GE Intelligent Platforms. Programmable Control Products. PACSystems RX3i. I/O Link Modules. User Manual, GFK May 2010

Transcription

1 GE Intelligent Platforms Programmable Control Products PACSystems RX3i I/O Link Modules User Manual, GFK-2358 May 2010

2 GFL-002 Warnings, Cautions, and Notes as Used in this Publication Warning Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use. In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used. Caution Caution notices are used where equipment might be damaged if care is not taken. Note: Notes merely call attention to information that is especially significant to understanding and operating the equipment. This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware and software systems. GE Intelligent Platforms assumes no obligation of notice to holders of this document with respect to changes subsequently made. GE Intelligent Platforms makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply. * indicates a trademark of GE Intelligent Platforms, Inc. and/or its affiliates. All other trademarks are the property of their respective owners. Copyright 2009 GE Intelligent Platforms, Inc. All Rights Reserved

3 Contact Information If you purchased this product through an Authorized Channel Partner, please contact the seller directly. General Contact Information Online technical support and GlobalCare Additional information Solution Provider 1H2Hhttp:// 3Hhttp:// Technical Support If you have technical problems that cannot be resolved with the information in this guide, please contact us by telephone or , or on the web at 5Hwww.ge-ip.com/support Americas Online Technical Support 6H7Hwww.ge-ip.com/support Phone International Americas Direct Dial Technical Support Customer Care Primary language of support Europe, the Middle East, and Africa Online Technical Support (if toll free 800 option is unavailable) English 12H13Hwww.ge-ip.com/support Phone EMEA Direct Dial Technical Support Customer Care Primary languages of support (if toll free 800 option is unavailable or if dialing from a mobile telephone) 14H15Hsupport.emea.ip@ge.com 16H17Hcustomercare.emea.ip@ge.com English, French, German, Italian, Czech, Spanish Asia Pacific Online Technical Support Phone Technical Support Customer Care 18H19Hwww.ge-ip.com/support (India, Indonesia, and Pakistan) 20H21Hsupport.cn.ip@ge.com (China) 22H23Hsupport.jp.ip@ge.com (Japan) 24H25Hsupport.in.ip@ge.com (remaining Asia customers) 26H27Hcustomercare.apo.ip@ge.com 28Hcustomercare.cn.ip@ge.com (China)

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5 Contents Chapter 1 Introduction System Overview Features of the GE I/O Link Master Devices on the I/O Link Slave Devices on the I/O Link PACSystems RX3i I/O Link Modules Chapter 2 Module Descriptions I/O Link Interface Module: IC694BEM Module Description I/O Link Master Module: IC694BEM Module Description Chapter 3 Installation Setting the Jumper on an I/O Link Interface Module Installing Modules Completing the I/O Link Network Cable Types for the I/O Link Cable Lengths on the I/O Link Serial Port Pin Assignments Cable Diagram, No Optical Adapter Optical Adapter Optical Adapter Installation Cable Diagram, Electrical Cable to Optical Adapter Starting Up the I/O Link Master Module Chapter 4 Configuration Configuring an I/O Link Slave Module Configuring an I/O Link Master Module Configuring Input and Output Defaults Making Input Assignments for the I/O Link Master Assigning Output References for the I/O Link Master Configuration Worksheet for the I/O Link Master and its Slaves Configuring Slave Devices on the I/O Link Chapter 5 Operation Operation of the I/O Link Structure of Data Sent by the Master Data Returned by Slaves CPU Interface in an RX3i I/O Link Slave System CPU Interface in an RX3i I/O Link Master System Master Begins Sending Data GFK-2358 v

6 Contents Slaves Return Data to the I/O Link Master Module Programming for an I/O Link Master Module Fault Handling on the I/O Link Network Fault Handling, RX3i I/O Link Master Module Fault Handling, RX3i I/O Link Interface Module (Slave) vi PACSystems RX3i I/O Link Modules April 2005 GFK-2358

7 Chapter 1 Introduction This chapter is an overview of the PACSystems RX3i I/O Link modules and I/O Link systems. The rest of the manual describes both modules in detail, and explains installation and configuration procedures. Chapter 2, Module Descriptions. This chapter describes the I/O Link Modules. Chapter 3, Installation. This chapter gives instructions for installing I/O Link Modules. It also explains how to connect the I/O Link network and start up the link. Chapter 4, Configuration describes the selectable parameters of the RX3i I/O Link modules, and explains how to configure the I/O Link. Chapter 5, Operation describes data exchanges on the I/O Link, and summarizes what happens if an error occurs on the I/O Link network. This chapter also describes the formats of the status and I/O data for the I/O Link Master Module and the I/O Link. For more information about RX3i products and systems, please refer to the manuals listed below. GFK-2222 GFK-2314 PACSystems CPU Reference Manual PACSystems RX3i System Manual Using Series I/O Link Modules in an RX3i System This manual describes the use of PACSystems RC3i I/O Link Modules in an RX3i System. Series I/O Link Modules are functionally-equivalent; they can be used an RX3i system in the same way. GFK

8 1 System Overview The proprietary GE I/O Link is a serial interface that provides high speed exchange of I/O data between the master and up to 16 slaves. Features of the GE I/O Link 1.5Mhz rate, 2ms update Up to 16 slaves Up to 2K of I/O per master 10 Meters with RS Meters with fiber optic cable between each slave Master Devices on the I/O Link Typical masters on the I/O Link include all modern GE CNCs and Power Mates, as well as PACSystems controllers and Series 90 PLCs equipped with I/O Link Master Modules. An Operator Panel and Power Mate would normally run as a slave under the command of a CNC. Typically, the PLC is used as a slave to the CNC. This arrangement allows small packets of data to be exchanged between a CNC, devices such as Power Mates, and a PLC system. Slave Devices on the I/O Link Typical items running under the control of an I/O Link master can include clusters of I/O (such as I/O Model A and Connector Panel I/O), PACSystems and Series 90 PLCs with I/O Link Interface (slave) modules, and Operator Panels that are I/O Link-compatible. PACSystems RX3i I/O Link Modules Two types of PACSystems RX3i I/O Link Modules are available: RX3i I/O Link Master Module: IC694BEM321: The RX3i I/O Link Master module (IC694BEM321) allows a PACSystems RX3i controller to act as a master on an I/O Link. It can exchange up to 1024 inputs and 1024 outputs with slaves on the link. RX3i I/O Link Module (slave): IC694BEM320: The RX3i I/O Link Interface Module (IC694BEM320) allows a PACSystems RX3i controller to act as a slave on the I/O Link network. It can exchange either 32 or 64 inputs and outputs with the master. See chapter 2 for descriptions of the RX3i I/O Link modules. 1-2 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

9 1 The illustration below shows a simple I/O Link system. It includes a PACSystems RX3i controller used as a master with one I/O Link. On the I/O Link are three Power Mates and another RX3i used as slaves. PACSystems RX3i with I/O Link Master Module IC694BEM321 as Master I/O Link PowerMates as Slaves PACSystems RX3i with I/O Link Interface Module IC694BEM320, as Slave I/O Link GFK-2358 Chapter 1 Introduction 1-3

10 1 As master, a PACSystems controller might communicate with a group of CNCs in "cluster". Each CNC could in turn be the master with respect to its own operator panel. The system might include Power Mates running as slaves under the PLC master or under a CNC master, depending on the application. PACSystems RX3i with three I/O Link Master Modules IC694BEM321 controlling three I/O Links CNCs I/O Link 3 Operator Panels I/O Link 1 I/O Link 2 I/O Link 1 If there are two masters on a single I/O Link, they have to interface via an I/O Link Master to Master Connection Unit catalog number A20B Some CNCs support two I/O Links within their hardware. They can run the "downstream" appliances (like Operator Panels) on one I/O Link, and communicate with "upstream" devices (like PLCs and Power Mates) on the other. 1-4 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

11 Chapter 2 Module Descriptions This chapter describes I/O Link Modules for PACSystems RX3i: I/O Link Module I/O Link Interface Module I/O Link Master Module Catalog Number IC694BEM320 IC694BEM321 GFK

12 2 I/O Link Interface Module: IC694BEM320 OK RDY IC694BEM320 I/O LINK JD1B JD1A The RX3i I/O Link Interface Module operates as a slave on a GE I/O Link network. It can exchange either 32 or 64 inputs and outputs with the master. Possible types of master on the link include PACSystems, Series 90-30, and Series PLCs, a GE Series 15, Series 16, or Series 18 CNC, a GE Series 0 Model C CNC, or a GE F D Mate CNC. An I/O Link Interface Module can be installed in any available backplane slot in an RX3i or Series PLC. The maximum number of I/O Link Interface Modules that can be installed in the backplane depends on the power that is available from the power supply. To determine the exact number of modules allowed in an RX3i system, see the information on power supplies in the Power Supplies chapter 3 of the PACSystems RX3i System Manual (GFK-2314). Usually, when there are multiple I/O Link Interface Modules in the same system, they are on separate I/O Links. However, it is possible to have more than one I/O Link Interface Module in the system connected to the same link, if that suits the needs of the application. Module Specifications Module type LEDs RX3i module, providing I/O Link communications with I/O Link master. OK, RDY I/O Points 32 or 64, jumper selectable +5V current without Optical Adapter connected: 205mA with Optical Adapter: 405 ma 2-2 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

13 2 Module Description The I/O Link Interface module is a standard RX3i module. It plugs easily into the PLC backplane. Instructions for module installation are given in chapter 3. The module s front cover is removable. A jumper plug inside the front cover is used to set up the module as a 32 point or 64 point I/O module. The factory default is 32. OK (LED) RDY (LED) JUMPER PLUG JD1B (CONNECTOR) JD1A (CONNECTOR) LATCH FRONT COVER JP1 To select 32 inputs and outputs, the jumper should be on the top and middle pins as shown at left I/O To select 64 inputs and outputs, the jumper should be on the middle and 3 64 bottom pins. LEDs The module has two LEDS that show its operating and communications status. OK: RDY: indicates the module s operating status. indicates the module s communications status. After power up, the OK LED should remain ON. The RDY LED turns ON after the I/O Link master has established communications with the module. Serial Ports The front of the module has two 20 pin connectors that are used to attach the I/O Link cable. One connector is for the cable to the previous device on the link either the master or another slave. The other connector is for the cable to the next slave on the link, if there is one. See chapter 3 for more information. Signal levels are RS422/485 compatible. GFK-2358 Chapter 2 Module Descriptions 2-3

14 2 I/O Link Master Module: IC694BEM321 The RX3i I/O Link Master module (IC694BEM321) allows a PACSystems RX3i controller to act as a master on a proprietary GE I/O Link. The master can receive 1024 discrete inputs from slaves, and send up to 1024 discrete outputs. An I/O Link Master Module can be installed in any available I/O slot in an RX3i or Series system. For best performance, it should be installed in the Main Backplane or in an Expansion Backplane. The maximum number of I/O Link Master Modules that can be installed in the backplane depends on the power that is available from the power supply. To determine the exact number of modules allowed in an RX3isystem, see the information on power supplies in the Power Supplies chapter 3 of the PACSystems RX3i System Manual (GFK 2314). If there are multiple I/O Link Master Modules in the same PLC system, they must be on separate I/O Links. Module Specifications Module type: I/O Points: +5V current required: PACSystems RX3i controller module, providing I/O Link communications with up to 16 slaves. Up to 1024 inputs and 1024 outputs without Optical Adapter connected: 415mA with Optical Adapter: 615mA 2-4 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

15 2 OK ACTV CFG IC694BEM321 I/O LINK MASTER LINK RESTART RS 422/ RS 485 The RX3i I/O Link Master module (IC694BEM321) allows a PACSystems RX3i controller to act as a master on a proprietary GE I/O Link. The master can receive 1024 discrete inputs from slaves, and send up to 1024 discrete outputs. An I/O Link Master Module can be installed in any available I/O slot in an RX3i or Series system. For best performance, it should be installed in the Main Backplane or in an Expansion Backplane. The maximum number of I/O Link Master Modules that can be installed in the backplane depends on the power that is available from the power supply. To determine the exact number of modules allowed in an RX3isystem, see the information on power supplies in the Power Supplies chapter 3 of the PACSystems RX3i System Manual (GFK 2314). If there are multiple I/O Link Master Modules in the same PLC system, they must be on separate I/O Links. Module Specifications Module type: JD1A GFK-2358 Chapter 2 Module Descriptions 2-5

16 2 Module Description The I/O Link Master module, IC694BEM321, is a standard PACSystems RX3i module. It plugs easily into the PLC s backplane. The latch on the bottom of the module secures it in position. The module s front cover is removable. OK LED ACTV LED CFG LED Link Restart Pushbutton Link Restart Pushbutton Fuse JD1A Connector Latch Front Cover Fuse A fuse protects the +5 volt signal pins used by the Optical Adapter cable. It is a replaceable 0.5A fast blow fuse (5mm diameter x 20mm length). The cutaway drawing on the right above shows the location of the fuse, directly below the Restart pushbutton. LEDs The module has three LEDS that show its operating and communications status. OK CFG ACTV Meaning off off off No power to module, or powerup in progress on off off Module powered up but not configured on on off Module powered up and configured with minimum configuration (input status reference assigned and output status reference assigned), but link is not yet active, or has been activated but has gone down on on on Normal operation with active link After power up, the OK LED should stay ON. The CFG LED goes on after the CPU supplies the module configuration. The ACTV LED goes on when link communications have been established. 2-6 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

17 2 Restart Pushbutton The LINK RESTART pushbutton can be used to restart the operation of the link if a failure occurs. Pushing the LINK RESTART button while the link is operating has no effect. If the link stops operating, all slaves must be power cycled before using the LINK RESTART pushbutton to restart operation of the link. Serial Port The front of the module has one 20 pin, Honda type connector, used for connection to the first slave on the I/O Link. Signal levels are RS422/485 compatible. Note GFK-2358 Chapter 2 Module Descriptions 2-7

18 Chapter 3 Installation This chapter explains how to install I/O Link Modules. It also explains how to connect the I/O Link network and start up the link. Setting the Jumper on an I/O Link Interface Module Installing Modules Completing the I/O Link Network Cable types for the I/O Link Cable Lengths on the I/O Link Serial Port Pin Assignments Cable Diagram, No Optical Adapter Optical Adapter Optical Adapter Installation Cable Diagram, Electrical Cable to Optical Adapter Startup For More Information Please refer to the PACSystems RX3i System Manual, GFl-2314, for RX3i system and module installation instructions. GFK

19 3 Setting the Jumper on an I/O Link Interface Module The jumper on the I/O Link Interface (slave) module, IC694BEM320, is used to set it up for either 32 point or 64 point input/output module operation. The factory default is 32. Before installing the module on a backplane, check the jumper setting to be sure it is correct for your application. The upper position selects 32 I/O. The lower position selects 64 I/O. JP I/O 3 64 To check or change the jumper position, follow these steps: 1. Remove the module s front cover. To do that, grasp the cover, placing a moderate amount of pressure on the cover sides while pulling it away from the module. 2. Check the jumper position. To select 32 inputs and outputs, the jumper should be on the top and middle pins. To select 64 inputs and outputs, the jumper should be on the middle and bottom pins. 3. Replace the cover by pressing it back onto the module. 3-2 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

20 3 Installing Modules Be sure the module catalog number matches the intended slot configuration. Holding the module firmly, align the module with the correct slot and connector. Engage the module s rear pivot hook in the notch on the top of the backplane (1). Swing the module down (2) until the module s connector engages the backplane s backplane connector, and the release lever on the bottom of the module snaps into place in the bottom module retainer (3). Visually inspect the module to be sure it is properly seated Removing Modules Locate the release lever at the bottom of the module and firmly press upward (1), toward the module. While holding the module firmly and fully depressing the release lever(s), pivot the module upward until its connector is out of the backplate (2). Lift the module up and away from the backplane to disengage the pivot hook GFK-2358 Chapter 3 Installation 3-3

21 3 Completing the I/O Link Network The I/O Link cable connects the master, through each slave, to the last slave in the network in a daisy chain arrangement. The slaves are numbered according to their positions in the chain. Slave 0 is the slave closest to the master. Using the correct cable type, connect the I/O Link Master Module to the first slave ( slave 0 ). Connect any additional slaves (up to a total of 16 slaves) in the same manner. Be sure the order in which modules are connected to the I/O Link cable matches the order to be used during configuration. Notice that the cables are marked JD1A on one end, and JD1B on the other. I/O Link Master Module I/O Link Interface (Slave) Module JD1B JD1A JD1A JD1B JD1A Connects to next slave Notes If the link includes an RX3i or Series I/O Link Interface module used as a slave, attach the cable from the previous device to the top connector on the I/O Link Interface Module (BEM320) as shown above. Be sure the cable routing between modules on the I/O Link matches the configuration expected by the master. The excellent noise reduction of the cable used for the I/O Link allows it to be mixed with other signaling systems and 120 VAC control circuits, without needing added shielding or conduits. Conservative wiring practices, as well as national and local codes, require physical separation between control circuits and power distribution or motor power. Refer to sections 430 and 725 of the National Electric Code. 3-4 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

22 3 Cable Types for the I/O Link The I/O Link consists of a full duplex serial data communications channel. Physically, the link consists of two twisted pairs of wire and a signal ground conductor. These wires are contained in a cable that has an overall shield. Signals are of the differential type and a wire pair is used for each signal. Signal levels are compatible with specification EIA RS 422/RS 485. The signal baud rate is 1.5 Mbaud maximum. The following cables and connectors can be used to complete the I/O Link between devices. Item Catalog Number Vendor Description Cable A03B 0807 K801 GE 5 meter length with connectors on both ends. Connects between master and slave device, or between two slave devices. Cable A03B 0807 K802 GE 10 meter length with connectors on both ends. Connects between master and slave device, or between two slave devices. Cable AMW 2076 OKI Electric Cable 10 pair shielded cable without connectors, for making custom length cable. Connects between master and slave device, or between two slave devices. Connector A02B 0120 K301 GE 20 pin connector with solder lug. Consists of the two following parts. Connector PCR E20FS Honda 20 pin female connector with solder lug. PRC V20L Honda Connector cover. Cable A03B 0807 K803 GE 1 meter length with connectors on both ends. Connects between master or slave and Optical Adapter. This cable can only be used with an Optical Adapter; do not use it for master/slave or slave/slave connections. Optical A B001 GE Required for optical fiber cable. Adapter Cable A66L GE Optical fiber cable for use with Optical Adapter. #L10R03 #L15R03 #L20R03 #L30R03 #L40R03 #L50R03 #L60R03 #L80R03 #L90R03 #L100R03 10m 15m 20m 30m 40m 50m 60m 80m 90m 100m GFK-2358 Chapter 3 Installation 3-5

23 3 Cable Lengths on the I/O Link The maximum distance between the master and the first slave, and between successive slaves, depends on whether electrical or optical cable is used. The maximum length of an electrical cable link is 10 meters (33 feet). The maximum length of an optical fiber cable is 100 meters (330 feet). Electrical and optical cables can be used in the same I/O Link. MASTER 10m 10m 1m SLAVE 0 SLAVE 1 OPTICAL ADAPTER OPTICAL FIBER CABLE 100m OPTICAL ADAPTER 1m 10m SLAVE 2 SLAVE 0 SLAVE PACSystems RX3i I/O Link Modules April 2005 GFK-2358

24 3 Serial Port Pin Assignments Pin # Signal Pin # Signal 1 SIN 11 0 volts 2 *SIN 12 0 volts 3 SOUT 13 0 volts 4 *SOUT 14 0 volts volts volts volts 9 +5 volts volts The +5 volt output powers the fiber optic link modules for long distance applications. Caution In all other cables, the signal pins for +5 volts should NOT be connected. These pins are protected by a replaceable 0.5A fast blow fuse (5mm diameter x 20mm length) located inside the front of the module. GFK-2358 Chapter 3 Installation 3-7

25 3 Cable Diagram, No Optical Adapter The following illustration shows connection details for electrical cable used between a master and slave or between two slave devices. This cable (A03B 0807 K801, A03B 0807 K802, or cable made using AMW 2076 and connectors A02B 0120 K301) does not include the +5 volt signal. Do not use Optical Adapter cable, which includes the +5 volt signal, to directly connect master and slave devices. JD1A JD1B SIN SIN 11 * SIN SOUT * SOUT PCR-E20FS SIN * 12 SOUT 13 SOUT * MASTER OR SLAVE JD1A SIN * SIN SOUT * SOUT (1) (2) (3) (4) (11) (12) (13) (14) (3) (4) (1) (2) (11) (12) (13) (14) JD1B SOUT SOUT * SIN SIN * SLAVE Connect the differential signals, SIN/*SIN, and SOUT/*SOUT using twisted pair wires. Caution The I/O Link cable s shield must be connected to chassis ground in your system. Use the grounding cable (44A729227) provided. 3-8 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

26 3 Optical Adapter An Optical Adapter (A B001) can be used to interface the electrical cable of the I/O Link with optical cable. ELECTRICAL CONNECTOR JD1 OPTICAL CONNECTOR COP1 Use pairs of adapters in applications where: distances of up to 100 meters (330 feet) are required between any two devices on the I/O Link. the I/O Link runs between different cabinets, and it is not possible to connect the cabinets with a wire of 5.5mm2 or thicker. excessive electromagnetic noise could affect the cable. This includes noise from machinery such as a welding machine, and noise generating cable such as power cable that run for long distances with the I/O Link cable. GFK-2358 Chapter 3 Installation 3-9

27 3 Optical Adapter Installation An Optical Adapter must be installed in a sealed enclosure. Avoid contact with other electrical components or wiring, which could short the unit. Use the adapter s casing screws to make earth ground connection. The electrical potential of the earth ground used for the adapter must be the same as that of the I/O Link to which it is connected. Cable Connections Connection between two Optical Adapters is made using optical fiber cable A66L Lengths of 10 to 100 meters are available. Connect the optical fiber cable to COP1 on the adapter unit. UNIT OPTICAL I/O LINK ADAPTOR OPTICAL I/O LINK ADAPTOR UNIT JD1A ELECTRICAL CABLE OPTICAL CABLE JD1 COP1 COP1 JD1 ELECTRICAL CABLE JD1B Connection between a master or slave device and an Optical Adapter is made using electrical cable A03B 0807 K803, which is a one meter cable with connectors on both ends. Connect this cable to JD1 on the adapter. A connection diagram is shown on the next page PACSystems RX3i I/O Link Modules April 2005 GFK-2358

28 3 Cable Diagram, Electrical Cable to Optical Adapter Cable A03B 0807 K803 provides the +5 volt signal required by the Optical Adapter. Do not use this cable to directly connect master or slave devices; use it only with an Optical Adapter. UNIT SIDE JD1A, JD1B ADAPTER SIDE JD SIN SIN * SOUT SOUT * 5V V 5V * SIN * SIN SOUT SOUT 5V 5V 5V (01) (02) (03) (04) (09) (18) (20) (11) (12) (13) (14) (15) (16) (03) (04) (01) (02) (09) (18) (20) (11) (12) (13) (14) (15) (16) SOUT SOUT SIN SIN * 5V 5V 5V * The +5 volt output on the I/O Link Master module is protected by a replaceable 0.5A fast blow fuse (5mm diameter x 20mm length). GFK-2358 Chapter 3 Installation 3-11

29 3 Starting Up the I/O Link Master Module (Note: If the I/O Link Master Module is installed in a Series PLC that has a CPU331, the CPU must be present before applying power to the I/O Link Master Module.) 1. Turn on power to the system where the I/O Link Master Module is installed, and observe the I/O Link Master Module s LEDs. I/O Link Master Module (BEM321) LEDs OK CFG ACTV Meaning off off off No power to module, or powerup in progress on off off Module powered up but not configured on on off Module powered up and configured with minimum configuration (input status reference assigned and output status reference assigned), but link is not yet active, or has been activated but has gone down on on on Normal operation with active link After power up, the OK LED should stay ON. The other LEDs should remain off. 2. Configure the module as instructed in chapter 4. When the module has been configured, its CFG LED should go on. 3. Apply power to all the slaves. (Note: If the I/O Link Interface Module is installed in a Series PLC that has a CPU331, the CPU must be present before applying power to the I/O Link Interface Module.) If the system includes an RX3i I/O Link Interface Module slave, its LEDs have the following meanings: I/O Link Interface Module (BEM320) LEDs OK RDY Meaning off off No power to module, or powerup in progress on off Module is operating properly, but I/O Link communications are not possible. on on Normal operation with active link 4. Place the master system in Run mode (the communications link will not be established until the PLC is in Run mode). The I/O Link should now be operational, and the ACTV LED on the I/O Link Master Module should go on PACSystems RX3i I/O Link Modules April 2005 GFK-2358

30 Chapter 4 Configuration Both the I/O Link Master Module and I/O Link Slave Module must be included in the configuration of their system CPUs. This chapter describes: Configuring an I/O Link Slave Module Configuring an I/O Link Master Module Configuring Input and Output Defaults Making Input Assignments for the I/O Link Master Assigning Output References for the I/O Link Master Configuration Worksheet for the I/O Link Master and its Slaves Configuring Slave Devices on the I/O Link GFK

31 4 Configuring an I/O Link Slave Module An I/O Link Slave Module (BEM320) must be included in the configuration of its own CPU and assigned suitable input and output references using the programming software. For the I/O Link Slave Module, no additional configuration is needed. The I/O Link Slave module can be set up for 32-bit or 64-bit operation using a jumper on the module. The default is 32 bits. The configured data length must match the jumper setting or a fault will occur. If the I/O Link Slave Module is on an I/O Link network with a PACSystems or Series 90 I/O Link Master, the slave must also be included in the master s configuration, as explained later in this section. Configuring an I/O Link Master Module The I/O Link Master module (BEM321) must be installed in its selected slot in the backplane and powered up. 1. Add the I/O Link Master to the rack configuration by selecting it from the list of modules. 2. Enter input table (%I) references for the I/O Link Master module s status information (information provided by the I/O Link Master Module to the CPU). The input length is fixed at 24 bits. 3. Enter output (%Q, %AQ, %G, or %R) references for the I/O Link Master module s command word (information sent from the CPU to the module). The output length is fixed at 16 bits or one word. 4. Specify whether the I/O Link Master module should default input data to 0 or hold data at its last state if the link fails. 5. Specify whether the I/O Link Master module should default output data to 0 or hold data at its last state if the link fails. 6. The slaves on the I/O Link that is controlled by the master must also be included in the master s configuration. Specify the following for each slave position on the link: a. the slave device type. b. input table (%I) references for that slave. The length is supplied automatically based on the slave type. Note that for some modules there are differences between the number of input points used by the module, and the number of points the module uses on the I/O Link. This is explained later in this section. c. The output table (%Q) references and length for each slave are computed automatically. 4-2 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

32 4 Configuring Input and Output Defaults This configuration step specifies how the I/O Link Master module will operate if it stops receiving data from slaves on the link, or from the PLC (for example, if the PLC is in STOP mode). Data Transfer on an I/O Link As long as the I/O Link Master Module is able to operate, it continually supplies data to the PLC CPU and to slaves on the link. PLC CPU I/O Link Master Module Inputs I/O Link Devices Outputs If normal operation stops, the module can either default input or output data to 0 (Off), or continue transmitting the last valid data it received (Hold Last State). GFK-2358 Chapter 4 Configuration 4-3

33 4 Making Input Assignments for the I/O Link Master The I/O Link Master Module itself requires 24 bits of %I memory in the CPU. The I/O Link Master uses these bits to provide status information to the PLC. Each slave on the I/O Link also requires input memory. When you configure the slaves (in a later step), you can assign each to any available references in %I or %AI memory. Input Data References for an I/O Link The locations assigned to the I/O Link Master module and the slaves on the I/O Link may or may not be grouped together in memory, as illustrated below. %I memory (bits) %AI memory (16 bit words) %I memory (bits) %AI memory (16 bit words) status bits status bits slave #0 slave #1 slave #2 OR slave #0 slave #2 slave #1 The total amount of input data that can be configured for all the slaves on the I/O Link 1024 input bits (128 bytes or 64 words). If this limit is exceeded, an error message is generated. 4-4 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

34 4 Assigning Output References for the I/O Link Master The I/O Link Master Module requires 16 bits of %Q or %AQ memory in the CPU. During system operation, the PLC uses these bits to provide command information to the module. In addition, the I/O Link Master module can send up to 1024 bits (128 bytes or 64 words) to the slaves on the I/O Link. This data is automatically assigned references that follow the I/O Link Master Module s selected command output references. Output Data References for an I/O Link The command data for the I/O Link Master module and output data for slave devices on the I/O Link reside together in memory. Output data for the slaves immediately follows the 16 bits of command data in the selected memory area (%Q, %AQ, %G, %R). %Q, %AQ, %G, or %R Memory Command Outputs (16 bits) Outputs for Slave #0 Outputs for Slave #1 Outputs for Slave #2... Outputs for Slave #15 GFK-2358 Chapter 4 Configuration 4-5

35 4 Configuration Worksheet for the I/O Link Master and its Slaves Master: Input Status references (24 bits): % to % Output references (16 bits): % to % Slaves: 0: Device type: % to % 1: Device type: % to % 2: Device type: % to % 3: Device type: % to % 4: Device type: % to % 5: Device type: % to % 6: Device type: % to % 7: Device type: % to % 8: Device type: % to % 9: Device type: % to % 10: Device type: % to % 11: Device type: % to % 12: Device type: % to % 13: Device type: % to % 14: Device type: % to % 15: Device type: % to % Data Defaults: Inputs: default to 0 or hold last state Outputs: default to 0 or hold last state 4-6 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

36 4 Configuring Slave Devices on the I/O Link Slave devices 0-15 are configured in sequence, beginning with the slave that is the next device on the link (Slave 0). Slave locations cannot be skipped in the configuration. Slave Types For each slave number, the default slave type is NONE. The configuration software lists many types of I/O Link slave devices. Specific slave types can be selected from the list, or universal slave types can be configured. The universal slave selections (slave256, slave128, slave64, and slave 32 make it possible to add a device that is not specifically listed in the table or recognized by the programming software. Because these selections do not represent specific device types, the I/O Link Master module is not able to verify that a correct slave module type is actually present at that location. Slave Reference Addresses After selecting each slave type, assign its starting input (%I or %AI) reference. Unlike outputs, which use a block of references, the input references for slaves do not need to be in sequential order. It is possible to assign some slaves to %I memory, which is bit mapped, and other slaves to %AI memory which is word based. Input references cannot overlap. Output references (%Q, %AQ, %G, or %R) are automatically assigned in sequential order for each configured slave. If, after configuring the slaves, you edit the reference address for the module command information, the slave output references will be automatically reconfigured. Output references can overlap. Slave Data Lengths Each slave will occupy the actual amount of CPU memory needed for its I/O data, as indicated by the configuration software. The table on the next page on shows the number of inputs and outputs used by many types of slave devices. The total number of I/O points allowed on the I/O Link network is 1024 inputs and 1024 outputs. Exceeding these limits will generate an error. It is important to know that the number of points used by a slave device on the I/O Link network may be more than its configured data length in the CPU. Because of the way I/O Link messages are structured, data lengths on the I/O Link network must always be a power of 2: 16, 32, 64, 128, 256, or 512. A device s actual, configured data may be less than a power of 2. For example, if a device in the table provides 96 inputs, its input data actually uses 128 of the allowed 1024 input points on the I/O Link, while only using 96 inputs in the CPU. See the table for more information about module data lengths. GFK-2358 Chapter 4 Configuration 4-7

37 4 Configuration Information for Slave Devices Slave Type Number of CPU References Number of I/O Link Points None; there is no slave assigned to the selected position PowerMate CNC, 64 PowerMate CNC, 32 RX3i or Series PLC I/O Link Slave Module, 64 RX3i or Series PLC I/O Link Slave Module, 32 Series PLC I/O Link Slave Module, 64 Series PLC I/O Link Slave Module, 32 Series 0 CNC 64 Series 0 CNC 32 Customer Operators Panel A Customer Operators Panel B Connection Unit 01 Connection Units 01 & 02 Slave 256 Slave 128 Slave 64 Slave 32 none 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 96 input points 64 output points 64 input points 32 output points 96 input points 64 output points 192 input points 128 output points 256 input points 256 output points 128 input points 128 output points 64 input points 64 output points 32 input points 32 output points none 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 64 input points 64 output points 32 input points 32 output points 128 input points 64 output points 64 input points 32 output points 128 input points 64 output points 256 input points 128 output points 256 input points 256 output points 128 input points 128 output points 64 input points 64 output points 32 input points 32 output points 4-8 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

38 Chapter 5 Operation This chapter describes operation of the I/O Link, I/O Link Interface Module, and PLC CPU. Operation of the I/O Link Input and Output Data Structure of Data Sent by the Master Data Returned by Slaves Faults on the I/O Link Fault Handing for the RX3i I/O Link Interface Module (Slave) CPU Interface in an RX3i I/O Link Master System Master Begins Sending Data Slaves Return Data to the Master Fault Handling for the RX3i I/O Link Master Module Data Defaults or Holds Last State Recovery from Interruptions in an RX3i I/O Link Master System Programming in an I/O Link System Application Programming for the I/O Link Interface Module Application Programming for the I/O Link Master Module Data Formats in the Master CPU GFK

39 5 Operation of the I/O Link For each device on an I/O Link: Input Data Output Data is data received from the link. is data sent to the link. So the same set of data is considered output data by the device that sends it and input data by the device that receives it. MASTER INPUTS SLAVE INPUTS OUTPUTS OUTPUTS 5-2 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

40 5 Structure of Data Sent by the Master The master sends output data for all slave devices in a continuous serial string. Slaves receive the data in order of their positions on the link. Each slave in turn reads out its configured amount of data, and passes the remainder on to the next slave. To a slave, data received from the master is input data. MASTER SLAVE 1 SLAVE 2 SLAVE 3 INPUTS INPUTS INPUTS OUTPUTS 1 OUTPUTS 2 OUTPUTS 3 OUTPUTS OUTPUTS 2 3 OUTPUTS 3 Multiple slaves on a link are connected in a daisy chain fashion so that the output of the first slave drives the input to the second, and so on. With this cabling sequence, each input appears as a single load to the slave that is driving it; therefore, loading on a particular slave output does not change with the total number of slaves in a system. Data Returned by Slaves The master also continuously reads the output data sent by each slave. MASTER SLAVE 1 SLAVE 2 SLAVE 3 INPUTS MASTER SLAVE 1 SLAVE 2 SLAVE 3 OUTPUTS The master identifies each set of data it receives with respect to the slave s position on the link. To the master, data received from slaves is input data. GFK-2358 Chapter 5 Operation 5-3

41 5 CPU Interface in an RX3i I/O Link Slave System The CPU handles I/O Link Interface Module (BEM320) data in the same manner as other types of I/O data. The CPU reads inputs from the I/O Link Module s assigned input references, executes the application logic, then writes outputs to the I/O Link Module s assigned output references. Because the master device controls operation of the I/O Link network, the CPU controlling an I/O Link Interface (slave) module requires no special programming for the module to transfer data on the link. CPU Interface in an RX3i I/O Link Master System In an RX3i I/O Link Master system, normal operation begins when: the I/O Link Master module has been configured. the CPU has been placed in Run mode. Note that the I/O Link Master module s Link ACTV LED and the equivalent input status bit are not turned on until the I/O Link Master Module receives data back from the slave devices. Master Begins Sending Data The CPU sends data on the system backplane from the configured output references to the RX3i I/O Link Master module. This data includes the command outputs and the output data for the slaves on the network. CPU Command Bits Output Data I/O Link Master Module I/O Link Devices After receiving this output data from the CPU, the I/O Link Master module begins transmitting it to slave devices on the I/O Link. CPU I/O Link Master Module I/O Link Devices Output Data The RX3i I/O Link Master module does not start transmitting on the I/O Link until it has received valid output data from the CPU. 5-4 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

42 5 Slaves Return Data to the I/O Link Master Module At initialization, slave devices start sending data on the I/O Link. CPU I/O Link Master Module I/O Link Devices Input Data When the RX3i I/O Link Master module receives data from slave 0, its Link ACTV LED lights, and it sets the equivalent input status bit to 1. Status bits are described later in this section. The I/O Link Master module then provides this data to the PLC CPU, where it is placed in the I/O Link Master Module s assigned status bits and the slave devices assigned input references: CPU Input References Status Bits I/O Link Master Module Input Data I/O Link Devices Programming for an I/O Link Master Module The application program running in the CPU that controls the I/O Link Master Module performs some or all of the following actions: it reads the most recent input data it has received from slaves on the I/O Link from their configured reference addresses in memory. Input and output data formats are explained in more detail on the following pages. at startup (or when restarting the system), the application program should: monitor the least significant 8 bits (byte 1) of the status bits to inform the CPU about the overall health of the I/O Link. GFK-2358 Chapter 5 Operation 5-5

43 5 monitor status bit 4 to be sure all of the configured slave devices are actually present. If bit 4 = 1, the application program may shut down operation of the system as a safety precaution. monitor the rest of the status bits to be sure the correct slave is present at each configured location. it supplies data to slaves by placing the data into the slaves assigned output references. if the CPU and the I/O Link Master Module are operating but the I/O Link has failed, the application program can use output bit 0 to restart the link. Data Formats in the Master CPU As explained previously, the I/O Link Master module itself and the slaves on its I/O Link use both input and output references in the PLC CPU. Data exchanged between the I/O Link Master module and the slaves on the I/O Link is coherent across 16 bits. Every 16 bit word, beginning with the starting reference assigned to each slave, is from the same data transmission. It is possible to have successive words of data to or from the same slaves that are from successive scans of the I/O Link. Input Data The I/O Link Master module itself requires 24 bits of %I memory in the PLC CPU for input status bits. In addition, slaves on the I/O Link are assigned input data references in %I or %AI memory during configuration. The memory type and length can be configured for each slave. The locations assigned to the I/O Link Master module and the slaves on the I/O Link may or may not be grouped together in memory. Both options are illustrated below. %I memory (bits) %AI memory (16 bit words) %I memory (bits) %AI memory (16 bit words) status bits status bits slave #0 slave #1 slave #2 OR slave #0 slave #2 slave #1 5-6 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

44 5 Input Status Bits The I/O Link Master module uses 24 input status bits of %I memory to inform the PLC CPU of its status, and that of the I/O Link. The application program can monitor these bits, and take appropriate action if necessary. The I/O Link Master module uses the least significant 8 bits (byte 1) of the status bits to inform the PLC CPU about the overall health of the I/O Link. Bits 8 through 23 inform the PLC CPU if it encounters a configuration mismatch at any slave location(s) when either initializing or restarting the I/O Link. byte bits 5 & 6 not used (reserved) Lowest missing slave (0 15) 1 = missing slave 1 = link active byte = Slave 0 configuration mismatch Slave 1 Slave 2 Slave 3 Slave 4 Slave 5 Slave 6 Slave 7 byte See the descriptions of these bits on the next page. 1 = Slave 8 configuration mismatch Slave 9 Slave 10 Slave 11 Slave 12 Slave 13 Slave 14 Slave 15 GFK-2358 Chapter 5 Operation 5-7

45 5 Status Bit 7: Link Status Input status bit 7 corresponds to the module s ACTV LED. If the link is active, the I/O Link Master module sets bit 7 to 1. If the link fails, the I/O Link Master module clears bit 7 to 0. Status Bits 0 to 4: Absent Slaves During link initialization, if the I/O Link Master determines that one or more of the configured slave devices is missing, it sets bit 4 to 1. The link may still operate, but some slaves will not be present. The application program can monitor bit 4, and take appropriate action if any slaves are absent. If bit 4 is 1, program logic can identify the lowest missing slave by checking bits 0 3. The I/O Link Master module cannot distinguish between a slave lost due to a power failure and a slave lost due to a cable break. If, before the I/O Link Master established the I/O link, power failed at slave #5 or a cable break existed between slave #4 and slave #5, the I/O Link Master status would indicate that slave #5 was missing. Slaves 0 through 4 would be on line. Status Bits 8 to 23: Slave Configuration Mismatch The I/O Link Master uses the rest of the status bits to inform the CPU if it encounters a configuration mismatch at any slave location(s) when either initializing or restarting the I/O Link. Either the configuration must be corrected, or the physical setup of the slaves must be changed (for example, if modules have been connected, or reconnected, to the link cable in the wrong sequence). Note The link may continue to operate if a mismatch is present. 5-8 PACSystems RX3i I/O Link Modules April 2005 GFK-2358

46 5 Output Data The I/O Link Master module itself requires 16 bits of %Q or %AQ memory in the CPU. In addition, slaves on the I/O Link are automatically assigned to the same type of memory directly following that used by the I/O Link Master. The locations assigned to the I/O Link Master module and the slaves on the I/O Link are always grouped together in memory, as illustrated below. %Q memory (bits) %AQ memory (16 bit words) command bits slave #0 slave #1 slave #2 OR command bits slave #0 slave #1 slave #2 The application program supplies data to slaves on the I/O Link by placing it into the slaves assigned output references. During configuration, the memory type and starting address for I/O Link output data can be selected. As slaves are configured on the link, their output addresses and lengths are assigned automatically. Two examples are discussed below. Example 1: Suppose the beginning address configured for I/O Link output data is: %Q401 The first 16 references from %Q401 through %Q416 are used for command bits. The first slave (slave #0) is a Power Mate set up as a 64 bit slave (PwrMate64). Its output data will be located directly after the command bits, at: %Q417 through %Q480 The next slave (slave (#1) would then be assigned references beginning at %Q481. Example 2: If the beginning address configured for I/O Link output data is: %AQ006 The first word (%AQ006) is used for command bits. The first slave (slave #0) is a Power Mate set up as a 64 bit slave (PwrMate64). Its output data will be located directly after the command word, at: %AQ007 through %AQ010 The next slave (slave (#1) would then be assigned references beginning at %AQ011. GFK-2358 Chapter 5 Operation 5-9