t u p ( s e r i a l
. . . .Display/Modify Machine Setup Data
. . . . . . . .r e t u r n t o S u p e r v i s o r M e n u
MSD
3SET UP 4FUNC
5
6
7
ver.)
SUPERV
8 MENU
The applicable function key is then pressed to select the desired Expanded functions.
CPU CONFlGURATON
Select DISPLAY/MODIFY CPU CONFlGURATlON
the CPU Configuration menu.
to display
l/O FAULTS
Select DISPLAY/CLEAR Genius I/O FAULTS to display the
Genius l/O Faults screen.
COMMUNICATlONS SET UP
This function key is displayed only for the Serial versions. Select COMM SET UP to set
up the system parameters for communicating with the CCM card.
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Expanded CPU Operation
4-14
GEK-96602
Making Entries on the CPU Configuration Set Up Page
The CPU Configuration Set Up Menu is used to enable Expanded I/O scan, Genius l/O
diagnostics, and the Computer Mail Box. Entries made on this page change the program
file in system memory. They do not change the user program in the CPU.
If the system is in On-Line or Monitor mode, changes are made to the program logic
only. If the system is in Off-Line mode, changes are made to the logic and the table data.
To edit this display, move the cursor to the item you want to change, and type in the new
value. Refer to the definitions that follow for more information.
Cancelling Entries to the CPU Confiquration Set Up Menu
To cancel entries and return to the Expanded Functions menu, press the Abort key. The
screen displays:
PRESS CONFIRM TO ABORT, ANY OTHER KEY TO PROCEED
Press the Confirm key to return to the values that were displayed when the page was
entered. Press any other key to cancel the abort.
CPU CONFIGURATION MENU: DEFINITIONS
Refer to the following definitions when changing the CPU Configuration Set Up Menu.
The entries on this page are stored in the Configuration function in the program.
EXPANDED I/O SCAN
ENABLED: Y, Default = Y, for Expanded l/O scanning by the
CPU. For normal I/O scanning, enter N. Note that Expanded
I/O is not required for Genius I/O diagnostics on Bus
Controllers located in the Main and Auxiliary status tables.
Expanded I/O must be enabled to use the diagnostics on Bus
Controllers located on channels 1-7 and 9-F.
BEGIN RANGE: If Expanded I/O scanning is enabled, this
entry specifies the channel and Point number within the
channel where the Expanded I/O scan should begin. The
default range is all channels and points. Change these entries
to select a smaller scan range.
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4-15
Expanded CPU Operation
GEK-96602
CPU CONFIGURATION MENU: DEFINITIONS (Continued)
The I/O structure in an expanded l/O system consists of as
many as 8 main channels (numbered 0 - 7) and 8 auxiliary
channels (8 - F). Valid entries for Begin Range and End Range
Channel are 0 to 7. Each of these specifies a main/auxiliary
channel I/O pair:
CHAINS:
MAIN AUXILIARY
CHANNELS
0
8
1
9
2
A
3
B
4
C
5
D
6
E
7
F
The value for Point is the I/O point from 1 to 1024 in the
speci fied channel. The system rounds this value to a byte
boundary.
END RANGE: The channel number and Point number within
the channel where the Expanded I/O scan should end. This
must be greater than the value for Begin Range.
GENIUS I/O:
DIAGNOSTICS ENABLED:
Default = Y, to enable the
minimum Genius I/O diagnostics (for everything except the
diagnostic tables). For no Genius I/O diagnostics, enter N.
DIAGNOSTIC TABLES:
Default = Y, to cause a Bus
Controller Status Bit Map to contain the locations of Bus
Controllers that have reported errors. In addition, a Point
Status Bit Map will specify any real l/O points that indicate
failures by a block, point, or Bus Controller fault. For no
Genius I/O diagnostics tables, enter N.
B/C -> POINT FAULTS: Default = N, to cause Bus Controller
errors to tell the CPU to set all 208 input and 208 output
point fault bits associated with that Bus Controller to a 1.
The user must exercise caution when referencing any of these
points, since all will be set to a 1 following a Bus Controller
f ailure.
If all blocks are assigned to addresses within the same 256
register segment as the Bus Controller, then a fault of the Bus
Controller equals a fault of all I/O. If all addresses are not
assigned as above, this feature should not be used.
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Expanded CPU Operation
4-16
GEK-96602
CPU CONFIGURATION MENU: DEFlNITIONS (Continued)
GENIUS I/O: (cont)
DIAGNOSTIC RANGE LIMIT: The range, by channel pairs, of
the diagnostics. Range = 0 to 7. Default = 7, which is 8 pairs
of channels to be checked.
CPU REGISTER SIZE: Enter the exact register size of the
CPU:
with
256 (Currently not compatible
diagnostics)
1024
(can be represented by entering a 1)
8192
(can be represented by entering an 8)
16384
(can be represented by entering a 16)
Genius
Default = the number of registers indicated by the Scratch
Pad.
The availability of register memory regulates the number of
I/O points on which Genius I/O diagnostics will be performed.
For a register size of 1K diagnostics are performed up to the
first 1024 inputs and 1024 outputs of the Main I/O chain.
Maximum register sizes of 8K or 16K allow the CPU to
perform diagnostics on the maximum 16K inputs and 16K
outputs.
The inputs and outputs included are the Main l/O chain (Main
I/O status table, I/O channels 1+ to 7+) and the Auxiliary I/O
chain (Auxiliary I/O status table, I/O channels 9+ to F+).
FAULT TABLE LENGTH: The maximum size of the fault
tabte, which depends on the CPU size, and on whether the
Computer Mail Box has been enabled. Maximum table sizes
are listed below. Default = 8.
REGISTER
SIZE
1K
8K
16K
MAXIMUM TABLE LENGTH *
COMPUTER MAIL BOX ENABLED?
NO
YES
75
406
1225
68
399
1218
* Each table entry is equal to IO registers.
BUS STATUS/CONTROL BYTE LOCATION: Some of the bits
in the original I/O status table can be used to enable and
monitor some of the Genius I/O functions. This is the main
I/O point address where the diagnostics’ discrete status (input
table) and control (output table) bytes are located. Allowable
entries are 0001 through 1017. Default = 0993.
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4-19
Expanded CPU Operation
GEK-96602
GENIUS I/O Fault Table Definitions
If a fault occurs that has more than one cause (see the definition of Fault Category,
below) each cause is listed as a separate line in the table. The entries in the table show
the following information about a fault:
BUS CONTROLLER ADDRESS: Displayed for a Bus Controller
error. This entry has two fields:
B/C
ADDR.
‘t
I
Channel Number: The number of the channel where
the error occurred. A hex value from 0 to F:
MAIN AUXILIARY
0
8
1
9
A
B
C
D
E
F
2
3
4
5
6
7
Byte Address: The byte address of the error. Range = 0
to 125.
POINT ADDRESS: Not displayed if the error is a Bus
Controller or Serial Bus fault. This entry has two
fields:
POINT
ADDR.
-w---c
Input/Output: The first two characters indicate
an input (I) or output (0). Both may appear
at the same time.
I
Address: The address of the error. Range = 1 to 1000.
CIRCUIT NUMBER:
Displayed only for a circuit fault. Range = 1 to 16.
The number displayed corresponds to a circuit number within
a block.
FAULT CATEGORY:
This entry shows the category of error that has occurred:
IOC FAULT
BUS ERROR
CIRCUIT FAULT
LOSS OF BLOCK
BLOCK ADDITION
ADDRESS CONFLICT
EEPROM FAILURE
????????????????
(displayed for
multiple
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errors)
Expanded CPU Operation
4-20
GEK-96602
FAULT TYPE:
The error type: BLOCK, DISCRETE, or ANALOG.
FAULT DESCRIPTION:
Displayed only if the Fault Category is CIRCUIT FAULT.
Multiple lines may be displayed. Possible descriptions are:
BLOCK
SWITCH FAILED
DISCRETE SWITCH FAILED
OVER TEMP
NO LOAD
OPEN WIRE
OVERLOAD
SHORT CIRCUIT
LOSS OF POWER
ANALOG
FAULT TIME:
INPUT HIGH ALARM
INPUT LOW ALARM
OUTPUT UNDERRANGE
OUTPUT OVERRANGE
INPUT OPEN WIRE
INPUT UNDE RRANGE
INPUT OVER RANGE
CHANNEL NUMBER
The day, hour, minute, second, and tenth of a second when the
error occurred, derived from the CPU’s real-time clock.
Viewing Additional Fault Listings
In order to display or print additional faults in the table, follow the steps below.
To move the display down one line at a time, press the Next key or the Down Cursor key.
To move the display up one line at a time, press the Prev key or the Up Cursor key.
To move the display down one page at a time, press SHIFT/NEXT or Next Page (F1).
To move the display up one page at a time, press SHlFT/PREV or Prev Page (F2).
To go to the top of the table, press the Top (F4) function key. To go to the end of the
table, press the Bottom (F5) function key.
Clearing
Faults
Use the Clear Faults (F3) key to clear the Fault Table. This sets the fault count to zero,
and clears the fault data at the Genius l/O blocks. Subsequent incoming faults fill the
Fault Table beginning with the next available location, with the oldest data at the top.
This will cause the Bus Controller to issue a CLEAR ALL FAULT command (see the
Genius I/O System User’s Manual for further information).
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4-21
Expanded CPU Operation
GEK-96602
FLOATING POINT FUNCTIONS
Seven function floating point arithmetic has been implemented as a feature of the
Expanded Functions. The available floating point functions are:
-
Floating
Floating
Floating
Floating
Point Addition
Point Subtraction
Point Multiplication
Point Division
- Floating Point Compare
- Integer to Floating Point Conversion
- Floating Point to integer Conversion
Floating Point Display Format
Two registers are required to represent each Floating Point reference which is stored in
IEEE format. The display for the Floating Point Arithmetic Functions is in decimal
scientific notation as shown in figure 4.5.
1 .234567+12
I
Two digits
of exponent
Sign of exponent
Six least significant digits
Decimal point
Most significant
digit (1)
Sign of entire number (2)
m
Figure 4.5 FLOATING POINT ARITHMETIC DISPLAY FORMAT
(1) Will only be zero (0) when all digits are zero.
(2) The + (plus) sign is implied and not displayed. The - (minus) sign will always be
displayed.
Floating Point numbers are stored in two consecutive registers as shown below.
8-bit
exponent
I
23 bits of mantissa
f23
Valid Number Format
The display format requires a total of 12 character spaces and is limited to 7 significant
digits. With 7 digits, any valid number can be stored in the 32 bits (2 registers) allocated
for floating point numbers. A number greater than 7 digits does not conform to the IEEE
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Expanded CPU Operation
4-22
GEK-96602
32-bit format and is considered to be not a number. The references to infinity refer to
the limits for numbers that may be operated on. These limits are +/-3.402823+38. An
attempt to exceed these limits will be interpreted by Logicmaster 6 software as an
overflow.
Programminq Floating Point Arithmetic Functions
All of the Floating Point functions are entered on the programmer using Logicmaster 6,
version 3.01 or later software. When entering a Floating Point function, conditional logic
to control power flow to the function should be entered before the function. If
conditional logic is not entered, the function will execute unconditionally with every
sweep.
To access Floating Point Arithmetic, with the programmer, select Advanced Mnemonic
Group (F7), then Expanded Arithmetic (F2), then Floating Point Arithmetic (F6). Next
the desired Floating Point Arithmetic function is selected with the applicable soft key.
KEY MNEMONIC
FUNCTION
(Fl)
(F2)
(F3)
(F4)
(F5)
(F6)
(F7)
Floating Point Addition
Floating Point Subtract ion
Floating Point Multiplication
Floating Point Division
Floating Point Compare
Integer to Floating Point Conversion
Floating Point to Integer Conversion
FADD
FSUB
FMULT
FDIV
FP GREATER THAN
INTEGER TO FLOATING POINT
FLOATING POINT TO INTEGER
For detailed information on how to enter the Floating Point functions, refer to the
Logicmaster 6 User’s Manual, GEK-25379.
Floating Point Addition
Program a Floating Point Addition function to add a floating point value in reference A
to the floating point value in reference B and place the result in reference C.
Every scan that power is received, the FADD function calculates the result using floating
point mathematics. The result is placed in reference C. Only the content of reference C
is altered by this function.
The function will output power flow if overflow occurs, if references A and B are
opposite signed infinities, or if either reference A or B is not a number.
Floating Point Subtraction
Program a Floating Point Subtraction function to subtract a floating point value in
reference B from the floating point value in reference A and place the result in reference
C.
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4-23
Expanded CPU Operation
~~
GEK-96602
Every scan that power is received, the FSUB function calculates the result using floating
point mathematics. The result is placed in reference C. Only the content of reference C
is altered by this function.
The function will output power flow if overflow occurs, if references A and B are
infinities having the same sign, or if either reference A or B is not a number.
Floating Point Multiplication
Program a Floating Point Multiplication function to multiply the value in reference A by
the value in reference B and place the result in reference C. Every scan that power flows
to the function, the system multiplies the value in reference A by the value in reference
8 and places the signed result in reference C. The possible sign of the result is shown
below.
Reference A
+
+
Reference B
+
Reference C
+
Floating Point Multiplication will not normally output power flow, except under the
follow ing conditions.
1.
2.
3.
4.
The result is too big to store (overflow).
The result is too small to represent (underflow).
Either reference A or B is infinity and the other is zero.
Either reference A or B is not a number (invalid format).
Floating Point Division
Program a Floating Point Division function to divide the value in reference A by the
value in reference B and place the result in reference C. The possible signs:
Reference A
Reference B
Quotient
+
Floating Point Division will not normally output power flow, except under the following
conditions.
1.
2.
3.
4.
5.
The result is too big to represent (overflow).
The result is too small to represent (underflow).
Reference B is a zero.
Both references A and B are infinities.
One or both of references A or B is not a number (invalid format).
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Expanded CPU Operation
4-24
GEK-96602
Floating Point Greater Than
Program a Floating Point Greater Than function to compare the value in reference A to
the value in reference B.
Every scan that power is received, the Greater Than function compares the content of
reference A to the content of reference B. Comparison is based on the signed, floating
point values of the contents.
Power flows only if the first value is greater than the second. Some example comparisons
are shown below.
Reference B
Reference A
+2.34595+1
Power Flow ?
+2.34595+0
YES
NO
YES
YES
NO
+2.34595+1
+9.99999-l
+1.00000-1
-1 .00000+1
+2.34595-l
+0.00000+0
+0.00000+0
+0.00000+0
Convert Integer To Floating Point
Every scan that power is received, the integer to Floating Point function reads the
integer value of reference A and places the floating point equivalent in reference B.
Power flows only when an error is encountered.
Convert Floating Point To Integer
Every scan that power is received, the Floating Point to Integer function reads the
floating point value of reference A, and places the integer equivalent in reference 8.
Power flows only when an error is encountered.
WINDOW (DPREQ) FUNCTION
The Window Function is a special Data Processor REQuest that supports the 16 channels
of the expanded I/O system. Each scan that power is received, the Window function
opens a window to the expanded I/O channel that is specified by the hexadecimal value
stored in the upper byte of the first reference.
15
FIRST
REFERENCE
8 7
0
‘~y-=q!
Address: 0 to 7c
|-Channel Address: 00 to 0F, or C0
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4-25
Expanded CPU Operation
GEK-96602
The first reference used by the Window function stores:
In the high order byte, the number in hexadecimal, of the I/O channel to be opened.
The number may be either:
00-0F: valid individual channel numbers as determined by the DIP switch
settings on the I/O Transmitter modules in the system.
CO: broadcast channel number.
In the low-order byte, the window address which is the module’s card address as set
by the DIP switches on the rack backplane. It may be any address from 0 to 7C. 7D,
7E and 7F are reserved for the Interrupt Input module, DPU and PDT windows, and
can not be used in this function.
The second reference is the start of the communications block in register memory.
Power flows out of the Window function only if the window address specified in the first
reference is out of range of the configured expanded address, or if the window fails.
Failure may be caused by:
Addressed device not responding (timeout).
Addressed device sends bad header (checksum).
Addressed device fails to close window (timeout).
Entering a Window Function
The Window function can be placed in columns 1 to 9 of a rung.
1.
Enter any logic required to control power flow to the function. If the function is
placed at the left rail, it will execute unconditionally upon every sweep.
2.
Select Advanced Mnemonic Group (F7), then Control Functions (F6), then Window
(F7). The DPREQ Window display appears.
+[
*******
WINDOW ADDRESS
R*****
COMM BLOCK ]+
3.
The cursor is at ADDRESS. Using the decimal keypad, type in number of the
reference. It may be any reference type. After entering the reference, press the
Enter key.
4.
The cursor moves to BLOCK. Enter the register that will store the communications
block or computer mail box address. It must be a valid register. Press the Enter key.
5.
Complete the logic for the rung, then press the Accept key. The Edit key functions
reappear at the bottom of the screen.
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Expanded CPU Operation
4-26
GEK-96602
USING THE DO I/O FUNCTION TO ADDRESS 16K INPUTS AND OUTPUTS
The DO l/O function as programmed with the Advanced Functions required entering a
start and end address for I/O points on the Main or Auxiliary chain to be serviced
immediately.
The DO I/O function for use with the Expanded I/O has been expanded to
address the full 16K inputs and 16K outputs of the expanded I/O references. When
expanded l/O is selected, the bits in the Do I/O function references have the meanings
shown below. These can be placed in the start and end references using an A to B Move
or similar function.
15
14
13 12
11
10
9
8
7
1 1 1 X 1 X 1 X 1 X 1 channel # 1 X 1
6
5
4
3
2
1
0
I/U address
Bit 15 must be set to 1 by the program.
If a constant value is used, bits 14 and 15 must both be set to 1.
Bits 8, 9, and 10 are the channel number, 0 - 7.
Bits 0 through 6 specify the I/O address.
Entering a Do I/O Function
The Do I/O function can be placed in columns 1 to 7 of a rung.
1.
Enter any logic required to control power flow to the function. If the function is
placed at the left rail, it will execute unconditionally upon every sweep.
2.
Select Advanced Mnemonic Group (F7), then Control Functions (F6), then Do I/O
(F4). The Do I/O display appears.
+[ DO I/O START
END ]+
3.
The cursor is at START, Using the decimal keypad, type in the reference that
contains the beginning I/O address. It may be a constant from 1 to 1000, any valid
register, or any I/O reference in the range 1-1024. After entering the reference,
press the Enter key.
4.
The cursor moves to END. Using the same parameters, enter the reference that
contains the final address. Press the Enter key.
5.
Complete the logic for the rung, then press the Accept key. The Edit key functions
reappear at the bottom of the screen.
When the DO I/O function is executed, through user logic, the I/O points specified by
START and END will be serviced immediately. When active, bit 15 (or 14 and 15) must
have been set to a 1 and the starting channel and address must be equal to or less than
the ending channel and address, in order for power flow to be passed through the
function. If either of these conditions are not met, the function will not pass power flow.
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4-27
Expanded CPU Operation
GEK-96602
EXPANDED TIME REFERENCE (REAL-TIME CLOCK)
This is a three-word real-time clock maintained by the CPU in three consecutive
registers. The exact register address is determined by the total register size in the CPU.
The clock is located in the following registers:
MAXIMUM REGISTERS
IN SYSTEM
1K
8K
16K
CLOCK
LOCATION
R0267, R0268, R0269
R4117, R4118, R4119
R4117, R4118, R4119
The function of the clock is to record elapsed time and maintain an accurate record of
the time that Genius I/O faults occur.
Format of the Real-Time Clock
The clock keeps track of time in hundreds of days, days, hours, minutes, seconds and
tenths of seconds. Each fault is time stamped with the clock reference and stored in the
Genius I/O Fault Table if it is enabled. The clock stops when power is removed and must
be reset by the user when power is restored. The clock can be synchronized by the user
through logic programming. The clock is updated once per sweep and has a cumulative
accuracy of 8 seconds per day.
The format for storing the clock data in the three registers is as shown below. Data
entered in each byte of each register is 2 BCD digits.
REGISTER
RXXXX
RXXXX +1
RXXXX +2
MOST SIGNIFICANT BYTE
Seconds (00 - 59)
Hours (00 - 23)
Hundreds of Days (00 - 99)
LEAST SIGNIFICANT BYTE
Tenth of Seconds (00 - 09)
Minutes (00 - 59)
Days (00 - 99)
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Expanded CPU Operation
4-28
CEK-96602
GENIUS I/O DIAGNOSTICS
The Genius I/O diagnostics must be enabled from the Configuration Menu in order to be
fully utilized by the CPU. The diagnostic features which can be enabled are: Diagnostic
Tables, Bus Controller Point Faults, Diagnostic range Limit, Fault Table Length, and Bus
Status/Control Byte Location. Enabling of these features was previously described in the
discussion on the Configuration Menu. The following discussion describes the diagnostics
and the interface between the CPU, Bus Controller and the Genius I/O Blocks.
DIAGNOSTIC FAULT TABLE
The first function is a diagnostic fault table which automatically stores any fault
reported by a Bus Controller, along with the time that the CPU received the fault. Ten
registers are used to store data related to each fault. The fault table can be as long as
desired, limited only by the quantity of registers available in the CPU. The location and
maximum length of the fault tables can be determined by referencing the memory maps
for 1 K, 8K and 16K registers (figures 4.3, 4.4).
REGISTER MEMORY SIZE VS GENIUS I/O DIAGNOSTlCS
The register memory size specified by the entry in the Configuration Menu tells the CPU
the amount of Genius l/O diagnostics to perform. Care should be exercised by the user
when specifying register sizes in order to ensure upward compatibility. For a register
size of 1K, diagnostics will be performed up to the first 1024 inputs and 1024 outputs.
Maximum register sizes of 8K or 16K will allow the CPU to perform diagnostics on the
maximum of 16K inputs and 16K outputs. References other than those specified for
diagnostics are available for general use by the user.
Fault Table Pointer
A counter located at the top of the fault table (first register in the table) is a pointer
that indicates how many faults have been stored in the table. When the table is full, no
additional entries are allowed until the counter is cleared or reduced in content by the
user’s program, thus indicating that space is available for new entries. The actual
content of the table is not cleared to zero. The pointer returns to the first register and
the next data is loaded into the pointer location. Any new data written to a register
writes over the old data. New data is loaded into the next available location, with the
oldest data at the top. The fault table length is specified in multiples of ten registers.
For example, a length of 27 indicates 271 registers assigned to the fault table. Each fault
recorded is represented by 10 words (registers).
Input Data From Bus Controller
Each Bus Controller with diagnostics uses 6 bytes to provide status information to the
CPU. The content of each of the bytes is described following figure 4.6. Bus Controllers
without diagnostics use only one Byte in the input table to provide status information.
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4-31
Expanded CPU Operation
GEK-96602
Bus Controller Status Byte 1 (Address 0) - Input 3
CIRCUIT FAULT - This input, when on, indicates a fault in one of the circuits on a
Genius l/O block. Bytes 3 and 4 of the 6 input bytes indicate the I/O reference (0001
through 1000) that has been assigned to the circuit.
-
Byte 2 (inputs 9 and IO) indicate whether the circuit is an input or output. Input 9
ON indicates that the circuit is an input, Input 10 ON indicates that the circuit is an
output. If both are On, the circuit is an output with feedback.
-
Byte 3 contains the least significant byte of the l/O reference (Input 17 contains the
least significant bit, LSB).
-
Byte 4 contains the most significant byte of the I/O reference (Input 26 contains the
most significant bit, MSB).
-
Byte 5 indicates the fault type and the relative circuit reference number of the fault
on the I/O block. Inputs 33 - 36 (with 33 the LSB) can display the value 0 through 15;
however, only 0, 1, and 2 are used. The value 0 indicates a fault with the EEPROM
in the block’s terminal assembly. The value 1 indicates that the circuit fault is on a
discrete I/O block and the value 2 indicates that the circuit fault is on an analog I/O
block.
Inputs 37 through 40 indicate the relative circuit number on this I/O block. The value 0
represents the top circuit of the block; 7 or 15 the bottom circuit for discrete blocks and
5 the bottom circuit on analog blocks). On the analog blocks, the values 0 to 3 indicate
input channels 1 to 4; 4 and 5 represent output channels 1 and 2.
-
Byte 6 (Inputs 41 through 48) are individual bits that indicate the type of fault. Only
one of these bits will be on at a time.
Table 4.5 defines the faults represented by the inputs 41 through 48. Notice that they are
decoded differently for discrete and analog blocks, as indicated by the fault type in Byte
5 (inputs 33 - 36).
Table 4.5 DECODING OF BYTE 6 FOR CIRCUIT FAULT TYPES
RELATIVE
INPUT
NUMBER *
41
42
43
44
45
46
47
48
SIGNIFICANCE
IF O N
DISCRETE I/O BLOCK
ANALOG I/O BLOCK
Loss of Circuit Power
Output:
Short Circuit
Output:
Overload
If Input:
Open Wire
If Output: No Load
Over Temperature
Failed Switch
not used
not used
Low Alarm
High Alarm
Input Underrange
Input Overrange
Open Wire
Output Underrange
Output Overrange
not used
* Adjust as necessary for different Bus Controller I/O reference assignments.
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Expanded CPU Operation
4-32
GEK-96602
Bus Controller Status Byte 1 (Address 0) - Input 4
LOSS OF BLOCK - This input, when ON, indicates that the Bus Controller has detected
the loss of an I/O block that had been operating.
Bus Controller Status Byte 1 (Address 0) - Input 5
ADD A BLOCK - This input, when ON, indicates that the Bus Controller has detected
that a block has been added to the bus where there had previously not been a block.
Both input 4 and 5 will be on for at least one CPU scan for each detected loss or addition
of a block, but they will never be on at the same time.
-
Byte 2 (Inputs 9 and 10) indicates whether this l/O block is an input only block (Input
9 ON), output only I/O block (Input 10 ON), or combination input/output I/O block
(Inputs 9 and 10 both ON).
-
Bytes 3 and 4 indicate the starting reference (0001 to 0993) assigned to this I/O block.
-
Bytes 5 and 6 contain the number of input and output addresses, respectively, used by
the I/O block.
Bus Controller Status Byte 1 (Address 0) - Input 6
ADDRESS CONFLICT - This input indicates a conflict between two I/O blocks on the bus
trying to use the same l/O reference. A block has been added with a reference used by a
block already on the bus. This conflict may be for two blocks with references overlapping
either partially or totally. Input 16 will be On for one scan for each conflict to be
reported. The last block with the conflicting address wilI be ignored.
- Byte 2 (Inputs 9 and IO) indicates whether this I/O block is an input only block (Input
9 ON), output only I/O block (Input 10 ON), or combination input/output l/O block
(Inputs 9 and 10 both ON).
-
Bytes 3 and 4 indicate the reference (0001 to 0993) of the lowest reference involved
in this conflict.
-
Bytes 5 and 6 provide the device numbers (0 to 31) of the two conflicting I/O blocks.
Byte 5 (Input 33 = LSB, Input 37 = MSB) contains the device number for the I/O
block that was not accepted. This l/O block is rejected by the system (no inputs
accepted/no outputs activated) and is left in a default state.
Byte 6 (Input 41 = LSB, Input 45 = MSB) contains the device number for the
existing I/O block.
Bus Controller Status Byte 1 (Address 0) - Inputs 7 and 8
These two inputs provide data independent of the other inputs. They can be turned on as
needed for indication of system status regardless of the ON and OFF state of the other
inputs.
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4-33
Expanded CPU Operation
GEK-96602
Input 7 , PULSE TEST ACTIVE - This input is turned on for one scan after the Pulse Test
is commanded by the CPU and remains on until all discrete I/O blocks configured for the
Pulse Test have completed the test. Faults detected during this test are provided to the
CPU through Input 3, Circuit Fault, which is described above. This allows circuit faults
to be identified as normal random actions or as faults identified as part of a pulse test.
Input 8, FORCED CIRCUIT - This input is on any time that at least one discrete I/O
circuit or Analog circuit is forced by the Genius I/O Hand Held Monitor (HHM). This
input can be used by the CPU to alert operators that a forced condition exists. The
operator can then determine if the forced condition is proper or should be removed, if
necessary, with the HHM. There is no indication as to which l/O block or reference
contains the forced reference. Only forced conditions set by the HHM on blocks
controlled by this Bus Controller affect input 8.
NOTE
When analyzing the data provided by the 48 input references, first examine the
lower 8 inputs of the reference (first byte). Input data in higher bytes (2
through 6) is used only if one of the Inputs 3 to 6 is ON. Inputs 1, 2, 7, and 8
are independent and can come ON or go OFF as required, regardless of the
state of the other inputs. If Input 1 is OFF, all other inputs have no validity.
Fault Table Reqisters
The content of each of the registers is further described below. The bits are
numbered from 0 through 15. Bits 0 through 7 are the Least Significant Byte and
bits 8 through 15 are the Most Significant Byte.
Register 1 - Genius I/O Bus Controller Address Decoding
The first register contains the I/O address of the Bus Controller that reported the
fault. The Bus Controller address is decoded by the state of the bits in this
register. The register contains the I/O channel (bits 12 -15, range 0 through F) in
which the Bus Controller is placed and its starting I/O reference (bits 0 - 9, with a
range of 0 through 1023). Bits 10 and 11 are unused.
Register 2
The second register contains the I/O channel number in Hexadecimal (0-F) and the
l/O reference of the faulty circuit or starting reference of the faulty I/O block. If
the fault is with the Bus Controller or the Genius I/O communication bus, the
reference value will be 0. Bits 10 and 11 in register 2 indicate whether the circuit
fault is with an input (bit 10 on) or output (bit 11 on) circuit, or l/O blocks
containing all inputs or outputs. If bits 10 and 11 are on, the circuit is an output
with feedback or an I/O mixed block.
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4-37
Expanded CPU Operation
GEK-96602
Output 2 (Bit 1) Definition, Clear All Faults
This bit clears all faults that are currently being stored in the I/O blocks connected on
this controllers bus. All faults will be cleared once for each transition of the Clear All
Faults output.
Output 3 (Bit 2) Definition, Clear Circuit Fault
Output 3 performs a function similar to Output 2, except it is limited to one circuit per
scan. Only the circuit identified in addresses 2 and 3 (bytes 3 and 4) by the I/O reference
1 to 1000 (input 17 = LSB, input 32 = MSB) will be cleared at the I/O block. No other
faults will be affected.
Since the analog circuits do not have a specific l/O reference assigned to them, the
circuits are identified by the first six references assigned to the block as shown in table
4.7. The example in the table assumes that the Analog I/O block starts at I/O references
10225.
Table 4.7 ANALOG I/O BLOCK REFERENCE EXAMPLE
I/O REFERENCE
ANALOG CIRCUIT
Starting Reference
Starting Reference +l
Starting Reference +2
Starting Reference +3
Starting Reference +4
Starting Reference +5
Input Circuit 1
Input Circuit 2
Input Circuit 3
Input Circuit 4
Output Circuit 1
Output Circuit 2
EXAMPLE
0225
0226
0227
0228
0229
0230
To clear more than one circuit (either discrete or analog) Output 3 must go from an off to
on transition (a one-shot could be used for this) and change the values in Bytes 3 and 4 to
reflect the actual individual circuits to be cleared.
Output 4 (Bit 3) Definition, Pulse Test
This output activates the pulse test. If this output is on for one scan, it will cause all
discrete I/O blocks connected to this bus to conduct a pulse test of their outputs.
Outputs configured to ignore this signal, input only blocks and analog I/O blocks will not
perform the pulse test.
The pulse test begins at device number 0 and as fast as it receives a test complete signal
from that device, proceeds to each block until it reaches device number 31. Faults
detected during this test are recorded by the CPU as circuit faults. When the test has
been completed by all l/O blocks on the bus, Input 7 (Pulse Test Active) wi I I be turned off .
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Expanded CPU Operation
4-38
GEK-96602
If this output is on when one test is completed, another will immediately begin. It is not
recommended that this output be left on for a continuous pulse test. It is recommended
that the pulse test be activated a minimum of once each 5 minutes. Input 7 will then
toggle as each pulse test is completed. The advantage of turning output 4 on for only one
scan is that only one test will be conducted as timed by input 7.
Output 9 (Bit 0 of Byte 2) Definition, Circuit Type
The state of this output is determined by the Circuit type (either Input or Output). If the
Circuit Reference indicated by the values in bytes 3 and 4 is an Input, this bit is set to a
1. If the Circuit Reference is an output, the bit is set to a 0.
POINT STATUS BIT MAP
Another Genius I/O diagnostic option selected when the Diagnostic Tables are enabled
through the Configuration Menu, is a point status bit map for each input and each output.
The status bit initial value will be zero. It is set to a one if a fault is received, which
affects this circuit or its entire I/O block (that is - loss of block).
Once set, status bits remain on until reset by the user’s program, even if the fault is
corrected, thus allowing a Matrix Compare function to monitor the status of all l/O
circuits, and identify a faulty circuit quickly and without extensive logic.
If faults are found with analog blocks, they will be indicated in the status by a special
pattern since there is no direct relationship between the fault circuit and an individual
I/O reference. The status for analog inputs is shown below for its three l/O addresses (24
bits).
Table 4.8 BIT STATUS MEANING FOR ANALOG BLOCKS
BIT
NUMBER
ADDRESS 0
ADDRESS 1
ADDRESS 2
Input 2 Underrange
Input 3 Open Wire
0
Input 1 Low Alarm
1
Input 1 High Alarm
2
Input 1 Underrange
Input 2 Open Wire
Input 4 Low Alarm
3
Input 1 Overrange
Not Used (OFF)
Input 4 High Alarm
4
Input 1 Open Wire
Input 3 Low Alarm
Input 4 Underrange
5
Not Used (OFF)
Input 3 High Alarm
Input 4 Overrange
Input 2 Overrange
Not Used (OFF)
6
Input 2 Low Alarm
Input 3 Underrange Input 4 Open Wire
7
Input 2 High Alarm
Input 3 Overrange
Not Used
(OFF>
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Expanded CPU Operation
4-40
GEK-96602
Output Control Definitions
On the output side, when the first output is set on, all Bus Controllers connected to the
CPU will begin to clear faults stored at the I/O blocks as well as in the Bus Controller.
When this master reset is removed, new faults can be recorded and reported to the CPU.
The second output causes a bit to be set which initiates a pulse test of alI Genius I/O
discrete outputs connected to the CPU, except those blocks configured to ignore the
test. If left energized, the second output will cause continuous pulse tests to be
conducted as soon as the previous test is completed.
COMPUTER MAIL BOX
The Computer Mail Box is an automatic communications window to the Genius I/O
system. The default entry for this option is N. To use the Computer Mail Box, change
this entry to Y. If set to Y, the CPU will open a communications window to any valid
address located in the first of 70 consecutive registers for the Computer Mail Box. The
window is opened once per sweep, when the CPU is in the RUN mode.
Using the Computer Mail Box to Communicate with Genius I/O Bus Controllers
The CPU interprets data in the first of 70 consecutive registers as an address to open
communications with a Genius Bus Controller. The registers in the CPU that are
allocated for the Computer Mail Box are used for transfer of data between Genius l/O
Bus Controllers and a Series Six Plus CPU in the Expanded mode. The window address of
the Bus Controller is placed in the first register and command data is placed in the next
five registers. The remaining 64 registers provide a buffer area for data to be
communicated. An illustration of the registers and their content is shown below.
a41086
RXXXX4
FIRST REGISTER
IN GROUP OF70
BUS CONTROLLER ADDRESS 1
CONSECUTIVE
REGISTERS
1 TARGET BLOCK START ADDRESS 1
+
COMMAND
DATA,
REGISTERS
c
DATA
BUFFER
IMAILBOX ADDRESS FOR DATA 1
IDATABUFFER LENGTH IN BYTES 1
I
FIRST
DATAREGISTER
I
Figure 4.9 REGISTER FORMAT FOR COMPUTER MAIL BOX
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Expanded CPU Operation
GEK-96602
The CPU, at the end of its sweep, detects that a command is waiting and opens an
executive window for communications. The addressed device can then either read data
from the mail box or place data for the CPU in the mail box. The window that allows a
Bus Controller to access the Computer Mail Box is generated automatically by the CPU
at the end of each sweep if commanded to do so by enabling the Computer Mail Box
option through the CPU Configuration Set Up menu.
NOTE
The following description of the mechanism for operation of the Computer Mail
Box is for use only with Genius I/O Bus Controllers.
Operation of the Computer Mail Box
The sequence outlined below describes the operation of the Computer Mail Box and
the content of each of the 70 registers is.
Communications Window Opens
The window to the referenced Bus Controller (channel 0 to F, address 1 to 1000) is opened
at the end of each CPU sweep if:
1.
The Computer Mail Box has been enabled through the CPU Configuration Set Up
Menu using Logicmaster 6 software in a Workmaster computer.
2.
If the content of the window address register in the CPU is in the range of 00001 to
16360.
Register R - Bus Controller Address
The Computer Mail Box address of the Bus Controller to be communicated with is placed
in the first of the group of 70 registers. The actual address to be entered into this
register is calculated by using the following formula:
Mail Box Window address = Channel number (0 to F) x 1024 + l/O address (1 to 993) of
the Bus Controller. Use the decimal equivalent of the channel number. For channels
A to F, use the decimal equivalent (A = 10, B = 11, etc.) of the hexadecimal value in
your calculation.
Example: Bus controller at I/O location 257 in channel 4 (4 x 1024 + 257 = 4353).
Enter 4353 in the first register of the Computer Mail Box.
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Expanded CPU Operation
4-42
GEK-96602
Command Data Registers
The next 5 registers contain command data. This data, which is in the form of numerical
values, provides control information, which includes:
-
What function is performed.
Which specific l/O block, if any, is involved.
How much data is to be communicated.
Where the data is to be sent in the Genius l/O system, or where data from the Genius
I/O system is to be stored in the CPU.
The content of each of the five command registers is described below.
Register R+1 - Operation (Read or Write)
The second register must contain an operation (command) number which indicates which
of the following operations is to be performed when communications is opened (DPREQ
receives power flow).
-
1 =
-
2=
-
3=
-
4=
-
5=
6=
7=
-
8=
9=
10=
Idle, no operation performed
Read the configuration of the I/O block or Bus Controller (into CPU registers)
specified in the fourth register. Immediate command *.
Write the configuration of the I/O block specified in the fourth register (from
CPU registers). Not an immediate command.
Read diagnostic data of the l/O block or Bus Controller (into CPU registers).
Immediate command *.
Reserved for future use.
Reserved for future use.
Read analog status (all analog inputs from a block into the CPU registers).
Immediate command *.
Reserved
Read Status Table Reference. Immediate command *.
Reserved
* Immediate only if the specified Status Table address is that of the Bus Controller.
Register R+2 = Communications
Status
The third register is loaded with a number by the CPU to indicate the status of the
communications (DPREQ). The register should initially be cleared to zero and will be
loaded by the CPU at the end of each scan when a status is available. The content of this
register as loaded by the CPU can be:
-
0=
-
1 =
2=
12=
-
20=??
Not accepted. The CPU or addressed Bus Controller is busy with the previous
communications request (DPREQ).
The operation is in process but not completed.
Operation has been completed successfully.
The operation has been terminated due to a syntax error in the DPREQ
registers.
Other error. Any errors that are involved in executing the command, such as
a communications timeout, NAK, internal Bus Controller error, etc.
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Expanded CPU Operation
4-43
.- ~.
GEK-96602
Register R+3 - Target Block Start Address
The content of the fourth register is an I/O reference to indicate the starting location of
the desired I/O block or Bus Controller. The register must contain a value between 1 and
993, which must be a valid I/O address. Three devices can be addressed: discrete I/O
blocks, analog l/O blocks, and the Bus Controller.
Register R+4 - Mailbox Address for Data
The fifth register indicates where the received data from the Genius I/O system should be
stored in the CPU for read operations (operations 2, 4, and 7 in register R+1).
Consecutive registers, beginning with the specified register, will be used until all
received data is stored. For write operations (operation 3) this register indicates where
the data to be sent to the Genius I/O system from the CPU, is to be stored.
Each device requires a different number of registers to store the configuration data in a
16-bit format. An 8-circuit discrete I/O block uses 6 CPU registers, a 16-circuit
discrete I/O block uses 10 CPU registers, an analog I/O block uses 42 registers, and the
Bus Controller uses 18 registers.
Register R+5 - Data Buffer Length
The sixth register specifies the length of the number of bytes to be read or written to by
the Bus Controller in a Read Device or Write Device command.
Data Registers
The remaining registers in the group of 70 registers in the Computer Mail Box may
contain the data to be read from or written to the specified Bus Controller and are moved
in one command.
Command
Verification
The Bus Controller then verifies the command block for valid command syntax and the
absence of a command of that type already in execution. If a syntax error does exist, the
Bus Controller writes an error code into the status code of the third register of the
command block in the CPU. If a command of the same type is already being executed,
the Bus Controller will not modify the status code in a subsequent Computer Mail Box
window when the busy condition disappears.
If the command number specifies a write command, the Bus Controller must read the
specified amount of data from the CPU register memory and store it in the serial bus
output queue.
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Expanded CPU Operation
4-44
GEK-96602
Terminating Computer Mail Box Communications
The Bus Controller will then close the communications window by issuing a Close Window
command, which terminates execution of the Computer Mail Box. The window address of
the Bus Controller (in the first register) that was communicated with is cleared when the
value placed in the status register (third register) by the CPU is not equal to 1 (any valid
number, except 1).
USlNG THE DPREQ FUNCTION TO COMMUNICATE WITH GENIUS I/O
The CPU can communicate with the Genius I/O system through a window opened during
the logic solution of the CPU’s sweep. When this window is opened is determined by
programming Data Processor Request (DPREQ) functions in the user program with a
constant parameter, which is a pointer to a group of registers that contain the command
block. The command block contains the Bus Controller’s window address (which
corresponds to its address defined by the DIP switch setting on the backplane), a
command number, and associated operands for the command.
Typical DPREQ Operation
The sequence below describes the operation of a typical DPREQ instruction.
1.
The window to the addressed Bus Controller is opened at the beginning of the DPREQ
instruction.
2.
Any pending data transfers from the Genius I/O serial bus are copied to or from the
CPU registers by the Bus Controller. Examples of these transfers are actions such as
the Hand Held Monitor reading a CPU register or the Bus Controller completing a
previously issued command.
Any communications or other error resulting from the previous command will be
flagged to the user in the status register.
3.
The Bus Controller will then read the CPU Scratch Pad memory (address 35 and 36).
If bit 7 in location 35 is set to a 1, then the window is interpreted as an executive or
Window instruction type. The Bus Controller then uses the lower 14 bits of the two
Scratch Pad addresses as a pointer to the command block in the registers.
If bit 7 of location 35 is reset, the Bus Controller will use the two bytes as a pointer
to the DPREQ instruction located in user memory that contains the 16-bit pointer to
the command block in register memory.
4.
The Bus Controller will then read the registers as described below.
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Expanded CPU Operation
4-45
GEK-96602
In the Series Six Plus ladder logic, the DPREQ function references six consecutive
registers. Data to be communicated to the Genius l/O system must be placed in
these registers before the DPREQ function is executed. This data, in the form of
numerical values, provide control information, which includes:
-
Which Bus Controller is to be communicated with.
What function is performed.
Which specific I/O block, if any, is involved.
How much data is to be communicated.
Where the data is to be sent in the Genius I/O system, or where data from the
Genius I/O system is to be stored in the CPU.
Contents of First Register
When programming a DPREQ function, the first register referenced indicates which Bus
Controller is to be accessed or through which the intended function is to occur. The
contents of this register must be equal to the Bus Controller’s first status reference plus
1000. For example if the first status reference is 425, and the Bus Controller is in the
Main I/O chain, enter the value 1425.
Contents of Second Register
The second register must contain an operation (command) number which indicates which
of the following operations is to be performed when the DPREQ receives power flow.
-
1=
-
3=
-
4=
5=
2=
-
6=
-
7=
Idle (no operation performed)
Read the configuration of the I/O block or Bus Controller (into CPU registers)
specified in the fourth register.
Write the configuration of the I/O block specified in the fourth register (from
CPU registers).
Read diagnostic data of the l/O block or Bus Controller (into CPU registers)
Reserved for future u se.
Reserved for future use.
Read analog status (all analog inputs from a block).
Contents of Third Register
The third register is loaded with a number by the CPU to indicate the status of the
DPREQ. The register should initially be cleared to zero and will be loaded by the CPU at
the end of each scan when a status is available. The content of this register as loaded by
the CPU can be:
-
0=
-
1=
12=
-
20=
2=
Not accepted. The CPU or Bus Controller is busy with the previous DPREQ.
The operation is in process but not completed.
Operation has been completed successfully.
The operation has been terminated due to a syntax error in the DPREQ
registers.
Other error. Any errors that are involved in executing the command, such as a
communications timeout, NAK, internal Bus Controller error, etc.
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Expanded CPU Operation
4-46
GEK-96602
Contents of Fourth Register
If the second register contains a 2, it will read the configuration of the l/O block or Bus
Controller specified in the fourth register. The content of the fourth register is an I/O
reference to indicate the starting location of the desired I/O block or Bus Controller.
The register must contain a value between 1 and 993, which must be a valid l/O address.
Three devices can be addressed: discrete I/O blocks, analog l/O blocks, and the Bus
Controller.
Each device requires a different number of registers to store the configuration data in a
16-bit format.
An
8-circuit discrete I/O block uses 6 CPU registers, a 16-circuit
discrete I/O block uses 10 CPU registers, an analog I/O block uses 42 registers, and the
Bus Controller uses 18 registers.
Contents of Fifth Register
The fifth register indicates where the received data from the Genius l/O system should be
stored in the CPU for read operations (operations 2, 4, and 7). Consecutive registers,
beginning with the specified CPU register, will be used until alI received data is stored.
For write operations (operation 3) this register indicates where the data to be sent to the
Genius I/O system from the CPU, is to be stored.
5.
The Bus Controller then verifies the command block for valid command syntax and
the absence of a command of that type already in execution. If a syntax error does
exist, the Bus Controller writes an error code into the status code of the third
register of the command block in the CPU. If a command of the same type is
already being executed, the Bus Controller will not modify the status code in a
subsequent DPREQ when the busy condition disappears.
6.
If the command number specifies a write command, the Bus Controller must read
the specified amount of data from the CPU register memory and store it in the
serial bus output queue.
7.
The Bus Controller will then close the communications window by issuing a Close
Window command, which terminates execution of the DPREQ instruction. The
window address of the Bus Controller (in the first register) that was communicated
with is cleared when the value placed in the status register (third register) by the
CPU is not equal to 1.
NOTE
for a more detailed description and examples of using the DPREQ function to
open communications with the Genius I/O system, refer to Chapter 6 in the
Genius I/O System User% Manual, GEK-90486.
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5-1
Troubleshooting and Repair
GEK-96602
CHAPTER 5
TROUBLESHOOTING AND REPAIR
INTRODUCTION
This chapter is a guide to the basic troubleshooting and repair information required if a
malfunction of your Series Six Plus PLC system should occur. Section 1 contains
information on troubleshooting and repair of the Central Processing Unit, while Section 2
contains information on troubleshooting and repair of the I/O system. Parts lists are
included as a reference for ordering renewal parts.
MINIMUM DOWNTIME
The technology used in the design of the Series Six Plus programmable logic control
system is such that under normat operating conditions few hardware failures are
expected. If any failures should occur, they can quickly be isolated and the defective
assembly replaced with minimum downtime. If GENIUS i/O blocks are included as part of
your l/O structure, downtime is reduced to an absolute minimum for the I/O structure.
LOGICAL TROUBLESHOOTING
Troubleshooting is accomplished by thinking logically of the function of each part of the
system and how they relate to each other. A basic understanding of the various indicator
lights will usually quickly isolate the problem to the CPU rack, an I/O rack, the
programming device or any peripheral device in the system.
By use of the programming device, which can be a Workmaster industrial computer,
CIMSTAR I industrial computer, IBM PC, PC-XT, PC-AT, or Program Development
Terminal (PDT cannot be used with the Expanded functions) in conjunction with the CPU,
troubteshooting of the program is easily accomplished. Most inputs or outputs can be
looked at and changed or overridden as required.
The GENIUS l/O diagnostics provide a great deal of information about faults that may
occur in the Genius I/O system. For use of the GENIUS I/O diagnostics, refer to Chapter
4 of this manual. For complete information on GENUS l/O hardware, refer to the
GENIUS l/O System User’s Manual, GEK-90486.
The total system must be considered when problems occur. The CPU, Workmaster
computer, PDT, or other programming device, Redundant Processor Unit, I/O modules,
GENIUS l/O blocks and external devices connected to or controlled by the PLC must all
be operating and connected properly. All screw-down or soldered connections should be
checked carefully as well as all cable connections.
Troubleshooting procedures for the RPU and other peripheral devices can be. found in the
user’s manual for the particular device.
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Troubleshooting and Repair
5-2
GEK-96602
TROUBLESt300TING
The troubleshooting and repair information contained in this chapter is designed to help
you isolate and correct any problems that may arise in your Series Six Plus programmable
logic control system. It is recommended that all maintenance and programming personnel
become familiar with this manual and all applicable related manuals so that if a problem
does arise it can be isolated quickly and the defective part replaced, thus minimizing
downtime of the system.
However, we realize that troubleshooting isn’t always that simple. Sometimes you need
someone to talk to who can answer your questions. When you do, don’t hesitate to call
your local authorized GE Fanuc - NA Programmable Control Distributor. If you are
unsure of the location of your nearest authorized Distributor, then call your local GE
Fanuc - NA Sales Office.
Replacement Module Concept
The troubleshooting and maintenance techniques described in this manual promote the
concept of complete board replacement. The prime objective of this concept is to
minimize system downtime.
lsolate the Problem
When a problem arises, first isolate it to the major assembly (programmer, Central
Processing Unit, I/O rack, etc.), then to the defective module within that assembly. The
defective module is then replaced from a duplicate set of modules maintained on site.
Your production line or system is back up fast.
The defective module can be returned through normal channels under warranty or for
service without keeping your production line or system down for an extended period of
time. The replacement concept minimizes downtime to minutes as opposed to days. The
potential savings far outweigh the comparatively small cost of duplicate modules.
If you did not purchase a duplicate set of modules with your initial system, we
recommend that you contact your local GE Fanuc - NA Programmable Control
Distributor or GE Fanuc - NA Sales office and do so. Then, with the help of this manual
and adequate spare parts, you will be able to troubleshoot and repair just about any
problem that may arise.
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Troubleshooting and Repair
5-3
GEK-96602
CENTRAL
SECTION 1
PROCESSING UNIT TROUBLESHOOTING
FAULT ISOLATION AND REPAIR
The malfunction causing the improper operation of a CPU can be isolated by checking the
condition of status indicator lights and key switch positions. The status indicator lights
and key switches indicate the current operating condition of the CPU and l/O system.
Check Condition of Status Indicator Lights
The normal condition of the status indicator lights is the ON state. If any of the status
indicator lights are not on, check the troubleshooting sequence in this section for the
proper course of action. Tables are provided throughout this section which provide
definitions of the ON/OFF status of each of the indicator lights.
Table 5.1 is an indicator chart that gives a quick reference to the normal condition and
definition of the status indicator lights for the Series Six Plus programmable logic
controller’s CPU.
Check Position of Key Switches
Be sure to note the positions of the key switches on the CPU, Workmaster computer, or
CIMSTAR I industrial computer, and any pertinent switches on other programming
devices, which can be the IBM PC, PC-XT, PC-AT Personal Computers, or the Program
Development Terminal.
Refer to Figure 5.1 which is an illustration of a Series Six Plus programmable logic
controller’s CPU showing the location of the status indicator lights and the key switches.
The numbers that point to indicators and switches on the illustration are for reference
purposes and refer to the same number in the troubleshooting sequences on the following
pages.
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Troubleshooting and Repair
5-4
GEK-96602
Table 5.1 CPU INDICATOR CHART
MODULE
INDICATOR
NORMAL
CONDITION
POWER
SUPPLY
POWER
ON
Power is applied, all dc voltages
are within tolerance.
ON
All I/O stations in primary chain
have continuity, good output parity
and power supply is good.
PARITY
ON
Input data parity is good.
ENABLED
ON
CPU is in the normal Run Enabled mode
(outputs enabled).
DPU
ON
DPU connected and operating
normally.
(If no DPU in system and
DPU present jumper is configured,
light will be on).
RUN
ON
User program is running with a sweep
time of less than 300 ms 250 ms.
CHECK
ON
CPU passed self-test routine which is
executed once per sweep, and user
program executes in less than 300 ms.
BATTERY
ON
Status of CMOS RAM back-up battery.
PARITY
ON
Parity error in Logic, Register or
Internal memory.
ON
All I/O stations in auxiliary chain
have I/O continuity, good output
parity and power supply is good.
PARITY
ON
Input data parity is good.
ENABLED
ON
CPU is in the normal Run Enabled mode
(outputs enabled).
CHAIN
I/O
CONTROL
ARITHMETIC
CONTROL
LOGIC
MEMORY
CHAIN
AUXILIARY
I/O
OK
OK
DEFINITION
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Troubleshooting and Repair
5-6
~~~
GEK-96602
(1) CPU RUN/STOP KEY SWITCH
Position
Definition
STOP
CPU is unconditionally in the STOP mode.
RUN
CPU is in the RUN mode unless this condition has been
altered by commands from the programmer or other device
or by the state of various control signals. When this
switch is turned from STOP to RUN, the system will
start with the outputs enabled. IF THE CPU WILL NOT
RUN, CHECK OTHER STATUS LIGHTS.
(2) MEMORY PROTECT KEY SWITCH
Definition
PROTECT
The contents of Logic Memory and Override Tables
are protected from beinq chanqed.
WRITE
The user program stored In the Logic memory may be
changed and an overrIde condition may be added to or
removed from inputs or outputs through the Override
Table.
If key switches in steps 1 and 2 do not operate and all status indicator lights are OK,
check the P2 connections on the CPAX board in the power supply module (See figure 5.2).
(3) POWER LIGHT - CPU POWER SUPPLY
Status
Definition
ON
The voltage levels of all 3 dc outputs V, +12V,
-12 V) are present and within the specified tolerance.
OFF
One or more of the voltage levels is out of tolerance.
The CPU RUN and ENABLE status indicator lights should
also be off. Alarm Number 1 switches.
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Appendix A - Glossary of Terms
A-1
GEK-96602
APPENDIX A
GLOSSARY OF TERMS
Address - A series of decimal numbers assigned to specific program memory locations
and used to access those locations. In the Series Six Plus, the addresses can range from
0000 to a maximum of 65534.
Analog - A numerical expression of physical variables such as rotation and distance to
represent a quantity.
A N D - An operation that places two contacts or groups of contacts in series. All
contacts in series control the resultant status.
ASCII - An 8-level code (7 bits plus 1 parity bit) commonly used for exchange of data
which is the American Standard Code for Information Interchange.
Backplane - A group of connectors physically mounted at the back of a rack so that
printed circuit boards can be mated to them. The connectors are interconnected by wire
wrapping.
Baud - A unit of data transmission speed equal to the number of code elements (bits) per
second.
BCD (Binary Coded Decimal) - A 4-bit system in which individual decimal digits (0
through 9) are represented by 4-bit binary numerals; for example, the number 43 is
represented by 0100(4) 001 1(3) in the BCD notation.
Binary - A numbering system that uses only the digits 0 and 1. This system is also called
base 2.
Bit - The smallest unit of memory. Can be used to store only one piece of information
that has two states (for example, a One/Zero, On/Off, Good/Bad, Yes/No, etc.). Data
that requires more than two states (for example, numerical values 000-999) will require
multiple bits.
BUS - An electrical path for transmitting and receiving data.
Byte - A group of binary digits operated on as a single unit. In the Series Six Plus PLC, a
byte is made up of 8 bits.
CHECK Light - An LED indicator on the Arithmetic Control module which, when on,
indicates that the execution sequence is normal and the self-test routine has passed at
least once every 200 milliseconds, +/-50 milliseconds.
CMOS - An acronym for Complementary Metal Oxide Semiconductor. A read/write
memory that has a low power consumption but requires a battery in order to retain its
content upon loss of power.
CPU (Central Processing Unit) - The central device or controller that interprets user
instructions, makes decisions and executes the functions based on a stored program. This
program specifies actions to be taken to all possible inputs.
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A-2
Appendix A - Glossary of Terms
GEK-96602
CPU Station - An I/O system consisting of a maximum of 10 l/O racks daisy chained on
the parallel I/O bus through the I/O Control module (or Auxiliary I/O module in an
Auxiliary l/O chain) to an l/O Receiver or Advanced l/O Receiver located in the rack
nearest to the CPU rack. The last rack can be no more than 50 feet from the CPU.
Counter - A function within the PLC that records- events based upon the On/Off
transition of a signal. A coil associated with the counter is energized at a user
determined preset value.
DIP Switch - An acronym for Dual-ln-Line Package, which is a group of miniature toggle
or slide switches arranged side-by-side in a single package. Commonly used as the
physical device for setting the configuration of various parameters necessary to the
operation of electronic equipment.
Data Link - The equipment including interface modules and cables that allow
transmission of information.
Discrete - Consisting of individual, distinct things such as bits, characters or
components. Also refers to On/Off type of t/O modules.
circuit
Field Devices - User supplied devices typically providing information to the PLC (Inputs:
pushbutton, limit switches, relay contacts, etc.) or performing PLC tasks (Outputs: motor
starters, solenoids, indicator Iights, etc.).
Firmware - A series of instructions contained in ROM (Read Only Memory) which are
used for internal processing functions only. These instructions are transparent to the user.
Hardware - All of the mechanical, electrical and electronic devices that comprise the
Series Six Plus programmable controller and its application(s).
Hardwired - Interconnection of electrical and electronic devices directly through physical
wiring.
Hexadecimal - A numbering system, having 16 as a base, represented by the digits 0
through 9, then A through F.
Input - A signal, typically ON or OFF, that provides information to the PLC. Inputs are
usually generated by devices such as limit switches and pushbuttons.
Input Module - An I/O module that converts signals from user devices to logic levels used
by the CPU.
Interface - To connect a programmable logic controller with its application devices,
communications channels, and peripherals through various modules and cables.
I/O (Input/Output) - That portion of the PLC to which field devices are connected.
Isolates the CPU from electrical noise.
I/O Electrical isolation - A method of separating field wiring from logic level circuitry.
Typically accomplished through the use of optical isolation devices.
I/O Module - A printed circuit assembly that interfaces between user devices and the
Series Six Plus programmable logic controller.
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Appendix A - Glossary of Terms
A-3
GEK-96602
I/O Scan - A method by which the CPU monitors all inputs and controls all outputs within
a prescribed time.
K- An abbreviation for kilo or exactly 1024 in the world of computers. Usually related to
1024 words of memory.
,
LED - An acronym for Light-Emitting-Diode, which is a solid state device commonly
used as a visual indicator in electronic equipment.
Ladder Diagram - A representation of control logic relay systems. The user programmed
logic is expressed in relay equivalent symbology.
Latch - A PLC function that causes a coil to stay on and remain on even if power or the
input is removed. Referred to as a retentive function.
Local I/O Station - An I/O system configuration consisting of a maximum of 10 I/O racks
interfaced to a Series Six Plus programmable logic controller through an l/O Receiver or
Advanced I/O Receiver module to an I/O Transmitter module in a CPU station or another
Local I/O station. The last Local l/O station in a chain can be located up to a maximum
of 2000 feet from the originating l/O Control or Auxiliary I/O module in a CPU station.
Logic - A fixed set of responses (outputs) to various external conditions (inputs). All
possible situations for both synchronous and non-synchronous activity must be specified
by the user. Also referred to as the program.
Logic Memory - In the Series Six Plus PLC, dedicated CMOS RAM memory accessible by
the user for storage of user ladder diagram programs.
Memory - A grouping of physical circuit elements that have data entry, storage and
retrieval capability.
Memory Protect - A hardware capability that prevents user memory from being altered
by an external device. This capability is controlled by a key switch on the CPU power
supply
?
Microprocessor - An electronic computer processor section consisting of integrated
circuit chips that contain arithmetic, logic, register, control and memory functions.
Microsecond (us) - One millionth of a second. 1 x 10 -6 or 0.000001 second.
Millisecond (ms) - One thousandth of a second. 1 x 10-3 or 0.001 second.
Mnemonic - An abbreviation given to an instruction, usually an acronym formed by
combining initial letters or parts of words.
Modules - A replaceable electronic subassembly usually plugged in and secured in place
but easily removable in case of fault or system redesign. In the Series Six Plus PLC , a
combination of a printed circuit board and its associated faceplate which when combined
form a complete assembly.
Nanosecond (ns) - One billionth of a second. 1 x 10-9 or 0.000000001 second.
Noise - Undesirable electrical disturbances to normal signals, generally of high frequency
content.
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Appendix A - Glossary of Terms
A-4
GEK-96602
Non-Retentive Coil - A coil that will go off when power is removed.
Non-Volatile Memory - A memory capable of retaining its stored information under
no-power conditions (power removed or turned off).
OFF-Line - Equipment or devices that are not connected to a communications line; for
example, the Workmaster computer, when off-line, operates independent of the Series Six
Plus CPU.
ON-Line
- Descriptive of equipment or devices that are connected to the
communications Iine.
OR - An operation that places two contacts or groups of contacts in parallel. Any of the
contacts can control the resultant status.
Optical Isolation - Use of a solid state device to isolate the user input and output devices
from internal circuitry of an I/O module and the CPU.
Opto-Isolator - A semiconductor device that isolates input or output circuits from the
control circuitry on an I/O module. These circuits are coupled together by transmission
of light energy from a sender (LED) to a receiver (photo-isolator).
Outputs - A signal typically ON or OFF, originating from the PLC with user supplied
power, that controls external devices based upon commands from the CPU.
Output - Information transferred from the CPU, through a module for level conversion,
for controlling an external device or process.
Output Devices - Physical devices such as motor starters, solenoids, etc. that receive
data from the programmable logic controller.
Output module - An I/O module that converts logic levels within the CPU to a usable
output signal for controlling a machine or process.
PLC - Commonly used abbreviation for Programmable Logic Controller.
Parity - The anticipated state, either odd or even, of a set of binary digits.
Parity Bit - A bit added to a memory word to make the sum of the bits in a word always
even (even parity) or always odd (odd parity).
Parity Check - A check that determines whether the total number of ones in a word is
odd or even.
Parity Error - A condition that occurs when a computed parity check does not agree with
the parity bit.
Peripheral Equipment - External units that can communicate with a PLC, for example,
programmers, printers, etc.
Preset - A numerical value specified in a function which establishes a limit for a counter
or timer. A coil will energize when this value is reached.
Program - A sequence of functions entered into a programmable logic controller to be
executed by the processor for the purpose of controlling a machine or process.
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Appendix A - Glossary of Terms
A-5
GEK-96602
Programmable Logic Controller or Programmable Controller - A solid-state industrial
control device which receives inputs from user supplied control devices such as switches
and sensors, implements them in a precise pattern determined by ladder diagram based
programs stored in the user memory, and provides outputs for control of processes or user
supplied devices such as relays and motor starters.
Programmer - A device for entry, examination and alteration of the PLC’s memory,
including logic and storage areas.
PROM - An acronym for Programmable Read Only Memory. A retentive digital device
programmed at the factory and not readily alterable by the user.
RAM - An acronym for Random Access Memory. A solid-state memory that allows
individual bits to be stored and accessed. This type of memory is volatile; that is, stored
data is lost under no power conditions, therefore a battery backup is required. The Series
Six Plus PLC uses a Lithium Manganese Dioxide battery or an optional external back-up
battery for this purpose.
RS-232C - A standard specified by the Electronics Industries Association (EIA) for the
mechanical and electrical characteristics of the interface for connecting Data
Communications Equipment (DCE) and Data Terminal Equipment (DTE).
RUN Light - An LED indicator on the Arithmetic Control module which, when on,
indicates that the execution sequence of the PLC is proceeding normally and the I/O scan
is completed at least once every 200 milliseconds, +/-50 milliseconds.
Read - To have data entered from a storage device.
Reference - A number used in a program that tells the CPU where data is coming from or
where to transfer the data.
Register Memory - In the Series Six Plus PLC, dedicated CMOS RAM memory accessible
by the user for data storage and manipulation.
Relay Line - A line of logic in a ladder diagram used to simulate the effect of mechanical
relays. The coil in a relay line is energized when continuity is complete from the left to
right vertical rail of a ladder diagram.
Remote I/O Station - An I/O system configuration allowing access to a maximum of 248
inputs and 248 outputs at a location distant from a CPU station or Local I/O station.
Connection is made through a serial communications interface consisting of a Remote I/O
Driver, a two-twisted pair shielded cable, and a Remote l/O Receiver. The serial link
can be located up to 10,000 feet from the originating Remote I/O Driver. When used with
an RS-232C modem communications link, the distance is virtually unlimited.
Retentive Coil - A coil that will remain in its last state, even though power has been
removed.
Rung - A sequence or grouping of PLC functions that control one coil. One or more rungs
form a ladder diagram.
Scan - The technique of examining or solving all logic steps specified by the program in a
sequential order from the first step to the last.
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Appendix A - Glossary of Terms
A-6
GEK-96602
Serial Communication - A method of data transfer within a PLC, whereby the bits are
handled sequentially rather than simultaneously as in parallel transmission.
Significant Bit - A bit that contributes to the precision of a number. The number of
significant bits is counted beginning with the bit contributing the most value, referred to
as the Most Significant Bit (MSB), and ending with the bit contributing the least value,
referred to as the Least Significant Bit (LSB).
Sol id State - Electronic circuitry using only transistors, diodes, integrated circuits, etc.
This circuitry has high reliability and low power consumption when compared to
electro-mechanical devices.
Storage - Used synonymous with memory.
Terminator - A device or load connected to the output end of a transmission line to
terminate or end the signals on that line. In the Series Six Plus PLC, DIP shunts and
jumper packs connect on-board resistors which terminate the I/O chain signals on an I/O
Receiver or Advanced l/O Receiver if it is the last Receiver in any I/O chain.
Thumbwheel Switch - A rotating numeric switch which can be used for inputting numeric
data to a PLC in the form of BCD digits.
Unit of Load - An expression used to describe the load placed on a power supply by an I/O
module or a CPU module. Also the amount of current or load capacity available from a
power supply.
Unlatch - A PLC function that causes an output previously turned on by a latch function
to turn off no matter how briefly the function is enabled.
User Memory - Term commonly used when referring to the memory circuits within the
PLC used for storage of user ladder diagram programs.
Volatile Memory - A memory that will lose the information stored in it if power is
removed from the memory circuit devices.
Watchdog Timer - A hardware timer within the PLC used to ensure that certain hardware
conditions are met. Used as a system check. In the Series Six Plus PLC, the duration of
the watchdog timer is 300 milliseconds, +/-50 milliseconds.
Word - A measurement of memory length, usually 4, 8, or 16 bits long (16 bits for the
Series Six Plus PLC).
Write - To transfer, record, or copy data from one storage device to another.
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Index
I-1
GEK-96602
INDEX
A
ASCII/BASIC module 1-17
Adaptor Unit
1-21
Addressing l/O 2-31, 2-33
Advanced I/O Receiver 2-46
I/O chain signal continuation
or termination 2-44
illustration of 2-47
status and diagnostic indicators 2-48
troubleshooting with 5-39 to 5-49
Advanced functions 1 - 1 0
Alarm conditions \ 2-7
Applications, list of typical
1-20
Arithmetic Control module
description of 2-14
illustration of 2-15
Arithmetic Control to Logic Control
cable 3-11
Auxiliary I/O module 2-61
illustration of 2-62
Auxiliary I/O system, description
of 2-61
Axis Positioning modules 1-1 7
Basic functions 1-9
Battery installation 3-8
Battery status indicator 2-18
Blocks, Genius I/O 1-13
Bus Controller module, description
of 2-21
C
CCM2 2-22
CCM3 2-25
Cimstar I computer 2-64
CPU I/O station 2-37
illustration of 2-38
CPU alarm conditions 2-7
CPU configuration set up menu 4-13
Genius l/O 4-15
Genius I/O fault table 4-16, 4-18
Genius I/O fault table definitions
4-19
bus controller locations page 4-l 7
computer mailbox 4-17
definitions 4-14
displaying and clearing Genius I/O
f a u l t s 4-18
expanded I/O scan 4-14
CPU module installation 3-7
CPU rack mounting 3-3
CPU troubleshooting 5-3
RUN/STOP key switch 5-6
Arithmetic Control module 5-12, 5-13
Combined memory module, battery
light 5-15
Combined memory module, parity
light 5-14
alarm relay 5-18
battery replacement 5-15, 5-16,
5-17
fault isolation and repair 5-3
indicators and switches, location of
5-5
indicator chart 5-4
I/O Control/Auxiliary I/O modules
5-9, 5-10
memory protect key switch 5-6
power supply 5-6 to 5-9
start-up instructions 3-31
Channel reference numbering 2-33, 4-4
Channels of I/O 4-3
selection of 4-4
Checksum, dynamic user memory 4-11
Combined Memory module 2-16
catalog numbers 2-16
description of 2-16
illustration of 2-20
location in rack 2-19
memory protection 2-19
precautions when handling 2-19
status indicators 2-18
Communicating to Genius I/O system
through the DPREQ function 4-44
Communications Control modules 2-22
description of 2-22
type 2 (CCM2) 2-22
type 2 (CCM2), illustration of, 2-24
type 3 (CCM3) 2-25
type 3 (CCM3), CCM2 mode 2-25
type 3 (CCM3), RTU mode 2-25
I/O C C M 2 - 2 6
I/O Link Local 2-27
Communications networks 1-18
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l-2
Index
GEK-96602
INDEX
greater than 4-24
multiplication 4-23
programming of 4-22
subtraction 4-22
Functions, advanced 1-10
Functions, basic 1-9
Functions, expanded 1-10
Compatibility guide, Series Six Plus
vs Series Six 1-22
Computer mail box 4-40
Configuration of expanded functions,
4-12
Configuration of the Series Six Plus
CPU 2-2
Configuration set up menu 4-13
G
D
DIP switch settings for I/O points
2-32
DO l/O function, addressing 16K I/O
points, 4-26
DPREQ function, communicating with
Genius I/O system, 4-44
DPREQ register references 4-45, 4-46
Datagram Communications Service 1-20
Definition of terms
Discrete references, internal 2-34
Dynamic user memory checksum 4-11
E
Enabling of expanded functions 4-14
Expanded CPU operation 4-1
Expanded functions 1-10, 4-1
Expanded functions menu 4-10
Expanded mode I/O addressing 2-33,
4-3
Expanded mode I/O references 2-34,
2-35
Expanded mode I/O references, table
of
4-8
Expanded time reference 4-27
Extraction/insertion tool 3-4
F
Fault isolation and repair
5-3
Features of Series Six Plus 1 - 4
Figures, list of xvi to xviii
Floating point functions 4-21
addition 4-22
convert floating point to integer
4-24
convert integer to floating point
4-24
display format 4-21
division 4-23
Genius l/O Bus controller 2-21
Genius I/O blocks 1-13
Genius I/O diagnostics 4-28
bus controller diagnostic storage
4-29
bus controller input and output
addresses 4-29
bus controller input status
definitions 4-29 to 4-33
bus controller output data 4 - 3 6
bus controller output data
definitions 4-36 to 4-37
bus status/control byte 4-39
fault table 4-28
fault table pointer 4-28
fault table registers 4-34
point status bit map 4-38
register memory size 4-28
Genius I/O system
general description 1-6
typical communications I ink 1 - 6
GEnet Factory LAN
1-18, 1-19
Global data service 1-21
Glossary of terms,
Grounding procedures, system 3-15
ground conductors 3-16
safety ground 3-16
signal ground 3-17
programming device grounding 3-16
H
How to enable expanded functions
I
I/O C C M 2 - 2 6
I/O Control Module
description of 2-10
illustration of 2-11
jumpers, configurable 2-11
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4-12
Index
l-3
GEK-96602
INDEX
l/O Link Local module 2-27
illustration of 2-28
I/O Receiver module 2-43
I/O chain signal continuation or
termination
2-44
illustration of 2-43
I/O Transmitter module 2-49
illustration of 2-50
status indicators 2-51
l/O addressing 2-31
expanded mode 2-33
normal mode 2-33
l/O blocks, Genius I / O
1-13
I/O cable catalog numbers 2-64
I/O channels 4-3
1-12
l/O circuitry, function of
I/O interface modules
Advanced l/O Receiver 2-46
I/O Receiver 2-43
I/O Transmitter 2-49
Remote l/O Driver 2-55
Remote I/O Receiver 2-58
list of 2-42
I/O module load 3-28
I/O modules 1-12
I/O modules, table of
1-12
I/O point DIP switch settings 2-32
I/O point address switches,
illustration of 2-31
I/O point selection 3-27
l/O power supply 3-20
ac power source connections 3-20
dc power source connections 3-21
specifications
2-30
I/O rack, description of 2-29
interconnections
2-36
2-30
specifications
typical, 2-29 3-19
I/O references, expanded mode, table
of 2-35
I/O station 2-36
CPU 2-37
Local 2-39
Remote 2-40
definition of 2-36
I/O structure 2-29
I/O system cables, parallel
3-24, 3-25
I/O system cables, serial link 3-26
I/O system configuration 2-36, 3-19
I/O system interface module
installation 3-21
I/O Receiver 3-22
l/O Transmitter 2-49, 3-22, 4-2
Remote I/O Driver 3-23
Remote I/O Receiver 3-24
l/O system troubleshooting 5-20
I/O rack power supply 5-20, 5-21
l/O indicator chart 5-22 to 5-27
I/O rack connections 5-27 to 5-30
intermittent fault conditions 5-37
suggested sequence of
5-31
CHAIN OK light 5-31
CHAIN PARITY light 5-32
FAULT ENABLE light 5-34
ISOLATED POWER light 5-33
LINK OK light 5-35
LOCAL OK light 5-34
LOCAL PARITY light 5-32
POWER light 5-33
REMOTE OK light 5-36
REMOTE PARITY light 5-37
check at CPU 5-31
input not recognized 5-38
no outputs function 5-38
only 1 output fails 5-38
with the Advanced I/O Receiver
5-39 to 5-49
Input/Output circuitry, function of
1-12
Inserting a printed circuit board 3-5
lnstal lation instructions for
Series Six Plus 3-1
Installing a battery 3-8
Internal discrete reference memory
al locat ion 2-34
Internal discrete reference mapping
4-5
Internal memory, function of
2-17
Interrupt Input module location in
system 4-2
Introduction to Series Six Plus 1 - 1
L
LAN interface module 1-20
List of figures xviii to xvix
List of tables xx to xxi
Local area network, GEnet 1-19
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Index
l-4
GEK-96602
INDEX
Local l/O station 2-39
Local I/O station, illustration of 2-39
Logic Control module
description of 2-12
illustration of 2-13
Logic Control to Arithmetic Control
cable 3-11
Logic memory, function of 2-16
Logicmaster 6 serial version 2-65
Logicmaster 6 software
1-7, 4-12
Loop Management Module 1-16
M
Maintenance of the Series Six Plus
PC 5-1
Manuals, related
Memory mapping 4-6, 4-7
Memory protection key switch 2-19
Memory types of
1-11, 2-18
Memory, CMOS RAM 1-11
Module installation, CPU 3-6
Module replacement concept 5-2
Modules, Communications 1-13
Modules, I/O 1-12
Modules, Intelligent
1-13
Modules, System lnterface 1-1 3
N
Planning, system 1-20
Power supply 2-4
auxiliary circuit board 2-8
block diagram 2-8
dc voltage outputs 2-8
specifications 2-7
terminal block connections 2-6
user items 2-5
Product structure 2-1
Preface iii
ProLoop Process Controllers 1 - 1 6
Programmable Controllers
Series Six Plus 1-2
advantages of 1-2
block diagram 1-1
concepts 1-11
definition of 1-1
terminology
1-21
Programming functional groups 1-9,
1-10
Programming language 1-9
Programming requirements 1-7
Programming the Series Six Plus,
general information 1-7
with a Cimstar I computer 2-64
with an IBM PC 2-65
with a Workmaster computer 2-62
R
Network interface 1-20
Normal mode I/O addressing 2-33, 4-3
Normal mode of operation 4 - 1
0
Operator Interface Unit 1-15
Operator lnterface Terminal
1-15
Optional devices 1 - 1 4
Operator Interface Unit
1-15
Operator Interface Terminal 1-15
ProLoop Process Controllers 1 - 1 6
Redundant Processor Unit 1 -14
Override Detect ion, Active 2-17
P
PC compatibility guide 1-22
PC terminology 1-21
Parallel bus I/O cables 2-64, 3-24
Physical equipment configuration 2-1
RPU addressing 2-65
RS-232 to RS-422 Adaptor 1-21
Rack configuration 2-2
Rack mounting brackets 2-3
Real I/O mapping 4-5
2-34
Real I/O memory allocation
Real-time clock 4-27
Redundant Processor Unit 1-14
Register memory size 4-5
Related publications iv
Remote I/O Driver 2-55
2-56
addressing
illustration of 2-55
opt ion jumpers 2-57
status byte 2-56
Remote l/O Receiver 2-58
illustration of
2-58
option jumpers 2-60
Remote l/O station 2-40
illustration of 2-41
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Index
l-5
GEK-96602
INDEX
Remote I/O system 2-52
configuration jumpers 2-54
remote l/O addressing 2-53
system response time 2-53
typical connections 2-52
Removing a printed circuit board
Required references, summary of
I/O references 4-9
Register references 4-19
3-6
4-9
S
Scan rate 1-5
Scratch pad 2-17
Series Six Plus
features of 1-4
I/O diagnost ics 4-2
I/O structure 2-29
instal lat ion 3-1
Arithmetic Control module 3-11
Auxiliary I/O module 3-13
CPU module installation 3-7
CPU power supply connections 3-14
CPU rack installation 3-2
Combined memory module 3-8
Communications Control modules,
3-13
I/O Control module 3-12
Logic Control module 3-11
extract ion/insertion tool
3-4
instruct ions 3-1
mounting, illustration of 3-3
Software packages 1-8
Specifications, General 1-5
Start-up CPU 3-31
System grounding procedures 3-15
ground conductors 3-76
safety ground 3-16
signal ground 3-17
programming device grounding 3-16
System planning 1-20
T
Table of contents vii to xvii
Tables, list of xviii to xix
Terminology, PC 1-21
Troubleshooting and repair
5-1
Troubleshooting, general information
5-2
Troubleshooting sequences 5-31
Troubleshooting with the Advanced
l/O Receiver 5-39 to 5-49
U - W
Units of load, 3-28, 3-29
Window function 4-24
Window function, entering a 4-25
Workmaster computer
general description of 1 - 7 , 1 - 8
connection to Series Six Plus
2-62
illustration of 2-64
to Series Six Plus adapter boards
2-62
to Series Six Plus connections 2-63
system grounding procedures 3-15
to Workmaster connections 2-63
GE FANUC AUTOMATION NORTH AMERICA, INC., CHARLOTTESVILLE, VIRGINIA
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
GfK-96602A
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com
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