PACSystems RX7i CPU, IC698CRE020
April 5, 2006
PACSystems™ RX7i CPU Module (700 MHz)
CPU Firmware Version 3.80
Ethernet Firmware Version 3.60
Firmware version 3.80 provides many of the features that previously existed only on the non-redundant RX7i
controllers to the CRE020 redundant controller. (The RX7i Ethernet firmware remains at release 3.60.) New
features in this release, which are all previously released in other PACSystems CPU products, are:
User Defined Function Blocks
Support for IEC 61131-3 compliant Function Block Diagram programming language.
Structured Text
Support for IO Variables (Symbolic Variables) in hardware configuration.
Support for managed and mapped variables (Symbolic Variables) in Redundant Transfer Lists including
User Defined Function Block Instance variables.
Support for Symbolic Variables in EGD configuration.
Support for access to managed and mapped variables from C Blocks.
Support for IEC 61131-3 compliant timer function blocks for pulse timer, on-delay timer, and off-delay
Support for the new RX7i power supply IC698PSD300
Ability for user to interrupt Flash Read, Write, and Clear operations
Support for the Horner Thermocouple Module (HE697THM160)
Support for Series 90-70 Discrete Input Module IC697MDL650.
For details on these features, see page 8. Problems resolved in this release are described on page 3.
IC698CPE020-Ax, IC698CPE020-Bx, IC698CPE020-Cx, IC698CPE020-Dx, IC698CPE020-Ex or
IC698CRE020-Ax, IC698CRE020-Bx, IC698CRE020-Cx, IC698CRE020-Dx, modules are field upgradeable
to IC698CRE020-xF using the firmware upgrade utility.
You may order the field upgrade kit, 44A752281-G08, or download it at no charge from the web at The hardware cannot be upgraded.
Error! Reference source not found.
Product Documentation
PACSystems RX7i CPU Reference Manual, GFK-2222
PACSystems RX7i Installation Manual, GFK-2223
PACSystems Hot Standby CPU Redundancy User’s Guide, GFK-2308
PACSystems RX7i Memory Xchange Modules User’s Manual, GFK-2300
TCP/IP Ethernet Communications for PACSystems User’s Manual, GFK-2224
PACSystems TCP/IP Station Manager Manual, GFK-2225
PACSystems RX7i C Toolkit User’s Guide, GFK-2259
Proficy™ Machine Edition Getting Started, GFK-1868
Proficy Machine Edition Logic Developer – PLC Programming Software Getting Started, GFK-1918
Important Product Information, PACSystems RX7i CPUs, GFK-2320H (this document)
CPU Functional Compatibility
For Ethernet functional compatibility, see page 3.
Programmer Version
Proficy Machine Edition Logic Developer PLC 5.5 Service Pack 1 or
later must be used for Release 3.80 new features,
Proficy Machine Edition Logic Developer PLC 5.0 Service Pack 3 or
later must be used to program the CRE020 when using Modbus/TCP
Server operation.
Proficy Machine Edition Logic Developer PLC 4.5 or later must be used to
program the CRE020
C Toolkit Compatibility
The C Toolkit Release 3.50 Build 34A1 is required for new features in
PACSystems Release 3.80. (Use of symbolic variables in C Blocks).
The C Toolkit for PACSystems is distributed with Machine Edition Logic Developer
PLC 4.0 or later. Toolkit build 21A2 or later is required for use with the RX7i.
Toolkit build 47A1 or later is required for use with the Release 2.00 new features.
Please note: The Series 90-70 Toolkit (IC641SWP709/719) is not compatible with
PACSystems RX7i.
Series 90-70 Expansion Rack
The PACSystems RX7i supports Series 90-70 expansion racks.
PACSystems RX7i CPUs and the RX7i Ethernet Module do not operate in a
Series 90-70 rack.
Series 90-70 Main Rack
Series 90-70 Main Racks cannot be used in a PACSystems RX7i system.
PACSystems RX7i CPUs and the RX7i Ethernet Module do not operate in a
Series 90-70 Rack.
Single Width I/O Module
The following additional single width I/O modules are supported by the
PACSystems RX7i :
Analog Input, 64 Channel, 16 bit resolution, Voltage (IC697VAL264)
Analog Input, 12 bit, 32 Channel single-ended or 16 Channel differential
Analog Output, 32 Channel, 12 bit (IC697VAL301)
Digital Input, 64 Point (IC697VDD100)
Relay Output, 64 Point (IC697VDR151)
Digital Output, 64 Point (IC697VDQ120)
Eight Channel RTD/Strain Bridge (IC697VRD008)
Note: These modules are fully integrated when installed in the Main Rack. When
installed in an expansion rack the module must be configured as a generic VME
Important Product Information
Ethernet Functional Compatibility
SRTP and EGD Performance
Differs from Series 90-70
SRTP and EGD performance in the RX7i differs slightly from the Series 90-70. Each
RX7i Ethernet Interface supports a greater number of SRTP connections and EGD
Please also note that the RX7i currently has several SRTP and EGD operational
restrictions when compared to the Series 90-70. When migrating Series 90-70
Ethernet applications to the RX7i, please carefully read the "Ethernet Operational
Notes” section on page 19.
Series 90-70 LAN Interface
Modules (IC697CMM741 and
IC697CMM742) not supported
by RX7i
Please note that the Series 90-70 LAN Interface Modules (IC697CMM741 and
IC697CMM742) are not supported by the RX7i and should not be placed in an RX7i
rack. The RX7i CPU contains an embedded Ethernet Interface. If additional Ethernet
Interfaces are required, the RX7i Ethernet Module (IC698ETM001) should be used.
Programmer Version
Proficy™ Machine Edition Logic Developer PLC 5.0 Service Pack 3 or later must be
used to program the PLC CPU for Modbus/TCP operation.
CIMPLICITY® Plant Edition
Version Requirements
CIMPLICITY® Plant Edition 6.1 Service Pack 1a with Update 040204_s90tcp_6101
or Service Pack 2 or later must be used for Ethernet communications with
CPU Problems Resolved by this Release (3.80)
Run mode store to redundant
controller fails
In a redundant controller with 512 blocks, resynchronization (one redundant
controller is running and the other redundant controller goes from stop mode to
run mode) may corrupt user memory.
ENET intermittently loses CPU
communication after Restart
When an Ethernet module is reset using the push button or a service request,
occasionally the module will fail to power-up and re-establish communications
with the PLC CPU.
CPU watchdog timer expires
during run mode store when
large number of blocks deleted
If a run mode store is performed that requires the PLC to delete a large number
of stored logic blocks the PLC watchdog timer may expire.
Power Cycle During Online Edit
In previous releases, if the user stores a project to flash that is configured to
power up from flash and then subsequently power is cycled in the middle of a
Online Edit session, the programmer will still indicate that the Online Edit
session is in progress after the power cycle. The user should cancel the Online
Edit session to continue. This problem is corrected in release 3.80.
RAND_MAX and rand()
Function Incompatible
In the C Toolkit, the RAND_MAX system variable is defined as a 32-bit integer.
However, in previous releases, the rand() function returns a 16-bit integer. In
release 3.50, rand() returns an integer between 0 and RAND_MAX.
COMMREQ Status Words
Declared in Bit Memory Types
Must Be Byte-Aligned
In previous releases, the CPU allowed configuration of COMMREQ Status
Words in bit memory types on a non-byte-aligned boundary. Even though the
given reference was not byte-aligned, the firmware would adjust it the nextlowest byte boundary before updating status bits, overwriting the bits between
the alignment boundary and specified location. To ensure that the application
operates as expected, release 3.80 requires configuration of COMMREQ Status
Words in bit memory types to be byte-aligned.
Timed interrupt response time
A GBC in the system may impact response time for timed interrupts. The worst
case interrupt response time for a PLC system with a GBC and no other Genius
devices is 0.5 milliseconds. The worst case interrupt response time for a PLC
system with a GBC and maximum amount of Genius data is 50 milliseconds.
Error! Reference source not found.
Possible ME disconnect when
multiple GBCs are present in
expansion/remote racks within
a system.
If a system contains multiple GBCs in expansion/remote racks, it is possible for
Machine Edition to timeout its connection to the PLC on a clear operation or a
store of configuration. For each GBC located in an expansion/remote rack, a 3
second delay is added to the time required for a clear/store of configuration.
This is true for both Ethernet and serial connections.
In previous releases, the default connection timeout is 10 seconds and the
default request timeout is 16 seconds. In release 3.80, these values have been
increased by at least 3 seconds per each GBC physically located in an
expansion/remote rack so that the default connection timeout is 13 seconds and
the default request timeout is 19 seconds.
Repeated store of project
containing C blocks
In previous releases, after many stores of a project that contains C blocks, the
PLC CPU and/or Ethernet module may cease operation, requiring a powercycle the main PLC rack to recover. This problem has been corrected in
release 3.80.
Service Request 6: rounding of
length parameter
In previous releases, processing for Service Request 6 Change/Read Number
of Words to Checksum incorrectly rounds the specified length to the next
largest multiple of 8 bytes, rather than 8 words. Consequently, each sweep
may checksum fewer words than expected. In release 3.80, the specified
length for Service Request 6 is not rounded.
Serial Port Lock-up after Bad
Modbus Message
In previous releases, if a badly formed Modbus RTU message is sent to the
PLC, the serial port will lock up, requiring a power-cycle to recover proper port
operation. In release 3.80, a defective Modbus RTU message does not cause
the serial port to lock up
High Speed Counter Module
Fails to Power Up Correctly
Rarely, after some extreme power loss events, a High Speed Counter with
interrupts enabled may fail to power up successfully. After failure, the HSC may
continue to function but will cease to communicate with the PLC. There are no
module fault indicators for this event and the HSC ready bit will remain ON.
The user should power cycle again to restore normal function. This problem
has been corrected in release 3.80.
Pushing Ethernet Restart
Button Multiple Times
In previous releases, pushing the Ethernet Restart button multiple times rapidly
without letting the Ethernet module complete the restart may cause the PLC to
go lights out. The user should power cycle the CPU to recover. This problem
has been corrected in release 3.80.
Powering Up Unconfigured
Expansion Racks During Run
In previous releases, powering up an expansion rack that is currently not
configured causes the sweep time to increase significantly (approximately 3040 ms for each rack) for one sweep. If the PLC is in run mode, and multiple
expansion racks are powered up at the same time, the software watchdog timer
may go off. The user should ensure that all expansion racks are configured
before being powered up, or power up the expansion racks while the PLC is in
stop mode, or increase the software watchdog timeout appropriately, in order to
avoid this problem. In release 3.80, powering up unconfigured expansion racks
in run mode does not cause a software watchdog timeout.
SNP Update Datagram message
In previous releases, if an Update Datagram message requests 6 or less bits or
bytes of data, the PLC will return a Completion Ack without Text Buffer. The
protocol specifies that the returned data will be in the Completion Ack message,
but it may not be. In release 3.80, the Completion Ack data includes the
returned data.
EGD continues to Produce
when the CPU is in STOP-HALT
EGD continues to produce exchanges when the CPU is in a STOP-HALT
condition. EGD production should stop when the CPU is in STOP-HALT.
Bit Value parameter for ShiftRight and Shift-Left function
blocks not initialized.
If the user does not provide an input value for the Bit value parameter (B1), the
value used for the shift will be random (i.e. 0 or 1).
There is no problem when a value is specified for the"B1" parameter.
Hardware Revision
The hardware revision, as displayed by the programmer, was not reported
correctly (always reported a value of 4.0 which corresponds to Fab Revision D).
Important Product Information
Avoid Ethernet module resets
Resetting the Ethernet module, either by Service Request 24 or by the restart
pushbutton, previously caused some of the PLC CPU’s internal memory to be
consumed if EGD was configured. The problem was more pronounced with
larger EGD configurations.
Nuisance faults at power-up
If the programmer attempted SNP communications while the PLC was powering
up, sometimes non-critical software event faults appeared in the PLC fault
table. These no longer occur.
Avoid moving switch to STOP
during power -up
If the RUN/STOP switch was in RUN when power was initially applied, and was
moved to STOP before power-up was complete, the PLC sometimes went into
RUN mode momentarily before entering STOP mode. This no longer occurs.
Power-up in over-temperature
If the PLC CPU is overtemperature when powered-up, it no longer logs a "PLC
CPU hardware failure" fault, E.C. 4, Group 13, Fatal. Re-applying power to a
PLC that has already detected that operating temperatures have been
exceeded no longer results in PLC CPU LEDs blinking an error code and loss
of memory contents.
Modbus RTU parity errors
In the case of an incoming message that contains a parity error, the message is
now dropped.
Repeated downloads
Many repeated downloads of configuration via Ethernet communication no
longer eventually result in Ethernet exception log event 28/9.
Nuisance Fault
The fault "Non-critical CPU software event -- serial port event" no longer
appears occasionally at power-up.
Some summary fault bits not
Previously, the summary fault %SC bits may not have been set for certain
conditions (%SC10 and %SC12 for overtemperature or power supply fault;
%SC9, %SC1, %SC13 for terminal block)
PLC CPU Communications
The PLC CPU no longer stops responding to any serial and Ethernet
communications after many, many repeated attempts to read or write bit
memory using an erroneous set of {segment selector, offset, length}.
Checksum SVC_REQ
Service Request 6 Change/Read Number of Words to Checksum previously
interpreted its parameter as a byte count. It now interprets the parameter as a
word count. (However, see open problem CR-6622.)
Discrete Inputs scanned as 1 in
Expansion rack with no power
In RX7i releases 2.56 and 2.57, turning power off of an Expansion rack would
result in all discrete Inputs being scanned as a value of 1. This has been
corrected such that discrete Inputs will be scanned as 0 (as specified) when an
Expansion rack has lost its power.
Fuse, Aux, and Watchdog faults
logged against Discrete IO
modules on Expansion Rack
powered down
If point faults are enabled in the configuration, the RX7i CPU will log up to two
extraneous faults per module every time an expansion rack containing a
discrete input and a discrete output module is powered DOWN.
Power Cycle During Large Run
Mode Store, Word-for-Word
Change or Online Edit Session
Previously, if a power cycle occurs during a run mode store, word-for-word
change or online edit change of a large program, the CPU might have powered
up with memory corrupted. This problem has been resolved.
Modbus Station Address
Configuration with Message
When a port is configured for message mode during run mode, it will
automatically switch to Modbus protocol during stop mode. There is now
support for configuring a Modbus Station Address in this mode using the
programmer. If not configured, the default address is 1.
GBC Will Not Default Its
Outputs 250ms Later Than
In previous releases of the RX7i CPU, an additional 250 ms was added to the
timer that the Genius Bus Controllers use for detecting CPU failures. The
resulting formula was: ( 2 x the CPU's configured watchdog timer) +250 ms
with a maximum value of 3 seconds. The maximum setting for the GBC's timer
was capped at 3 seconds. Therefore, in certain cases of RX7i CPU failure, the
GBCs would default their outputs up to 250ms later when compared to the
same scenario with a 90-70 CPU. Starting with this release, this is no longer
Error! Reference source not found.
Mode Transition with Scan Set
When a scan set greater than one has been configured and stored, an attempt
to go from Run Mode I/O Disabled to Stop Mode I/O Enabled will now be
rejected. Previously, the PLC would transition to Stop Mode I/O Disabled.
%T Reference Table Cleared
Even if no logic is currently stored in the PLC, the %T reference memory is now
cleared on a stop to run transition.
Fault Tables can be Cleared
When Memory is Protected
If the switch on the PLC is configured for memory protection, and is in the
“memory protect” position, you are now allowed to clear the fault tables.
Service Request 24 Only
Generates Expected Faults
When Service Request 24 (Reset Smart Module) is executed, unexpected
faults are no longer logged in the fault table. Please note that, because this
service request resets a module, faults associated with resetting the module are
Attempting To Update ETM
When Module In Slot Is Not ETM
If an attempt to upgrade ETM firmware is inadvertently directed to a slot
containing an analog module, CMM, PCM, or GBC, WinLoader will no longer
fail with the error "Target is unable to enter boot mode. Serial comm error:
Request timed out." Now, WinLoader will produce a "Target device does not
support firmware FLASH updates" error message. You should direct the
upgrade to the correct slot.
Load or Store of Logic
Containing Large Numbers of
Blocks or Symbols Do Not
Cause Disconnect
Previously, if the user attempted to load or store logic containing large numbers
of blocks (>120) and/or large numbers of symbols to or from the PLC, the CPU
would disconnect with the programmer and not reconnect until the connection
timed out. In some cases, the user would need to power cycle with the battery
disconnected in order to reconnect. This problem has been resolved.
CommReq Writing to %SC
A CommReq initiated to read and write to %SC memory using Bit Mode
(Decimal 28) will now correctly access %SC memory (previously it was writing
to %SB memory).
Canceling Download Does Not
Cause Disconnect
Previously, if a download from the programmer was cancelled between the
times that some files had been stored but no program files were yet stored, the
PLC would disconnect and not reconnect. This problem has been resolved.
Service Request 7 Does Not
Accept Invalid Day of Week
If an invalid day of the week is passed as a parameter to Service Request 7 in
the unpacked BCD 2 or 4 digit year formats, the service request will now
correctly not pass power.
Genius Redundancy with
Faulted or Missing Module
Previously, if a GBC was configured for either Redundant Controller External or
Dual Bus External mode, incorrect data would be scanned from redundant
devices that were not connected, powered off, or failed. Both the scanned input
data and associated point fault information (fault contacts) were incorrect. This
problem has been resolved.
Ethernet Exceptions No Longer
Logged When Passwords
When password protection is enabled for levels 2 - 4, the Ethernet interface no
longer logs the following two exception events at powerup or restart.
Event = 2, Entry 2 = 0030H and Event 8, Entry 2 = 000bH
Second programmer can
change logic while in Test &
Edit mode
While currently active in a Test and Edit session using Machine Edition on one
PC, Machine Edition running on another PC is not prevented from storing new
logic to the PLC.
Serial Port Diagnostic Failure
on Power-Up
Activity on serial ports during power-up of the PLC no longer cause the PLC to
log a fatal diagnostic fault. Now, a non-fatal diagnostic fault is logged. To avoid
this fault, the serial cable can be disconnected during power-up, or the
application sending the data to the serial port can be disabled.
Piggy Back Status Switch
Position Bit Correct
The switch position bit in the piggy back status of SRTP traffic was inverted and
based on the PLC sweeps state in previous releases. The bit now operates
Run Mode Store Following A
Failed Run Mode Store Does
Not Cause Stop/Halt
Previously, attempting a Run Mode Store after a failed Run Mode Store could
cause the CPU to go to Stop/Halt.
Important Product Information
Configured Fault Actions
Applied During Power Up When
Loading From Flash
In previous releases, the fault actions in the hardware configuration loaded from
flash were not applied until power up was complete. Default fault actions were
always applied for any faults relating to hardware configuration that occurred
during power up when loading from flash. With this release the fault actions
specified in the configuration loaded from flash are applied during power up.
Power Cycle of Interrupt Block
in Expansion Rack While in
Run Mode Handled Correctly
Previously, if an interrupt module tied to an interrupt block was located in an
expansion rack and the expansion rack was power cycled while in run mode,
the interrupt block would no longer be triggered and an Unrecognized VME
Interrupt Source fault would be logged. This problem has been resolved.
Invalid PTR Input to FIFO_RD
Function Handled Correctly
Previously, if the value passed to PTR input of the FIFO_RD function was
greater than constant which defined the table length, the PLC would go to
Stop/Halt mode.
Communications Device Failure
During Store
If the embedded Ethernet or ETM module resets in the middle of the store
during a Stop Mode Store, Run Mode Store, or Test and Edit, or if the serial
connection is lost in the middle of the store, the possibility of seeing a CPU
software fault has been removed.
Configuration Changes for
Generic VME Module Applied
When Stored
In release 1.5 and 1.6 changes to the configuration of a previously configured
VME 1-slot or 2-slot module are not applied when hardware configuration is
Configuration mismatch with
unsupported module causes
PLC sequence store failure
If you attempt to store a hardware configuration to the CPU that has a module
configured for a slot that physically contains an unsupported module, the store
will fail with a sequence store failure.
Verify of Initial Values of FLASH
after power-cycle may fail
In previous releases, a verify FLASH operation of initial values after a powercycle may indicate that initial values are not equal. The “not equal” is a result of
non-retentive variables being cleared during power-up, when compared with the
non-zero values stored in FLASH. PLC operation has been changed to no
longer clear non-retentive variables during power-up when a read from FLASH
is performed as part of power-up, therefore non-retentive variables will have the
values read from FLASH in this case.
Interrupt blocks execution in
In previous releases, interrupt block execution continued when the CPU entered
STOP/HALTED mode. They now stop execution.
Modbus RTU Station Address
Greater than 127
Modbus RTU station addresses with a value greater than 127 will now function
correctly. Previously, values greater than 127 could be configured, but would
cause communication to fail with a timeout.
HCT Request Failure
On previous releases, requests would fail when sent from applications using the
following Host Comm Toolkit interfaces: HCT_estab_mem_list,
HCT_cancel_mem_list and HCT_read_req with an address.addr_type of
HCT_MEMLIST. This problem has been resolved.
Ethernet Problems Resolved by this Release (3.60)
Pushing Ethernet Restart Button
Multiple Times
Pushing the Ethernet Restart button multiple times rapidly without letting the
Ethernet module complete the restart no longer causes the PLC to go lights
EGD Production Continues when
CPU goes to HALT mode
EGD production no longer continues even when the CPU goes to HALT mode.
This issue is resolved with CPU Firmware Release 3.11 or later and Ethernet
release 3.60.
Producer ID of Zero in Capabilities
Producer ID no longer is set to zero in the EGD Capabilities response if the IP
address is set up by the “setIP” utility.
Error! Reference source not found.
New CPU Features and Enhancements in this Release (3.80)
Release 3.80 provides the following new features.
User Defined Function Blocks
Structured Text
Support for IO Variables (Symbolic Variables) in hardware configuration.
Support for IO Variables (Symbolic Variables) in Redundant Transfer Lists including User Defined
Function Block Instance variables.
Support for Symbolic Variables in EGD configuration.
Support for access to managed and mapped variables from C Blocks.
Support for IEC 61131-3 compliant Function Block Diagram programming language.
Support for IEC 61131-3 compliant timer function blocks for pulse timer, on-delay timer, and off-delay
Support for variables (managed and mapped) in redundant transfer lists.
Support for the new RX7i power supply IC698PSD300
Ability for user to interrupt Flash Read, Write, and Clear operations
Support for the Horner Thermocouple Module (HE697THM160)
Support for Series 90-70 Discrete Input Module IC697MDL650.
Note that features, such as interrupt blocks, that were intentionally excluded from release 2.00 of the
CRE020 will continue to not be supported on the CRE020.
New Ethernet Features and Enhancements (Release 3.60)
Release 3.60 of the RX7i Ethernet interfaces provides the following features and enhancements.
Modbus/TCP Client
Modbus/TCP Client capability has been added to PACSystems. The Modbus/TCP Client supports Modbus
Conformance Class 0 function codes 3 and 16, Conformance Class 1 function codes 1, 2, 4, 5, 6, and 7, and
Conformance Class 2 function codes 15, 22, 23, and 24. PACSystems Ethernet supports 32 Client
connections shared between all Client protocols. For example, if 16 Client connections are used for SRTP
Channels, 16 Client connections are available for Modbus/TCP Channels. Any given channel can be
assigned to only one protocol at a time.
Ethernet Daughterboard BootLoader Firmware
The Ethernet Daughterboard BootLoader firmware was updated to support Ethernet Plug-in Applications.
Important Product Information
CPU Restrictions and Open Issues
Battery Installation
When installing a new battery, when there currently is no battery installed, the
battery must be installed while the CPU has power. Failing to follow this
procedure could result in the CPU not powering up.
If a battery is installed while power is off (and there was no battery previously
installed), and the CPU fails to power up, simply remove the battery, power
cycle the CPU and then install the battery.
Ethernet Disconnect During Word
for Word Change
If the Ethernet connection is broken during a word–for-word change, the
programmer may not allow a subsequent word-for-word change after
reconnecting due to the fact that it thinks another programmer is currently
attached. If this occurs, you should go offline and then back online again.
Non-GE Fanuc VME Modules
Operating as VME Masters
Non-GE Fanuc VME modules operating as VME bus masters have not been
tested with the RX7i. Users interested in integrating this type of functionality
should contact technical support.
Store of Hardware Configuration
with Multiple GBCs
Storing a hardware configuration containing two or more GBCs twice may
cause one GBC to fail configuration. Clearing the hardware configuration
between stores will prevent this fault from being generated.
Simultaneous Clears, Loads and
Stores Not Supported
Currently, the RX7i does not support multiple programmers changing CPU
contents at the same time. The programming software may generate an error
during the operation.
Fault Reporting With Analog
For fault reporting when an analog expander is used in a Series 90-70
Expansion Rack, a special case exists when the ALG230 base module is in
slot 2 and an expander module is present in slot 9. In this case, if any
expander module loses communication with the base module, then the fault
reports for all 16 channels for that expander display the slot number as 0. The
circuit number will be a value from 9 to 120, as shown in the following table.
The I/O reference address for each channel is displayed as blank.
For fault reporting when an analog expander is used in a PACSystems RX7i
rack, a special case exists when the base is in slot 4 and an expander is
present in slot 11. In this case, the slot number for a faulty expander is always
displayed as slot 2, and the circuit number will display according to the slot
used for the expander, as shown in the following table. The I/O reference
address for each channel is displayed as blank.
Power Cycle During Write to Flash
If the CPU is power cycled during the process of writing to flash, and is
configured to power up from flash, a fault will be generated on power up.
Error! Reference source not found.
Hardware Configuration Not Equal
After Changing Target Name
If the user stores a hardware configuration to flash which indicates that
“Logic/Config Power up Source” is set to “Always Flash” or “Conditional Flash”
and then subsequently changes the name of the target in the programming
software, the hardware configuration will go Not Equal and will not Verify as
PLC and IO Fault Tables May
Need to be Cleared Twice to Clear
Faulted State
Both PLC and IO fault tables need to be cleared to take the CPU out of
Stop/Fault mode. If one of the tables contains a recurring fault, the order in
which the tables are cleared may be significant. If the CPU is still in Stop/Fault
mode after both tables are cleared, try clearing the fault tables again.
VME Modules Using Program
Type AM Codes
When Block Transfers are enabled with a VME memory region that uses one
of the program type AM Codes, the Rx7i CPU sometimes generates block
transfer (BLT & MBLT) cycles to access the associated VME memory.
Therefore, if you have a VME memory region configured to use one of the
program type AM Codes (AM Codes 3Ah, 3Eh, 0Ah, or 0Eh), be sure to follow
at least one of these two rules:
a) The memory region's Interface Type parameter must not be set to "Qword
Access (64-bit)", and the VME Block Transfer parameter must be set to
-ORb) The system may not contain any "program" and "data" VME memory
regions with overlapping VME addresses. (If more than one VME module
were to respond to a BLT or MBLT cycle, a system error could result.)
Setting Force On/Off by Storing
Initial Value
Once a force on or force off has been stored to the PLC, the user cannot
switch from force on to force off or vice-versa directly by downloading initial
values. The user can turn off the force by doing a download, and then change
the force on or off by another download.
CMM COMMREQ Restriction
Due to an issue in the CMM firmware, the SNP COMM_REQ Read System
Memory (7202) executed on a CMM module does not execute correctly for
lengths greater than 760 words. Incorrect data is written to the SNP Master.
Users should not use lengths greater than 760 words.
Number of Active Programs
Returned as Zero
The SNP request Return Controller Type and ID currently returns the number
of active programs as zero.
Serial I/O Failure at 115K During
Heavy Interrupt Load
Rare data corruption errors have been seen on serial communications when
running at 115K under heavy interrupt load on the PLC. Under heavy load
applications, users should restrict serial communications to 57K or lower.
Synchronized Backup Unit May
Log Over Sweep Faults In
Constant Sweep Mode
A synchronized backup unit may report over sweep faults in constant sweep
mode regardless of the amount of time spent servicing IO, logic, and
communications in the sweep.
Ret Control Info Doesn’t Return
Controller ID
RET_CONTROL_INFO request currently always returns zeroes for the
controller ID.
Null SNP ID From Service
Request 11
Service Request 11 currently always returns zeros.
Bus Read or Write May Return
Status of 5 Instead of 4.
In some cases, the Bus Read/Write Status Word returned may be 4 instead of
5 when the ending address is out of range.
Hardware Configuration and Initial
Values May Not Load From Flash
The CPU may not load hardware configuration and/or initial values from flash
when the configuration indicates to load from flash when the hardware
configuration and/or initial values are stored to RAM without storing logic and
then written to flash.
Important Product Information
PACSystems C Toolkit Definition
for Unpacked BCD 4 Digit Year
Structure Wrong
The definition of unpacked_bcd_tod_4_rec in release 1.0 and earlier of the
PACSystems C Toolkit is incorrect. The definition should be:
struct unpacked_bcd_tod_4_rec{
T_WORD huns_year;
T_WORD tens_year;
T_WORD month;
T_WORD day_of_month;
T_WORD hours;
T_WORD minutes;
T_WORD seconds;
T_WORD day_of_week;
CPU Sweep Time Increases
During Overtemp Operation
When the operating temperature of the CPU exceeds the normal operating
temperature, system variable #OVR_TMP (%SA8) turns ON (Fault group 24,
error code 0x0001). When this occurs the sweep time periodically increases
because the CPU executes a new task to read the actual temperature
reported by a temperature sensor. This increase can be as much as 2 ms.
GBC in Expansion Rack May Fail
to Power Up
Occasionally, a EM731 module located in an expansion rack may fail to power
up when power to that rack is cycled off/on. The module’s OK light will flash
and then all module lights will go off. Power cycle the rack again to recover.
Possible ME inability to connect
Infrequently, an attempt to connect a programmer to a PLC via Ethernet will be
unsuccessful. The normal connection retry dialog will not be displayed.
Rebooting the computer that is running the programmer will resolve the
Don’t use multiple targets
In a system in which the hardware configuration is stored from one target and
logic is stored from a different target, powering-up from flash will not work.
The observed behavior is that, following a power up from flash, ME reports
hardware configuration and logic "not equal".
Nuisance Faults (GBC in
Four “Non-critical CPU software event” faults may appear when some
hardware configurations that contain GBC modules are stored. These faults
may be ignored.
Sequence Store Failure
In systems with very large hardware configuration, it is possible to encounter a
“PLC Sequence Store Failure” error when writing the configuration to flash. To
avoid this error, either:
1. Perform an explicit clear of flash prior to performing the write.
2. Increase the operation timeout used by ME prior to performing the write.
Thermocouple Module Fails to
Power Up Correctly
After some power loss events, the Horner Thermocouple module
(HE697THM160) may fail to power up successfully. After failure, the AI data
will not be updated correctly and will continue to return zero values. There are
no module fault indicators for this event. The user should power cycle again to
restore normal function.
C Toolkit PlcMemCopy
Documentation Incorrect
This routine does allow the destination and source pointers to be outside of
reference memory. If the destination points to discrete reference memory,
overrides and transitions will be honored. Note that the header for
PlcMemCopy has been updated in Release 3.50 of the C toolkit.
Fault Contacts on Modules in
Expansion Rack
When an expansion rack powers up, the slot fault contacts will prematurely
indicate that the modules in the expansion rack are not faulted before they
complete their power up. Use I/O point fault contacts to verify validity of
the I/O.
Fault Contacts on Remote I/O
If multiple faults exist in a Series 90-70 Remote I/O Station and one of them is
corrected, a FAULT contact that uses the Remote I/O Station’s module
reference will incorrectly indicate that no faults exist at the Remote I/O Station.
Error! Reference source not found.
BIT_SEQ Function Block DIR
The BIT_SEQ Function Block should require the user to flow BOOLEAN logic
into the DIR parameter, but currently does not. If no DIR parameter is present,
the BIT_SEQ will increment by default.
Improper use of BIT_SEQUENCER
could result in CPU going to StopHalt
Before using the BIT_SEQUENCER function block, the current step number
(in the control block) must be set to a valid between 1 and the length (in the
control block). Failure to properly initialize the count step number in the BIT
SEQUENCER function block may result with the CPU going to
CPU may not detect low-battery
PACSystems CPUs may not detect a low-battery condition early enough to
provide a meaningful warning to the user to replace the battery. A battery with
very low capacity may still have a terminal voltage high enough to report that it
is a good battery. In this case, when the battery starts supplying the memory
power (battery backup), the battery voltage would quickly drop to
unacceptable levels, with little warning to the user before failure. To insure
against data loss, users should replace batteries in accordance with the
guidelines provided in the CPU Reference Manual, GFK-2222. Additionally,
users could save logic and hardware configuration to flash.
Battery Status Shows Good with
No Battery Attached
In rare conditions on some RX3i and RX7i CPU hardware, the battery status
(Fault and %S14) may show good even when no battery is attached.
Ethernet Restrictions and Open Issues
Ethernet module stays in
Backup mode when CPU goes to
Primary mode
When a system is goes from RUN mode to STOP mode and a new hardware
configuration is stored to the system, the Ethernet module and CPU module are
in different redundant states. To recover, hot swap (the Ethernet module) or
power-cycle the system.
Number of SRTP Requests
Tallied May Vary
When running multiple SRTP client channels, the number of requests, as
reported by the client and the server, may differ between the connections.
SRTP Connections Remain Open
After IP Address Changed
The Ethernet Interface does not terminate all open SRTP connections before
changing its IP address. Once the local IP address has changed, any existing
open TCP connections are unable to normally terminate. This can leave SRTP
connections open until their underlying TCP connections time out. If quicker
recovery of the SRTP connection is needed, modify the “wkal_idle” Advanced
User Parameter to reduce the TCP keep alive timer down to the desired
maximum time for holding open the broken connection. Refer to TCP/IP
Ethernet Communications for PACSystems, GFK-2224, for details.
Reporting of Duplicate IP
The RX7i does not log an exception or a fault in the PLC Fault Table when it
detects a duplicate IP address on the network.
REPP Does Not Save Results of
Aborted PING
The station manager REPP command does not retain the results of a PING that
is aborted due to error. The PING results are reported when the PING is
aborted, but subsequent REPP commands give the results of the last
successfully terminated PING.
Multiple Log Events
The Ethernet Interface sometimes generates multiple exception log events and
PLC Fault Table entries when a single error condition occurs. Under repetitive
error conditions, the exception log and/or PLC Fault Table can be completely
filled with repetitive error messages.
Intermittent SNTP Loss of
Under moderately heavy EGD traffic load, the Ethernet Interface may
occasionally lose synchronization with its SNTP time server and generate
exception log event 29, entry 2=bH.
Important Product Information
Reduced EGD Consumption with
Large Numbers of Produced
When large numbers of EGD exchanges are produced at a rapid rate, some
consumed EGD exchanges may exhibit lower rates of consumption than
expected. To better balance produced and consumed EGD exchange
performance, reduce the number or frequency of the produced exchanges
configured at this Ethernet Interface.
SRTP Communication Delays
Average latency of communications on SRTP channels may vary considerably
due to TCP retransmissions. SRTP client applications should be designed to
take this variance into account. In particular, SRTP client applications migrating
from Series 90-70 SRTP Servers to RX7i may need to lengthen SRTP timeout
PLC Fault Table Last Update
Date and Time
The PLC Fault Table web page does not display the correct data for the PLC
date and time field. The date and time displayed are the PCs local date and
time, not the PLCs date and time.
Spurious “Ethernet Failure”
On rare occasions, the error “Module hardware fault” may be reported on the
Ethernet daughterboard. The corresponding fault in the exception log is Event =
1, followed by text "Ethernet failure". This fault is a nuisance fault and may be
Web Server Failure Under Heavy
After several hours of heavy load on the web server, the web server may fail to
return pages and may cause a LAN system-software fault to be logged. The
web server will resume serving pages when the load is reduced. (This applies
only to the embedded Ethernet Interface.)
Reference Table Web Page
After the user selects a user defined table, if the user then tries to go back to
the pre-defined table of %R1-%R60, an error message may be displayed
stating “An error was detected when trying to retrieve setting from PC cookie”.
Fault Table Web Page
On both the I/O and PLC Fault Table web pages, the PLC program name is not
currently displayed in the area provided.
Cannot Set FTP Password
The CHPARM TPASSWORD Station Manager command fails. Processing an
AUP File containing parameter “tpassword” generates an error.
Reference Table Web Page
When using Netscape 4.7 to view the reference table web page, the size of the
columns is incorrect. The first column is much wider than the others.
Spurious Ethernet Fault
In rare instances, after power cycle, the Ethernet Interface may log the following
fault, Event = 28H, Entry 2 = 000eH. This fault can be safely ignored.
Release 2.00 PLC Faults Are Not
Identified on Web Page
When any PLC Fault Table entries defined for Release 2.00 or later are
displayed using the Ethernet interface web server, the PLC Fault description
contains only a generic message instead of the proper fault text.
Cannot send EGD Commands to
EGD Commands return COMMREQ Status 8F90H (= invalid IP address) when
addressed to initiating Ethernet Interface’s own IP address. If you wish to send
an EGD command to yourself, please use the loopback IP address (
Unexpected EGD COMMREQ
EGD Commands may return COMMREQ Status 9590H (= internal error)
instead of the expected B190H (= Can’t locate remote node) when unable to
locate a remote device on the network.
Too many EGD Commands
Reported as Internal Error
The Ethernet Interface supports 10 simultaneous EGD commands. When an
11 EGD Command COMMREQ is issued, the CSW value 9590H (= internal
error) is returned.
EGD Command Passwords are
not Supported.
Optional passwords are not allowed within EGD Command COMMREQs.
Very Heavy EGD
Production/Consumption at
Server May Cause EGD
Command Timeouts
Very heavy EGD production and/or consumption at a server device may cause
EGD command timeout errors when another device attempts to send EGD
commands to that server. If EGD commands must preempt normal production,
you may set the “gcmd_pri” Advanced User Parameter to 2 (see GFK-2224,
Appendix A). Note that by doing so, EGD exchange production may be delayed.
Error! Reference source not found.
SRTP Server Errors Can Cause
Timeouts at Channels Client
The SRTP Server in the PACSystems Ethernet Interface can encounter various
errors when the remote Series 90 PLC client takes down an SRTP connection
and then establishes a new connection. This can cause unexpected channel
timeout errors 0190H or 0290H at the client.
The SRTP server errors in the Ethernet exception log are identified as Event =
2; Entry 2 may be 001cH, or 0021H.
EGD Command Range Failure
Can Write Partial To PLC Bit
When an EGD Command attempts a write operation to a bit-mode PLC
reference memory range (%I, %Q; %T, %M, %SA, %SB, %SC) where the
amount of data be written exceeds the configured size of that reference
memory, the command will return failure status but partial data may be written
into the reference memory. The amount of partial data written depends upon the
starting bit memory location and the data length as follows:
If data starts on a byte boundary (location = (8*n) + 1), no partial data is
If data does not start on a byte boundary (location = (8*n)+1) and data
exceeds the configured reference memory by 8 or more bits, partial data is
written from the starting location to the next byte boundary after the starting
If data does not start on a byte boundary (location = (8*n)+1) and data
exceeds the configured reference memory by less than 8 bits, partial data
is written from the stating location to the end of configured reference
For a Write PLC Memory command, this can occur when writing data into the
target PLC. For Read PLC Memory or Read Exchange commands, this can
occur when writing data received from the target PLC into the local PLC
memory. The logic application must not use any data returned to the local PLC
if the EGD command status indicates failure.
To avoid writing partial data to the local or remote PLC, be sure that bit memory
data transfers do not exceed the configured reference memory sizes at the
appropriate PLC.
Usage of New IP/Subnet Mask
Because the Ethernet interface operates using a retained set of IP address +
subnet mask information, a change to these values does not take effect until a
restart of the module or power cycle of the rack containing the module. The user
should be aware when altering these configuration values that their effect is not
Cannot Change EGD Class 2
UDP Port Number
Processing an Advanced User Parameter File containing parameter “gctl_port”
does not actually change the value.
COMMREQ Length Error
The COMMREQ Status Word value 8190H (="COMMREQ is too short") may
also be reported for EGD Command COMMREQs that are too long (contain
more words than expected).
No CPU fault logged when
Ethernet Interface in fatal blink
The CPU does not log any PLC or I/O Faults when the Ethernet Interface has a
fatal blink code. The user’s application should monitor the LAN interface OK
status bit to detect loss of module.
EGD I/O has unexpected
variability under heavy load
EGD I/O has intermittent unexpected variability under heavy load. For a
Produced Exchange, EGD samples may occasionally be delayed by as much
as a production period.
Configuration of Direct IP and
Redundant IP on different
subnets not detected.
If the user configures the Direct IP and Redundant IP addresses on different
subnets, this will not be detected either by Proficy Machine Edition Logic
Developer or the Ethernet Interface. The Ethernet Interface will fail to activate
the Redundant IP address, but will report successful activation.
Clear of large hardware
configurations may cause log
event 08/20
A Log event 08/20 may occur when very large hardware configurations are
cleared and transfers are active on other Server connections. This log event
can be safely ignored.
Important Product Information
COMMREQ Status Word of
0x54A0 occasionally returned for
EGD commands
Occasional COMMREQ Status Word values of 0x54A0 are returned to
COMMREQs for EGD commands when the previously transferred command
has experienced retries in the network. Executing the COMMREQ again results
in successful transfer of the command.
CPU Operational Notes
Transfer List Validation not
compatible with Release 2.0x
Redundant transfer lists generated using CPU Firmware release 2.05 or
earlier are not compatible with the release 3.80 transfer lists. Redundant
controllers that are running release 2.05 will not be able to synchronize with
controllers that are running release 3.80 firmware.
Only One BTM Allowed in Main
Only one BTM is allowed in the main rack. Multiple BTMs in the main rack will
result in undefined operation.
Logic Executed in Row Major
Instead of Column Major
Logic execution in PACSystems RX7i is performed in row major order (similar
to the Series 90-30) instead of column major (similar to the Series 90-70).
This means that some complicated rungs may execute slightly differently on
PACSystems RX7i and Series 90-70. For specific examples, see the
programming software on-line help.
Upgrading Firmware with Modules
in Rack
The process of upgrading the CPU firmware with the WinLoader utility may
fail when multiple IO modules are in the main, remote or expansion racks,
due to the time it takes to power cycle the rack system. If the upgrade
process fails, move the CPU to a rack without IO modules and restart the
upgrade process.
NaN Handled Differently Than in
The PACSystems RX7i CPU may return slightly different values for Not A
Number as compared to Series 90-70 CPUs. In these exception cases (e.g.,
0.0/0.0), power flow out of the function block is identical to Series 90-70
operation and the computed value is still Not A Number.
PID Algorithm Improved
The PID algorithm used in PACSystems RX7i has been improved and
therefore PID will function slightly differently on PACSystems RX7i than on
the Series 90-70. The differences are:
The elapsed time is computed in 100 µS instead of 10 mS units. This
smoothes the output characteristic, eliminating periodic adjustments that
occurred when the remainder accumulated to 10mS.
Also, previous non-linear behavior when the integral gain is changed
from some value to 1 repeat/second was eliminated.
Service Request 13 Command
Block Must Contain Zero
When the Service Request function block is used to invoke Service Request
#13, the first word of the command block sets the number of last scans to be
executed. If the value of that word is -1 (or 0xFFFF), then the number of last
scans is set to the value in the configuration.
Changing IP Address of Ethernet
Interface While Connected
Storing a hardware configuration with a new IP address to the RX7i while
connected via Ethernet will succeed, then immediately disconnect because
the RX7i is now using a different IP address than the Programmer. You must
enter a new IP address in the Target Properties in the CME Inspector window
before reconnecting.
Error! Reference source not found.
Stack Allocation for Folders
Converted from Series 90-70 Must
be Increased
Series 90-70 folders are converted to PACSystems RX7i with the same stack
allocation. PACSystems RX7i uses more stack space than the Series 90-70,
so some folders may not run after conversion. To increase the stack space,
right click the _MAIN block and select Properties. Stack Size is listed at the
bottom of the Properties page. The default stack size in new PACSystems
RX7i folders is 64KB. Folders with a large number of nested calls may need
more stack space. As a general rule, the stack for the converted
PACSystems RX7i folder should be set to approximately three times the
stack size of the Series 90-70 version of the folder. A diagnostic fault will be
displayed if the folder runs out of stack space.
Duplicate Station Address for
Modbus Will Conflict with Other
The default serial protocol for the RX7i is Modbus RTU. The default Station
Address is 1. If the PLC is added to a multi-drop network, care must be taken
that the PLC is configured with a unique Station Address. Nodes with
duplicate Station Addresses on the same network will not work correctly.
FST_EXE No Longer Represented
by %S121
The PACSystems RX7i implementation of #FST_EXE is different from the
Series 90-70 implementation. #FST_EXE is no longer stored in %S (%S121)
memory. Instead, it is stored in a local memory that is not accessible to the
user. You can reference #FST_EXE only by using its name (similar to
referencing a symbolic variable).
The #FST_EXE system variable can be accessed (read) in the logic of any
block. Just as in the Series 90-70, PSB blocks and C blocks inherit the
#FST_EXE value of their calling block. Again, as in the Series 90-70,
#FST_EXE cannot be written.
Format for Fault Locating
References Changed
Compared to the Series 90-70 CPU, syntax for the fault locating references
has changed as follows:
#RACK_00r is now #RACK_000r.
#SLOT_rss is now #SLOT_0rss.
#BUS_rssb is now #BUS_0rssb.
#M_rssbmm is now #M_rssbmmm (adds support for 256 modules).
Existence of old style (Series 90-70) fault locating references will cause
errors to be generated during logic validation. The error generated will have
the following format:
Error 9618: Invalid reference type for operand [LD Block,’_MAIN’: Rung
Slot Restrictions for Analog
Expander Module in RX7i Rack
The following restrictions apply to Analog Expansion Modules in a
PACSystems RX7i rack:
The base module must be in a slot no lower than Slot 4.
The expander module must be in a slot no higher than Slot 11.
No expander module may be in a slot lower than the base module.
Because of these restrictions, and because the 90-70 modules occupy two
slots in the PACSystems RX7i rack, a maximum of three expanders are
possible. (Base in Slot 4, Expanders in Slots 6, 8, and 10 or Base in Slot 5,
Expanders in Slots 7, 9, and 11.) Please note that these restrictions do not
apply to Analog Expansion Modules in Series 90-70 Expansion Racks.
Important Product Information
Genius Bus Controller Restrictions
The following restrictions apply to GBCs in PACSystems RX7i:
The minimum CPU sweep time will be gated by the time it takes the
GBC to refresh its outputs and collect its inputs + 500 microseconds. To
obtain a smaller sweep time, use the SUSIO function block or place the
GBCs in a scan set that has non-default characteristics.
If a %W reference address is used for COMMREQ status or return data,
it must be in the range %W00001 - %W65536.
Storing or clearing a hardware configuration containing two GBCs
attached to the same Genius network may cause a Loss of Device fault
for one of the GBCs. This is caused by the GBCs clearing their SBAs
asynchronously. The user can safely ignore the Loss of Device fault.
PCM (to CPU) Communications
The PCM has a default backplane communications timeout value of 5
seconds. After the PCM has sent a request to the CPU, the PCM applies this
timeout while waiting on a response back from the CPU. In most cases, the
CPU will respond well within the 5–second timeout; however, in certain
instances the CPU can take longer than 5 seconds to respond. These cases
are limited to LOADs or STOREs of program and/or configuration -especially
if blocks in the program are larger than 8 KBytes. Folders containing EXE
blocks (again with *.EXE files >8 KBytes) are most likely to cause problems.
To ensure that the PCMs do not observe backplane timeouts, a file must be
loaded (using termf) to the PCM. The file must be a binary file named
CPU.ENV. The contents of this file are as below (all values are specified in
Once the binary file CPU.ENV (below) is created, use termf to load CPU.ENV
to the PCM. Then execute a soft reset of the PCM. After executing the soft
reset, the PCM’s backplane communications timeout should be 10 seconds.
Note: A copy of the CPU.ENV file can be obtained from
The CPU.ENV file will not be used when a hard reset is performed on
the PCM. With the CPU.ENV file resident in the PCM, a soft reset must
be performed after every hard reset of the PCM. Be aware that it is
possible to issue a soft reset COMMREQ from the Ladder Diagram
application; therefore, the application can be modified to handle the
required reset of PCMs after a power cycle of the PLC system.
LZ. . . . . . . . . .
K . C O D . –b . 6 4 .–t . 2
00 . .C P U L I NK . D C B .
. N U L L: . N U L L : . N U L
Error! Reference source not found.
Backplane Comm window Setting
and Genius Redundancy
When using Genius Redundancy, do not set the backplane communications
window timer to 0. Also be sure to allow enough time for the backplane
communications window to run when using Constant Sweep mode. Ample
backplane communications window time must be available for the GBCs to
exchange information about Genius devices that are lost and added.
Expansion Rack ID
Series 90-70 expansion racks are shipped with the rack ID strapped for
rack 0 (the main rack). If the rack jumper is not changed, the PLC CPU will
not recognize the rack and may not properly identify the error.
Expansion Rack Cable
Connection and disconnection of an expansion rack cable while the CPU is
running should not be attempted. This will cause the PLC to go to the
STOP/HALT state.
Expansion Rack Power
Expansion racks should be powered up at the same time the main rack is
powered up or they should be powered up after the main rack has completed
its power up initialization. Do not power up an expansion rack while the PLC
CPU is running power-up diagnostics.
Timer Operation
Care should be taken when timers (ONDTR, TMR, and OFDTR) are used in
program blocks that are NOT called every sweep. The timers accumulate
time across calls to the sub-block unless they are reset. This means that they
function like timers operating in a program with a much slower sweep than
the timers in the main program block. For program blocks that are inactive for
large periods of time, the timers should be programmed in such a manner as
to account for this catch up feature.
Related to this are timers that are skipped because of the use of the JUMP
instruction. Timers that are skipped will NOT catch up and will therefore not
accumulate time in the same manner as if they were executed every sweep.
Constant Sweep
Constant Sweep time, when used, should be set at least 10 milliseconds
greater than the normal sweep time to avoid any over-sweep conditions
when monitoring or performing on-line changes with the programmer.
Window completion faults will occur if the constant sweep setting is not high
Large Number of COMMREQs Sent
to Module in One Sweep Causes
A large number of COMMREQs (typically greater than 8) sent to a given
board in the same sweep may cause Module Software faults to be logged in
the PLC fault table. The fault group is MOD_OTHR_SOFTWR (16t, 10h) and
the error code is COMMREQ_MB_FULL_START (2). When this occurs, the
“FT” output of the function block will also be set. To prevent this situation,
COMMREQs issued to a given board should be spread across multiple
sweeps so that only a limited number (typically 8 or less) of COMMREQs are
sent to a given board in each sweep. In addition, the FT output parameter
should be checked for errors. If the FT output is set (meaning an error has
been detected), the COMMREQ could be re-issued by the application logic.
C Block Standard Math Functions
do not Set errno
In C Blocks, standard math functions (e.g. sqrt, pow, asin, acos) do not set
errno to the correct value and do not return the correct value if an invalid
input is provided.
Loss of VDD100 or VAL132 After
Multiple Power Cycles
In rare instances, a VDD100 or VAL132 module may not configure after
power has cycled repeatedly in a very brief period of time. A Loss of IO
Module fault will be generated.
In extremely rare instances, this may also cause other modules to fail to
configure, without generating additional loss of module faults. These
additional failures may cause communication with the Ethernet Interface to
The user can recover from either of these cases by turning off power for at
least 5 seconds and then restoring power. This will provide sufficient "offtime" to ensure that all modules can powerup properly.
Important Product Information
Modules not Reset During
Firmware Upgrades
The RX7i currently does not reset any other modules in the system after a
firmware upgrade. This may result in Loss of module faults being generated
for smart modules.
Unable to Communicate Through
Some Third Party Serial Cards
PACS Systems serial ports do not work with some third party serial cards.
Incorrect COMMREQ Status for
Invalid Program Name
The program name for PACSystems is always LDPROG1. When another
program name is used in a COMMREQ accessing %L memory, the error that
is generated is 05D5, which is an invalid block name.
Ethernet Operational Notes
MAC address
Configuration of IP Address is
Required Before Using Ethernet
A label on the rear wall inside the CPU’s
battery compartment identifies the MAC
address assigned to the CPU’s embedded
Ethernet Interface. The label is visible when
the battery is removed from its compartment.
(The battery does not need to be disconnected
to temporarily remove it from the
Battery Pack
MAC Label
located on rear wall of
battery compartment
The Ethernet Interface within the CPU module cannot operate on a network until a
valid IP address is configured. The necessary Ethernet addressing information
must be configured prior to actual network operation, or to recover from inadvertent
changes to the Ethernet addressing data at the Ethernet Interface. Use one of the
following methods to initially assign an IP address:
Connect a serial terminal to the Station Manager port of the PACSystems
RX7i . Then use the CHSOSW command to enter the desired IP address.
For details, see the PACSystems TCP/IP Communications Station Manager
manual, GFK-2225.
Temporarily assign an IP address to the module using the SetIP tool over
the Ethernet network. For details, see TCP/IP Ethernet Communications for
PACSystems, GFK-2224.
The Ethernet Interface automatically obtains a temporary IP Address from a
BOOTP server on the network. For details, see TCP/IP Ethernet
Communications for PACSystems, GFK-2224.
Once a temporary IP address has been set up, the Ethernet Interface can be
accessed over the network (such as by the Machine Edition programming
software). The programmer should then be used to configure the proper IP address
for the Ethernet Interface.
Error! Reference source not found.
Proper IP Addressing is Always
The PACSystems RX7i CPU’s embedded Ethernet Interface must be configured
with the correct IP Address for proper operation in a TCP/IP Ethernet network. Use
of incorrect IP addresses can disrupt network operation for the PACSystems RX7i
and other nodes on the network. Refer to TCP/IP Ethernet Communications for the
PACSystems RX7i, GFK-2224 for important information on IP addressing. When
storing a new HW configuration to the RX7i, be sure that the HW configuration
contains the proper Ethernet addressing data (IP Address, Subnet Mask, and
Gateway IP Address) for the RX7i.
Note: Machine Edition programming software maintains the target IP address
(used to connect the programmer to the target) independent of the contents of the
HW Configuration for that target. The target IP address is set in the Target
Properties in the CME Inspector window. Storing a HW Configuration whose
Ethernet addressing data contains an IP Address that is different from the RX7i
target IP address will change the IP address used by the target RX7i as soon as
the Store operation is completed; this will break the Programmer connection.
Before attempting to reconnect the Programmer, you must change the target IP
address in the Target Properties in the CME Inspector window to use the new IP
address. To regain communication at the former IP address, use the manual
corrective action described above.
Storing a HW Configuration containing default ( or incorrect Ethernet
addressing data to the PACSystems RX7i will result in loss of the Programmer
connection and will require manual corrective action as described above.
Default IP Address (
Attempts to Set IP Address via
The default IP address value (, whether obtained from HW Configuration or
backup configuration, causes the Ethernet Interface to request a temporary IP
address from a BOOTP server device on the network.
LAN Must be Tree, Not Ring
The two Ethernet network ports on the PACSystems RX7i Ethernet Interface must
not be connected, directly or indirectly, to the same network device. The hub or
switch connections in an Ethernet network must form a tree and not a ring;
otherwise duplication of packets and network overload may result. In this situation,
the RX7i Ethernet modules will continually reset.
Reporting of Duplicate IP
The PACSystems RX7i does not log an exception or a fault in the PLC Fault Table
when it detects a duplicate IP address on the network.
Multiple Zero Period EGD
Exchanges May Not Produce
Similar Numbers of Samples
If more than one EGD produced exchange is configured for a production period of
zero, the exchanges may not produce similar numbers of samples. Due to the way
that scheduling occurs when multiple exchanges are scheduled “as fast as
possible,” some zero period exchanges may produce significantly more samples
than others. For more consistent EGD production, configure the produced EGD
exchanges with non-zero production periods.
Changing IP Address While
SRTP Connection Open May
Generate Log Events
Open SRTP Server connections established with a remote SRTP client are not
terminated as expected when the RX7i’s IP address is changed (typically by storing
a new HW Configuration to the RX7i). A Series 90 SRTP client (“SRTP channels”)
reports either a 9690H or 0190H status; the SRTP connection may remain open
until the connection is terminated as a result of a client timeout.
Series 90-70 Datagrams are Not
Series 90-70 datagrams are not supported. This means that Series 90-70 - format
variable list requests from Host Comm Toolkit applications will fail. (Series 90-30 –
format datagrams are supported, but cannot access %P or %L memory in the
AUP Parameter Should Not be
The Advanced User Parameter “wsnd_buf” should not be changed by the user.
Changing the value of this parameter may cause the LAN LED to go out and the
Ethernet Interface to drop connection.
Heavy Load can Block Station
As explained in TCP/IP Communications for PACSystems Station Manager
Manual, GFK-2225, Chapter 1, a heavy EGD and/or SRTP load can block Station
Manager operation.
Important Product Information
One-time delay of EGD
Production (and possibly
Consumption) if more than 24
SRTP Server Connections are
started simultaneously
If more than 24 SRTP Server connections are established simultaneously, EGD
Production may be briefly delayed for each connection after the 24 when the
connections are first made after power is applied. If EGD consume acceleration has
been disabled, then EGD Consumption will also be delayed. The delay only occurs
once when the SRTP Server connection is established for the first time after
Powerup. No delay is experienced for the first 24 SRTP Server connections.
Web Server Browser
Internet Explorer version 4.0 running on Windows 98 will give an error when the
reference table web page is accessed. Web Server operation has been verified
with Internet Explorer version 5.0
Very Heavy EGD
Production/Consumption at
Server May Cause EGD
Command Timeouts
Very heavy EGD production and/or consumption at a server device may cause
EGD command timeout errors when another device attempts to send EGD
commands to that server. If EGD commands must preempt normal production, you
may set the “gcmd_pri” Advanced User Parameter to 2 (see GFK-2224, Appendix
A). Note that by doing so, EGD exchange production may be delayed.
AUP Parameter Name Change
Beginning with Release 2.00, the following Advanced User Parameters have been
renamed to match the Ethernet hardware port identification:
“lduplex1” is changed to “lduplex1a” (Ethernet Port 1A duplex state)
“lduplex2” is changed to “lduplex1b” (Ethernet Port 1B duplex state)
“lspeed1” is changed to “lspeed1a”
(Ethernet Port 1A network speed)
“lspeed2” is changed to “lspeed1b”
(Ethernet Port 1B network speed)
The old parameter names are no longer supported; use of an obsolete parameter
name will result in a configuration processing error and an Ethernet exception
(Entry = 2, Entry 2 = 06).
Existing AUP files using the obsolete parameter names will have to be changed to
use the new parameter names.
SRTP Application Timeouts
Must Accommodate Network
Connection Overhead
The application timeouts within SRTP Channels also include the time needed to
establish and maintain the underlying network and SRTP connection. Examples are
establishing the TCP connection for a new channel, establishing communication
with the remote device, and TCP retransmissions during Channel operations. If the
time needed for TCP connection establishment or maintenance exceeds the userspecified channel application timeout values, an application timeout will occur.
Channel application timeouts are temporary errors; the channel continues to run.
Error! Reference source not found.
Client Channels TCP Resource
The OS Network stack hangs on to the TCP resources associated with a
connection for a period of time after the connection is closed. It applies to the
initiator of the close, which is almost always the client side. This time is referred to
as the “TCP Linger Period”. Once the TCP Linger Period expires (60 seconds in the
current OS implementation), the TCP resources are released. Application
developers using client channels need to be aware of this behavior when designing
their logic. A finite number of TCP resources are allocated to client channels, and if
channel connections are brought up and down so fast that these resources are
depleted, then the application may have to wait until a TCP resource frees up in
order to establish another client channel (a COMMREQ Status of 0xA890 is
returned if no TCP resources are currently available; application should wait and try
SRTP Client Channels provides features that help the user preserve TCP
connections. These include a period time where one can establish an SRTP
Channel and specify the channel to run at a given interval, or run as fast a possible.
One can also specify a number of iterations, or allow the channel to run forever.
Additionally, SRTP Channels allows channel re-tasking of an active channel to the
same remote device, where the parameters of an active channel, such as changing
the channel command type (Read/Write), number of repetitions, time periods, local
memory address, remote memory address, etc. can be changed. SRTP Channels
also allows channel re-tasking of an active channel to a different remote device
(changing the remote device’s IP address, etc.). However, re-tasking to a different
remote device will neither conserve TCP connections, nor save on the time it takes
to create a channel.
Client Channels and Redundant
In a Redundancy System, Client Channel COMMREQs can only be initiated from
the unit that owns the Redundant IP address. Therefore, the user application logic
should use Bit 6 in the LAN Interface Status bit area, “Redundant IP Active” as part
of their enabling logic that drives a client channel COMMREQ.
Idle Modbus/TCP connection
between a Series 90 and a
PACSystems may be
prematurely terminated
An idle Modbus/TCP connection between a Series 90 and a PACSystems may be
prematurely terminated. There is an incompatibility between the TCP "Keep-Alive"
timer values on the PACSystems Ethernet Interfaces and Series 90 Ethernet
Interfaces. The issue is that the default value of the keep-alive timer for the Series
90 modules is set to a much higher value than for the PACSystems.
To keep TCP connections open between a Series 90 Ethernet Interface and a
PACSystems Ethernet Interface, the Series 90 Interface Advanced User Parameter
wkal_time should be set to the value 750 to match that of the PACSystems. With
this change, TCP connections remain open indefinitely. Note that this same issue
occurs for SRTP Client Channels that have infrequent traffic and can be resolved
by using the same technique.
Attempt to open 17 or more
Modbus server connections
may appear successful
If more than the maximum 16 supported Modbus Server Connections are
attempted, the TCP connection may succeed, but no data may be subsequently
Installation in Hazardous Locations
The following information is for products bearing the UL marking for Hazardous Locations:
Warning - explosion hazard - substitution of components may impair suitability for class i, division 2;
Warning - explosion hazard - when in hazardous locations, turn off power before replacing or wiring
modules; and
Warning - explosion hazard - do not disconnect equipment unless power has been switched off or
the area is known to be nonhazardous.
Equipment labeled with reference to class i, groups a, b, c, & d, div. 2 hazardous locations is suitable
for use in class i, division 2, groups a, b, c, d or non-hazardous locations only.
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