PACSystems RX3i CPUs, IC695CPU320

PACSystems RX3i CPUs, IC695CPU320
PACSystems™ RX3i
IC695CPU320-AB
Central Processing Unit
GFK-2488A
February 1, 2008
The RX3i CPU can be used to perform real time
control of machines, processes, and material handling
systems. The CPU communicates with the
programmer and HMI devices via a serial port using
SNP Slave protocol. It communicates with I/O and
smart option modules over a dual backplane bus that
provides:
■
■
CPU OK
I/O FORCE
RUN
OUTPUTS ENABLED
BATTERY
SYS FLT
CPU320
High-speed, PCI backplane for fast throughput of
new advanced I/O.
RESET
STOP
Serial backplane for easy migration of existing
Series 90-30 I/O
RUN I/O
ENABLE
RUN OUTPUT DISABLE
COM 1
Features
■
Contains 64 Mbytes of battery-backed user
memory and 64 Mbytes of non-volatile flash user
memory.
■
Provides access to bulk memory via reference
table %W.
■
Configurable data and program memory.
■
Programming in Ladder Diagram, Structured
Text, Function Block Diagram, and C.
■
Supports auto-located Symbolic Variables that
can use any amount of user memory.
■
Reference table sizes include 32Kbits for discrete
%I and %Q and up to 32Kwords each for analog
%AI and %AQ.
■
Supports most Series 90-30 modules and
expansion racks. For a list of supported I/O,
Communications, Motion, and Intelligent
modules, see the PACSystems RX3i System
Manual, GFK-2314.
■
Supports up to 512 program blocks. Maximum
size for a block is 128KB.
■
In-system upgradeable firmware.
■
Two serial ports: an RS-485 serial port and an
RS-232 serial port.
■
Ethernet communications via the rack-based
Ethernet Interface module (IC695ETM001). For
details on Ethernet capabilities, refer to TCP/IP
Ethernet Communications for PACSystems
User’s Manual, GFK-2224.
■
PLC time synchronization to SNTP Time Server
on Ethernet network when used with Ethernet
Release 5.0 or later module.
COM1 ACTIVE
COM2 ACTIVE
COM 2
BATT
Ordering Information
Description
Catalog Number
RX3i 1GHz Celeron M CPU
IC695CPU320
Auxiliary Battery Module
IC693ACC302
RX3i Power Supplies
40 Watt High Capacity Universal AC
40 Watt High Capacity 24 VDC
For additional power supplies, see the
PACSystems RX3i System Manual,
GFK-2314.
IC695PSA040
IC695PSD040
[Optional] RS-232 Cable
IC200CBL001
Rx3i Standard 12 Slot Rack
IC695CHS012
Rx3i Standard 16 Slot Rack
IC695CHS016
Note:
For Conformal Coat option, please consult the
factory for price and availability.
2
RX3i CPU320
GFK-2488A
CPU320 Specifications
Battery: Memory retention
Estimated 30 days using an IC693ACC302 Auxiliary Battery Module
at 20ºC.
For details on the operation of the Auxiliary Battery Module, refer to the
datasheet, GFK-2124.
Note: The IC698ACC701 Lithium Battery Pack is not compatible with
the CPU320.
Program storage
Up to 64 Mbytes of battery-backed RAM
64 Mbytes of non-volatile flash user memory
Power requirements
+3.3 VDC: 1.0 Amps nominal
+5 VDC: 1.2 Amps nominal
Operating Temperature
0 to 60°C (32°F to 140°F)
Floating point
Yes
Boolean execution speed, typical
0.047 ms per 1000 Boolean contacts/coils
Time of Day Clock accuracy
Maximum drift of 2 seconds per day
Elapsed Time Clock (internal timing)
accuracy
0.01% maximum
Embedded communications
RS-232, RS-485
Serial Protocols supported
Modbus RTU Slave, SNP, Serial I/O
Backplane
Dual backplane bus support: RX3i PCI and 90-30-style serial
PCI compatibility
System designed to be electrically compliant with PCI 2.2 standard
Program blocks
Up to 512 program blocks. Maximum size for a block is 128KB.
Memory
%I and %Q: 32Kbits for discrete
%AI and %AQ: configurable up to 32Kwords
%W: configurable up to the maximum available user RAM
Symbolic: configurable up to 64 Mbytes
Note
For environmental specifications and compliance to standards (for example, FCC or European Union
Directives), refer to the PACSystems RX3i System Manual, GFK-2314.
Product Documentation
PACSystems CPU Reference Manual, GFK-2222
TCP/IP Ethernet Communications for PACSystems User’s Manual, GFK-2224
TCP/IP Ethernet Communications for PACSystems Station Manager Manual, GFK-2225
PACSystems RX3i System Manual, GFK-2314
C Programmer’s Toolkit for PACSystems User’s Manual, GFK-2259
Proficy® Machine Edition Getting Started, GFK-1868
Proficy® Logic Developer – PLC, GFK-1918
RX3i CPU
3
GFK-2488A
Release Information
Firmware release 5.11 resolves an issue where Series 90-30 Smart modules in the main rack do not transition to stop
mode after a Loss of Module fault is logged. For details refer to “CPU Problems Resolved by Firmware Version 5.11”
on page 4.
Release History
Catalog Number
Firmware Version
Date
IC695CPU320-AB
5.11
Feb, 2008
IC695CPU320-AA
5.10
Nov. 2007
Upgrades
The IC695CPU320 can be upgraded to firmware version 5.11 using upgrade kit 82A1145-MS10-000-A2, available at
http://www.gefanuc.com/support.
CPU Functional Compatibility
Subject
Description
Programmer Version
Requirements
Proficy® Machine Edition Logic Developer 5.70 SIM2 Build A is required to
use the Release 5.10 features with the RX3i CPU320
C Toolkit Compatibility
C Toolkit Release 5.00 Build 16C1 is required when the PACSystems CPU
contains firmware Release 5.00 or later.
Note: All C blocks must be recompiled using the new toolkit before
downloading to a PLC CPU that contains Release 5.00 or later
firmware.
Backplanes, power supplies and
system modules
As listed in the PACSystems RX3i System Manual, GFK-2314C or later.
Series 90-30 Expansion Rack
Compatibility
The PACSystems RX3i supports Series 90-30 expansion racks, both local
and remote.
PACSystems RX3i CPUs do not operate in a Series 90-30 Rack.
Series 90-30 Main Rack
Compatibility
Series 90-30 Main Racks cannot be used in a PACSystems RX3i system.
Series 90-30 CPUs do not operate in PACSystemsRX3i Racks.
Isolated 24V power
In applications that use the IC69xALG220/221/222, consult PACSystems
RX3i System Manual, GFK-2314 for details of wiring the 24V power.
COMMREQ to PBM300
In Release 3.0, the behavior of the COMMREQ fault output on a
COMMREQ sent to the PROFIBUS master module IC695PBM300 had
been changed to be compatible with the Series 90-30 CPU366 PROFIBUS
Master. Previously, the fault output is enabled when the module receives a
COMMREQ and it is busy. Now, the busy condition does not result in the
fault output enabled.
4
RX3i CPU320
GFK-2488A
Subject
Description
Recommended IC200ALG240
revision
When a VersaMax™ system Genius® Network Interface Unit
(IC200GBI001) interoperates with a Genius Bus Controller located in a
PACSystems PLC, and the VersaMax system contains an IC200ALG240
Analog Input Module, it is recommended to update the IC200ALG240
firmware to at least Revision 1.10.
However, it is preferable to update the IC200ALG240 firmware to Revision
1.20, which contains resolutions for all issues found after Revision 1.10.
Upgrade kits are available at http://www.gefanuc.com/support. Use
firmware update kit 44A752313-G01 to update the IC200ALG240 firmware
to Revision 1.10, or upgrade kit 44A752313-G02 to update the
IC200ALG240 firmware to Revision 1.20.
Configuration of IC694MDL754
Always configure 16 bits of module status when using this module.
Configuring 0 bits of module status will result in invalid data in the module’s
ESCP status bits.
Problems Resolved by Firmware Version 5.11
Subject
Description
Series 90-30 Smart Modules in a
main rack now correctly transition to
stop mode after a “Loss of Module”
fault is logged.
The initial release of the RX3i CPU320 did not notify a Series 90-30 Smart
Module in the main rack when the CPU transitioned to STOP mode if the
CPU had logged a Loss of Module fault against that Smart Module. When
this condition occurred any Series 90-30 Smart module that had a “Loss of
Module” fault logged against it continued to drive outputs when the CPU
(and the System) had stopped.
This issue is corrected in Release 5.11
CPU Restrictions and Open Issues
Subject
Description
Hot swapping some analog
modules slowly causes these
modules to delay in reporting
input values.
Occasionally during a hot insertion (hot swap) of IC695 Non-Isolated Analog
Input Modules, input channels may take up to 2 seconds to reflect actual input
values after the module OK bit is enabled in the module status word. This delay
has only occurred when the hot insertion has been done slowly (i.e.
approximately 1.5 seconds to insert the module)
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.
Simultaneous clears, loads
and stores not supported
Currently, PACSystems CPUs do not support multiple programmers changing
CPU contents at the same time. The programming software may generate an
error during the operation. Simultaneous loads from a single PLC are allowed.
Hardware configuration not
equal after changing target
name
If the user stores a hardware configuration to flash that sets “Logic/Config Power
up Source” 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 equal.
PLC and IO fault tables may
need to be cleared twice to
clear faulted state
Both PLC and IO fault tables may 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.
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.
RX3i CPU
5
GFK-2488A
Subject
Description
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.
SNP ID not always provided
Unlike the Series 90-30, the RX3i CPU’s SNP ID will not appear in the Machine
Edition programmer Show Status display. Service Request 11 will always return
zeros.
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.
Must have logic if poweringup from flash
If the application will configure the CPU to retrieve the contents of flash memory
at power-up, be sure to include logic along with hardware configuration when
saving to flash memory.
Otherwise, after the write to flash memory is completed, if power is removed from
the CPU then turned back on, the CPU will not retrieve the hardware
configuration saved in flash memory during the next power-up, and the Machine
Edition programmer will report “Config NE” (configuration not equal) after
reconnecting to the CPU.
Two loss of module faults for
Universal Analog Module
Occasionally, the hot removal of the Universal Analog Input Module
(IC695ALG600) results in two “Loss of I/O Module” faults instead of one.
Power up of HSC may take as
long as 20 seconds
As power is applied to a 90-30 High-Speed Counter, the "module ready" bit in the
status bits returned each sweep from the module may not be set for as long as
20 seconds after the first PLC sweep, even though there is no "loss of module"
indication. I/O data exchanged with the module is not meaningful until this bit is
set by the module. For details, see “Data Transfer Between High Speed Counter
and CPU” in the Series 90-30 High Speed Counter User’s Manual, GFK-0293C.
Info fault at power up
Intermittently during power-up, an Informational non-critical CPU software fault
may be generated with fault extra data of 01 91 01 D6. This fault will have no
effect on the normal operation of the PLC. But, if the hardware watchdog timer
expires after this fault and before power has been cycled again, then the outputs
of I/O modules may hold their last state, rather than defaulting to zero.
Extended memory types for
IO triggers
%R, %W and %M cannot be used as IO triggers.
Possible Machine Edition
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 behavior.
SNP Update Datagram
message
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.
Series 90-30 GBC may not
resume operation after power
cycle
In rare instances, a Series 90-30 Genius Bus Controller module in an expansion
rack may not resume normal operation after a power cycle of either the
expansion rack containing the GBC module or the main rack. To recover the
GBC, the expansion rack containing the GBC must be power cycled.
Configuration of third-party
modules
Do not specify a length of 0 in the configuration of a third-party module. The
module will not work properly in the system.
Power supply status after
CPU firmware update
The PLC will report a “Loss of or missing option module” fault for the
IC695PSD140 RX3i power supply following an update of PLC CPU firmware.
Also, the slot will appear empty in the programmer’s online status detail view. The
power supply continues to operate normally. Power cycle to restore normal status
reporting.
Power supply status after
power cycling
Rarely, turning a power supply on or off may not result in an add or loss fault.
Also, the slot will appear empty in the programmer’s online status detail view. The
power supply continues to operate normally. Power cycle to restore normal status
reporting.
6
RX3i CPU320
GFK-2488A
Subject
Description
Do not 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".
Missing “Loss of terminal
block” fault
The IC695ALG600/608/616 analog input modules do not produce a “Loss of
terminal block” fault when hardware configuration is stored or the module is hotinserted, and the terminal block is not locked into place.
Sequence Store Failure
In systems with very large hardware configurations, it is possible to encounter a
“PLC Sequence Store Failure” error when writing the configuration to flash. To
work around this error, either:
1. Perform an explicit clear of flash prior to performing the write.
2. Increase the operation timeout used by Machine Edition software prior
to performing the write.
IC694MDL754: Must configure
module status bits
Always configure 16 bits of module status when using this module. Configuring 0
bits of module status will result in invalid data in the module’s ESCP status bits.
IC695ALG600 lead resistance
compensation setting
A configuration store operation will fail if a channel is configured for 3-wire RTD
and Lead Resistance Compensation is set to Disabled. A Loss of Module fault
will be logged in the I/O Fault table at the end of the store operation. To recover
the lost module, change the configuration to enable Lead Resistance
Compensation and power cycle the module
WinLoader may stop
operating
On computers running Windows 2000 and using some versions of Symantec
Antivirus protection, WinLoader will fail if used in advanced mode. Recovery
requires cycling the computer's power.
Simultaneous upload and
download failure
While downloading a Machine Edition folder to the target over a serial connection
established between a Machine Edition session and the target, a simultaneous
upload from the same target in a second Machine Edition session established
over Ethernet will fail with Error 8523: Unknown Upload Exception.
Issues Related to the IC693DNM200 DeviceNet Master Module
Please see GFK-2194D or later for open issues related to the IC693DNM200 DeviceNet Master Module.
CPU Operational Notes
Subject
Description
Length of Serial I/O
buffer
(Release 5.10 or later) The "Set Up Input Buffer Function" always allocates a buffer
containing 2049 bytes. This is one byte more than previous PACSystems releases.
Important Installation
Instructions for Battery
An IC693ACC302 battery module is recommended for use with the CPU. When
installing the battery, do not connect the battery until the CPU is installed in the rack
and the rack is powered on. The battery may then be attached to either of the two
terminals in the battery compartment. Once that is done, the CPU may be powered
down and normal battery back up operation will begin. To save battery life, do not
connect the battery for the first time until the CPU is powered up.
Note: If installing a battery when there currently is no battery installed, the battery
must be installed while the CPU has power. Failure 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, remove the battery, power cycle the CPU and then install the
battery.
Small batteries that fit in the battery compartment on the faceplate are not
recommended for use with the CPU.
RX3i CPU
7
GFK-2488A
Subject
Description
Indication of low
battery capacity
When power is cycled to a PLC with a battery attached, a “Corrupted user memory”
fault (group 130, error code 7) will appear in the CPU fault table when the battery
capacity is low.
LD-PLC operations
Machine Edition LD-PLC no longer supports a function that connects to the PLC,
downloads, then disconnects from the PLC. The connect and download functions are
now separate. To perform a download to the PLC, you must first connect to the PLC.
Changing IP address
of Ethernet Interface
while connected
Storing a hardware configuration with a new IP address to the RX3i while connected
via Ethernet will succeed, then immediately disconnect because the RX3i is now
using a different IP address than the Programmer. You must enter a new IP address
in the Target Properties in the Machine Edition Inspector window before reconnecting.
Duplicate station
address for modbus
will conflict with other
nodes
The default serial protocol for the RX3i 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.
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 enough.
Large number of
COMMREQs sent to
module in one sweep
causes faults
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 COMM_REQ 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.
Upgrading firmware
The process of upgrading the CPU firmware with the WinLoader utility may fail when
multiple IO modules are in the main rack, 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.
The Winloader initial connect baud rate is fixed at 19200 baud. Note that the firmware
download will occur at 115.2K baud by default.
Note that if you have hyperterm open on a port, and then try to use Winloader on the
same port, Winloader will often say “Waiting for Target” until the hyperterm session is
closed.
Hot Swap
Hot Swap of power supplies or CPUs is not supported in this release
8
RX3i CPU320
GFK-2488A
Subject
Description
No serial communication
with CPU
Warning
The following combination of circumstances may render serial communications with
the CPU impossible:
Ethernet module is not present in main rack.
User configuration disables the Run/Stop switch
User configures the power up mode to Run or Last
Logic is stored in FLASH and user configures CPU to load from FLASH on
powerup.
User application issues COMMREQs that set the protocol on both serial ports to
something that does not permit communications to the Machine Edition
programmer.
Incorrect COMMREQ
status for invalid
program name
The program name for PACSystems is always "LDPROG1". When another program
name is used in a COMM_REQ accessing %L memory, an Invalid Block Name
(05D5) error is generated.
FANUC I/O Master and
Slave operation
Scan sets on the master do not work properly for the first operation of the scan set
after entering RUN mode. They do work properly for subsequent scans.
After downloading a new hardware configuration and logic, a power cycle may be
required to resume FANUC I/O operation.
Use PLCs of similar performance in FANUC I/O networks. If a master or slave is
located in an RX3i system, the other PLCs should be RX3is or Series 90-30
CPU374s.
Repeated power up/down cycles of an expansion rack containing FANUC I/O slaves
may result in failure of the slaves’ operation, with the RDY LED off.
Lost count at power up
for Special IO Processor
The special IO Processor (IC693APU305) will lose the first count after every power up
or every time the module receives a configuration.
COMMREQ Status words
declared in bit memory
types must be bytealigned
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 next-lowest 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 3.50
requires configuration of COMMREQ Status Words in bit memory types to be bytealigned. For example if the user specified status bit location of %I3, the CPU aligns
the status bit location at %I1. Release 3.50 firmware requires the user to specify the
appropriate aligned address (%I1) to ensure that the utilized location is appropriate for
their application. Note that the actual reference location utilized is not changed, but
now is explicitly stated for the user.
RX3i CPU
9
GFK-2488A
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 CONNECT OR 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
The tightening torque range for the control terminals is 9.6-11.5 in. lb. Use only wire rated for 90°C. Be sure to
observe any additional ratings that are provided with the modules.
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