Modicon TSX Atrium. User Manual

Transcription

1 Modicon TSX Atrium User Manual 880 USE / Breite: 185 mm Höhe: 230 mm

2 Data, Illustrations, Alterations Data and illustrations are not binding. We reserve the right to alter products in line with our policy of continuous product development. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us using the form on one of the last pages of this publication. Training Schneider Automation offers suitable further training on the system. Hotline See addresses for the Technical Support Centers at the end of this publication. Trademarks All terms used in this publication to denote Schneider Automation products are trademarks of Schneider Automation. All other terms used in this publication to denote products may be registered trademarks and/or trademarks of the corresponding Corporations. Microsoft and MS-DOS are registered trademarks of Microsoft Corporation, Windows is a brandname of Microsoft Corporation in the USA and other countries. IBM is a registered trademark of International Business Machines Corporation. Intel is a registered trademark of the Intel Corporation. Copyright All rights are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including copying, processing or by online file transfer, without permission in writing by Schneider Automation. You are not authorized to translate this document into any other language Schneider Automation GmbH. All rights reserved

3 Contents Contents Info Symbols Used Terms and Abbreviations Used Additional Documentation Validity Note Kapitel 1 General Overview Components PLC modules Voltage Supply of the Module Kapitel 2 Requirements Hardware Requirements Software Requirements Kapitel 3 Installation and Voltage Supply Installation into PC Prior to Installation into PC Installation into the PC Voltage Supply Kapitel 4 Initial startup when using Modbus Plus Requirements Activating the Modbus Plus Interface of the PLC Module Activation under Windows 3.11 / Windows for Workgroups (Concept V2.1 only) Activating under Windows 95 and Windows Activating under Windows NT Building the Hardware Connection Initial Startup Initial Atrium Startup with the Windows Loader Initial Atrium Startup with the DOS Loader Building the Software Link Module Description CCO / 180 CCO Modicon TSX Atrium PLC Module CPX 1 00 External power supply adapter Index III Breite: 185 mm Höhe: 230 mm

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5 Info This documentation gives information about acting, requirements and installation of Modicon TSX Atrium. Furthermore you will find the hardware descriptions. Caution The relevant regulations must be observed for control applications involving saftey requirements. For reasons of safety and to ensure compliance with documented system data, repairs to components shoud be performed only by the manufacturer. 1 Width: 185 mm Height: 230 mm

6 Info Symbols Used Note This symbol emphasizes important facts. Caution This symbol refers to sources of frequently appearing errors. STOP Warning This symbol points out potential dangers to you which could result in financial damage, personal injury or other serious consequnces. Expert This Symbol is used if more detailed information is given which is intended exclusively for experts (with special training). Skipping this information does not affect the clarity of the publication nor does it restrict the standard application of the product. Tip This symbol is used to emphasize the explanation of special tips when working with the product. Example This symbol identifies examples of applications. Please proceed as follows: The start of a sequence of applications, the execution of which is neccessary to obtain a specific product function, is marked with this. This symbol indicates manuals/other sources dealing with the topic in greater detail. 2

7 Info Terms and Abbreviations Used The method of writing numbers complies with international practice as well as an approved SI (Système International d Unités) presentation: Each thousand is separated by a space; and the decimal point is used, e. g IBS IPC MB+ PC INTERBUS Industrial Personal Computer Modbus Plus Personal Computer Additional Documentation Description Type Installation Instructions Concept V USE Concept V2.2, User Manual (Vol. 1 + Vol. 2) 840 USE IEC Block Library Concept V2.2 (Vol. 1 + Vol. 2 + Vol. 3) 840 USE LL984 BLock Library Concept Concept V2.2 (Vol. 1 + Vol. 2) 840 USE Modicon TSX Quantum PLC Series, Hardware User Manual 840 USE Modicon TSX Quantum 140 NOA User Manual 840 USE Modbus Plus Network, User Manual 890 USE Modicon IBM Host Based Devices, User s Guide GM HBDS 001 BM85 Modbus Plus Bridge / Multiplexer, User s Guide GM BM Modicon TSX Momentum I/O Series, User Manual 870 USE Modicon TSX Momentum INTERBUS Communication Adapter 870 USE Modicon TSX Momentum 170 PNT Series 870 USE Validity Note This documenation applies to Concept Version Width: 185 mm Height: 230 mm

8 Info 4

9 General 1 This chapter contains general information about Modicon TSX Atrium PLC modules: Overview Components 5 Width: 185 mm Height: 230 mm

10 General 1.1 Overview Modicon TSX Atrium is a PC based control system, that means it is a controller which can be used as a part of a PC system. The Modicon TSX Atrium is designed as a coprocessor for realtime PLC functionality and for the use in a PC with ISA (AT )bus. The coprocessors 180 CCO 121/241 are PLC CPUs with integrated Modbus Plus interface, an additional INTERBUS interface and separate power supply. The module operates by means of the seperate power supply independent of the host PC, i.e. even if the PC fails, it will continue to operate. Figure 1 Overview Use of 180 CCO 121/241 Momentum Quantum Compact SA CCO 121 / 241 Modbus + INTERBUS TIO / IS Compact Momentum 6

11 General 1.2 Components The PLC family Modicon TSX Atrium consists of the PLC modules 180 CCO / 180 CCO and a separate power supply, providing a supply voltage for the PLC module, which works independent from the host PC PLC modules The 180 CCO 121/241 coprocessors are PLC CPUs with I/O and communication interface for use on a PC with an ISA (AT ) bus. The PLC module 180 CCO has a 386EX CPU with 2 MB RAM and the PLC module 180 CCO has a CCO 586 CPU with 4 MB RAM memory for application programs and data on the central processing unit HighLowIRQ 10 1 Module components 1 Motherboard (see page 36) 2 386EX CPU or CCO 586 CPU (see page 40) 3 IBS PC 104 SC T (see page 42) 4 Interface card (see page 46) 5 Backup battery on motherboard (see page 45) 6 Backup battery on the CPU (180 CCO only (see page 45) 7 Width: 185 mm Height: 230 mm

12 General The module consists of the following components: Standard AT format motherboard with PC 104 interfaces and Modbus Plus interface CPU with 386 EX microprocessor (180 CCO ) or 80486DX5 133 microprocessor (180 CCO ) INTERBUS module, Generation 4 Interface card The module operating system is a Schneider Automation standard operating environment (standard EXEC in conjunction with the 32 bit IEC operating system). Further information you will find in the corresponding module description Voltage Supply of the Module The supply voltage for the PLC modules can be provided either via an external power supply unit or from the host PC supply unit. When using an external power supply unit the module will not be dependent on the host PC, i.e. even if the PC fails, the module will continue to operate.this means that your program will continue running if the PC is switched off. The TSX Quantum 140 CPS or power supply module acts as an external power unit and is installed on the TSX Quantum 140 XBP backplane together with the power supply adapter. The power supply is connected to one of the two 8 pin connectors on the PLC module using the preassembled 180 XCA connection cable. Further Information you will find in the corresponding module description and in Chapter 3. 8

13 Requirements 2 In this documentation you will find notes to hard and software requirements for using the PLC module. 9 Width: 185 mm Height: 230 mm

14 Requirements 2.1 Hardware Requirements The PLC module can be used with any PC which provides an empty ISA slot that has 2 mechanically adjoining slots with full length. Programming with Concept is generally based on the same requirements as Microsoft Windows 3.1, Microsoft Windows for Workgroups version 3.11, Windows 95/98 or Windows NT. The following list of requirements represents a minimum. Concept is no different than Windows; the faster the processor, the more free RAM and the greater the processing speed, which means increased ease of use for the operator. PC with Intel 386SX or 386DX processor or higher 8 MB RAM (16 MB or more is recommended) 80 MB free hard disk space 3 1/2 inch disk drive (1.44 MB) CD ROM drive optional SA85 module or NHM 212 if choosing Modbus Plus connection TCP/IP network adapter if choosing Ethernet VGA graphics adapter and screen (recommended resolution: > 640 x 480) Microsoft compatible mouse Note Additional information regarding hardware requirements can be found in the README.WRI Concept file. 10

15 Requirements 2.2 Software Requirements The host PC works with the Microsoft Windows 3.1 (Concept version 2.1 only), Microsoft Windows for Workgroups version 3.11 (Concept version 2.1 only), Windows 95, Windows 98 (as of Concept version 2.2) or Windows NT V4.0 operating system. The Concept software package as of version 2.1 must also be installed on the host PC. This will enable you to program and monitor your PLC board directly from the host PC via the ISA bus DPM. As a prerequisite there must be installed an corresponding bus driver at the PC. Alternatively you can program and monitor the PLC module via Modbus Plus. 11 Width: 185 mm Height: 230 mm

16 Requirements 12

17 Installation and Voltage Supply 3 In this documentation you will find infomation about the installation of the PLC module and about the voltage supply. 13 Width: 185 mm Height: 230 mm

18 Installation and Voltage Supply 3.1 Installation into PC Prior to Installation into PC Please proceed the following steps before placing the module into the PC: Step 1 Step 2 Attach the connection cable of the backup battery to the connector on the central unit. Use the power supply switch to select the connector for the supply votage connection: Figure 2 Power supply switch Power supply External (factory setting): feed to connector at the connector panel (in front) external internal Internal: Feed to connector at motherboard Step 3 Check the settings of the following addresses (please refer to the module descriptions for the location of the switches): Address Factory Setting Modbus Plus Address (on motherboard) 01 PC Interrupt Address (IRQ) (on motherboard) 9 PC Address (Base Address) (on motherboard) D000 Write protection for memory (on central unit) in the middle (not active) INTERBUS Port Address (on IBS module) 1 Hex Caution The addresses in your system must be unique. Check to make sure that the preset addresses do not collide with already existing components and if so, change any affected addresses. If addresses are not unique, the system will malfunction. 14

19 Installation and Voltage Supply Installation into the PC Please proceed the following steps for installing the module into the PC: Step 1 Please open the housing of your PC how described in the PC User Manual. 3 Components 1 PC 2 ISA slot 3 PLC module 4 Holes for connector panels Step 2 Step 3 Step 4 Insert the PLC module into your PC onto an empty ISA slot that has 2 mechanically adjoining slotls with full length. Tightly screw on the connector panel of the motherboard. Screw the connector panel of the interface card into the slot adjoining the motherboard. 15 Width: 185 mm Height: 230 mm

20 Installation and Voltage Supply 3.2 Voltage Supply The supply voltage for the PLC module can be provided either via an external power supply unit or from the internal host PC supply unit. Power supply via an external power unit The external power unit used is the TSX Quantum 140 CPS or 140 CPS supply module that is mounted together with the adapter for the power supply 180 CPX 1 00 on the TSX Quantum backplane 140 XBP The power supply is connected to one of the two 8 pin connectors on the PLC module using the preassembled 180 XCA connection cable. In this case the module will not be dependent on the host PC, i.e. even if the PC fails, the module will continue to operate. This means that your program will continue running if the PC is switched off. Moreover the external power supply unit provides undervoltage warning signals, which are used to acivate the backup battery, if the power supply unit shuts down. Power supply via the host PC power supply unit If selecting a power supply via the internal power supply unit of the host PC, your module is dependent on the host PC. The backup battery is not activated because the required undervoltage warning signals are missing. STOP Warning If the module power is supplied via the host PC power supply unit, the module will be cut off when you shut down the PC. This will cause a loss of data on the CPU, and all application data will have to be reloaded into the PLC module when the PC is restarted. Power Supply Components In the following table you will find the components with their module numbers using for installation of the power supply: Table 1 Power supply components Type Module Number Power supply module 140 CPS or 140 CPS Power supply adaptor 180 CPX 1 00 Backplane 140 XBP Connection cable for adaptor 180 XCA Connection cable for PC power supply unit 180 XCA

21 Initial startup when using Modbus Plus 4 This chapter provides a brief description of the initial startup: Requirements Initial startup Width: 185 mm Height: 230 mm

22 Initial startup when using Modbus Plus 4.1 Requirements The PLC modules 180 CCO 121/241 are shipped with the current systems software (Executive files). However, due to performance upgrades or error corrections it may be necessary to modify the systems software. In such case, a new Executive file must be downloaded into the CPU of the PLC module. The following requirements must be met for hardware and software: Hardware To establish the hardware requirements for the EXEC file download into the CPU of the PLC module, the following options are available: inserting an additional SA85 in the host PC or utilizing a second PC with SA85 and installed software, Concept as of V2.1 or utilizing a second PC with a PLC module and installed software, Concept as of V2.1 Inserting an additional SA85 in the host PC 3 Components 1. PC 2. SA85 3. PLC module 4. MB+ cable, e.g. 990 NAD (2.4 m long) The description for SA85 and driver installation can be found in the Concept installation guide as of version 2.1 as well as in the IBM Host Based Devices documentation

23 Initial startup when using Modbus Plus The Modbus Plus interface of the PLC module and the SA85 are connected via a Modbus Plus cable, e.g. the 990 NAD cable (2.4 m long). Please refer to the user manual Modbus Plus Networks and the Chapter Activating the Modbus Plus Interface of the PLC module (page ) for further information. Utilizing a second PC with SA85 and installed software, Concept as of V CCO 121 / 241 SA85 Modbus + The Modbus Plus interface of the PLC module and the SA85 in the second PC are connected via the Modbus Plus network. Please refer to the user manual Modbus Plus Networks and the Chapter Activating the Modbus Plus Interface of the PLC module (page ) for further information. Utilizing a second PC with a PLC module and installed software, Concept as of V CCO 121 / CCO 121 / 241 Modbus + The Modbus Plus interfaces of the two PLC modules are connected via the Modbus Plus network. Please refer to the user manual Modbus Plus Networks and the Chapter Activating the Modbus Plus Interface of the PLC moudle (page ) for further information Width: 185 mm Height: 230 mm

24 Initial startup when using Modbus Plus Software /network driver The appropriate Modbus Plus drivers for 180 CCO 121/241 and SA85 must be downloaded to your PCs and the interfaces must be activated. The current Executive file (EXEC file) is in the Concept software package as of version 2.1/2.2: Table 2 Initial startup software requirements PLC module EXEC file 180 CCO atrium.bin 180 CCO atr586.bin (as of Concept version 2.2) 4.2 Activating the Modbus Plus Interface of the PLC Module The activation of the Modbus Plus interface of the PLC module is subject to the operating system on your PC: Windows 3.11 / Windows for Workgroups (Concept V2.1 only) (page 21) or Windows 95 or Windows 98 (as of Concept V2.2) (page 22) or Windows NT (page 25) 21

25 Initial startup when using Modbus Plus Activation under Windows 3.11 / Windows for Workgroups (Concept V2.1 only) To activate the Modbus Plus interface, please perform the following steps: 1. Set the Modbus Plus node address (MB+ address) and the PC address on the motherboard of the PLC module. 2. Record the set Modbus node address on a label that can be affixed to the host PC. 3. Perform the installation according to Chapter Copy the mbhost.sys file from the enclosed diskette to hard disk (e. g. into the SA85 directory). 5. Enter the driver into config.sys. e. g. device=c:\sa85\mbhost.sys /mc800 /s5c /n0 /r3 The parameters must be separated by spaces. /m = Base address for memory window /s = Software interrupt for Windows /n = Peripherals adapter number in the computer /r = Driver version If using Windows for Workgroups, please inter the s5d interrupt. The dual port memory of the Modbus Plus communications interface is 1 Kbyte and cannot be used by the memory management of the other programs, i.e. it should be shielded in config.sys: device=c:\windows\emm 386.exe x=c800 c83f Additional information about config.sys can be found in the IBM Host Based Devices documentation and in the README.WRI Concept file. 6. If using Windows for Workgroups, please modify the modicon.ini file (in the Windows directory). [ports] mbp0=5d Width: 185 mm Height: 230 mm

26 Initial startup when using Modbus Plus Activating under Windows 95 and Windows 98 To install the driver for Modbus Plus under Windows 95 or Windows 98, the following additional driver diskettes from Schneider Automation are needed: Description Local Netlib Library for Windows 95 Virtual device driver for Windows 95 Order No. SW_LNET_I95 SW_WVDD_I95 Software installation Prior to installing a new beta software version, previous versions have to be deleted. For more information, refer to the Deinstalling section. For software installation proceed as follows: 1. Insert the Local Netlib Library for Windows 95 diskette in the drive. 2. Invoke the control panel, activate the Software icon and click the button Install. 3. Click on Next > and then again on Next. Initial driver configuration After driver and library installation on hard disk. Perform the following configuration steps: 1. Open the control panel and select Hardware. 2. Answer No when asked if Windows should search for new hardware. 3. Select the hardware type MODICON Modbus Plus Adapters. 4. Select the card type and click Next > to continue. Result The memory address will be automatically selected. The standard mode of operation is set as Polled (with a scan rate of ms)

27 Initial startup when using Modbus Plus Configuration change To change the configuration of the installed cards, perform the following steps. Proceed as follows for a configuration change: 1. Invoke the control panel and click on the System icon. Result The corresponding properties window will be displayed. 2. Select the register card Device Manager. 3. Go to the branch Modbus Plus Adapters of the directory tree and bring up more information. 4. Select the adapter to be modified and click on Properties. 5. Select the register card Adapter Settings: Adapter number: This is an important value if several cards were installed in the system. Each card must be assigned a unique adapter number. When configuring the driver, the adapter number of each card is set to zero. This number must then be manually corrected. The first card should be assigned Adapter Number 0, the second Adapter Number 1, etc.. Polling Interval: If the operating mode Polled was set for the card, this value can be modified for the setting of the expected card scan rate. Approved values for this parameter are in the 100 ms range. Socket Number: PC Card/PCMCIA only. Physical slot where the PC card is installed. The respective slot can be determined by activating the PC card icon (PCMCIA) in the control panel. A corresponding list informs about the allocation of each PC card slot. Node Address: PC Card/PCMCIA only. This parameter contains the Modbus Plus network address of the drop. The number has to be unique for each network device. Reload Driver: If selecting and confirming this check box, the driver will reinitialize the communication with the current adapter. Due to this manual reload function, it is not required to restart the system for the activation of performed changes. For more information, refer to the section on PC cards (PCMCIA). 6. Select the register card Resources: The Basic Configuration 0 setting is the operating mode Polled, while Basic Configuration 1 specifies Interrupt mode Width: 185 mm Height: 230 mm

28 Initial startup when using Modbus Plus 7. For memory area modification, select Memory Range, click the button Change Setting... and then mark the address range of choice. Only valid address ranges will be displayed. 8. For interrupt number modification, select Interrupt Request, click the button Change Setting... and then pick the interrupt of choice. Note The PLC module (corresponds to card type SA85 or AT984) is shipped with the setting for operating mode Polled. To employ the card in Interrupt mode or to change the memory address of the card, the respective settings have to be modified. References for additional specific information can be found in the corresponding module description in the appendix of this manual. 9. Before proceeding with the next steps, please check if the needed resources are not used by another device. To do this, open the list box Device conflicts in the lower area of the properties window. 10. If there are no conflicts, click on OK. Result If changes were made, the dialog window will bring the display Create specified configuration. This message points out that the assignment of a certain memory address for the card (including the option to use a specific interrupt) is going to restrict the flexibility of Windows. This means, Windows will no longer be able to change the card configuration if other cards are later installed in the system. Since the PLC module (and also SA85 and AT984) is not a real Plug and Play device, their configuration cannot, per definition, be changed automatically and, therefore, it may be advantagous that Windows is not able to make automatic resource assignment modifications for the cards. 11. Click on Yes to complete the modifications. Result Since this is a Plug and Play driver, it is not necessary to restart the system for its activation. A new line Local NETLIB Library was created under the topic Programs of the Start menu. 12. Select this entry and invoke MBPDEMO to test if the driver functions correctly. The other demo programs (e.g. TEST4, TESTSLAV) are 32 bit versions of the test program shipped with the adapter. They are using the same parameters. Before starting these programs, modify their command line parameters

29 Initial startup when using Modbus Plus Deinstall For deinstallation, proceed as follows: 1. Invoke the control panel and click on the System icon. Result The corresponding properties window will be displayed. 2. Select the register card Device Manager. 3. Go to the branch MODICON Modbus Plus Adapters of the directory tree and bring up more information. 4. Select the adapter you want and click on Remove. Result All adapters have been permanently deleted from the system. 5. Invoke the control panel and click on the Software icon. Use this function to deinstall the software Activating under Windows NT To install the driver for Modbus Plus under Windows NT you must have the following additional driver diskettes from Schneider Automation: Description Local Netlib Library for Windows NT Virtual device driver for Windows NT Order No. SW_LNET_INT SW_WVDD_INT To install the Modbus Plus driver, please perform the following steps: 1. Start Windows NT. 2. Insert the MBX Driver Win NT Ver. 4.0 diskette. 3. Select the Start Run command. 4. Enter a:\setup in the command line. 5. Confirm by clicking OK. 6. Follow the instructions displayed on the screen. Result At end of installation, the MBX Device Configuration icon will be created. 7. To configure the driver, click on the icon. 8. Select New. 9. Under Device Type, enter your type (SA85 or AT984) Width: 185 mm Height: 230 mm

30 Initial startup when using Modbus Plus 10. Under Memory Address enter the address set on your PLC module using the rotation switch Base Address. 11. Save the settings and leave the dialog box. 12. Restart Windows NT. 13. Insert the MBX Driver Win NT Ver. 4.0 diskette. 14. Select the Start Run command. 15. Enter a:\setup in the command line. 16. Confirm by clicking OK. 17. To complete the installation, follow the instructions on the screen. 18. In the c:\winnt\system32 directory, open the config.nt file. 19. Enter the driver: device=%systemroot%\system\mbp16.sys. Save the entry and leave the file. 21. In the same directory, open the autoexec.nt file. 22. Enter the following line: %SystemRoot%\System\mbp16vec (NetBIOS vector) for instance: %SystemRoot%\System\mbp16vec 5d 23. Save the entry and leave the file. 24. Restart Windows NT Building the Hardware Connection Note The detailed description for the hardware startup of Modbus Plus is included in the Modbus Plus Network user s guide. To build the hardware connection, please perform the following steps: 1. Install the PLC module in the PC. 2. Use a Modbus Plus cable to connect the Modbus Plus interface of the PLC module with the SA85 or the Modbus Plus interface of another PC. Result The MB+ indicator of the PLC module will blink 3 x per second

31 Initial startup when using Modbus Plus 4.3 Initial Startup The chapter describes initial startup of an Atrium when using Modbus Plus. Chapter 4.1 contains the hardware and software requirements. For initial startup via Modbus Plus, different loaders are available when downloading the Executive files (EXEC) to the PLC. Windows loader DOS loader Initial Atrium Startup with the Windows Loader For initial startup, first download the EXEC file to the PLC module, then establish the software link from Concept to the CPU of the PLC module. EXEC file download to Flash RAM of the PLC module CPU To download the EXEC file to Flash RAM of the CPU, please perform the following steps: 1. Start the Windows installation program Loader by clicking on the proper icon in the Concept start menu. Result The main menu of the installation program for the Executive file (EXEC) will open. 2. If the Run indicator of the PLC module is on, stop the program with Stop PLC (in the Controller Operations menu). Result The RUN indicator is no longer on, but the RDY indicator will be. 3. Start the installation with the command button Setup. Result The dialog box Communication Mode will open. 4. Select the Modbus Plus option button and continue the installation with the command button Next. Result The dialog box Modbus+ Address will open. 5. In the text box Address enter the Modbus node address of your PLC module. 6. In the text box Adapter enter the adapter address in the config.sys file (parameter /n) as per LAN address setting. 7. Continue the installation using the command button Next. Result The dialog box Select Target Processor will open Width: 185 mm Height: 230 mm

32 Initial startup when using Modbus Plus 8. Select the PLCoption button and continue the installation with the command button Next. Result A standard Windows window (Executive File Name) will open. 9. In the field Folder, open the Concept/dat directory. 10. Select the EXEC file corresponding to your Atrium PLC module in the field File Name: PLC module EXEC file 180 CCO atrium.bin 180 CCO atr586.bin 11. Confirm the entry with the command button OK. Result You are returned to the main menu Load Executive. 12. Start the download process with the command button Download. 13. Acknowledge the warning with the command button OK. Result The dialog box Download Progress will open and the Executive file is downloaded to Flash RAM of the CPU. The message Waiting for node to enter normal mode will appear. 14. Confirm the message with the command button OK. Result The message Download was Successful will appear. 15. Confirm the message with the command button OK. Result You are returned to the main menu Load Executive. 16. To leave the installation program, go to the File menu and select the command Exit

33 Initial startup when using Modbus Plus Initial Atrium Startup with the DOS Loader For initial startup, first download the EXEC file to the PLC module, then establish the software link from Concept to the CPU of the PLC module. EXEC file download to Flash RAM of the CPU To download the EXEC file to Flash RAM of the CPU, please perform the following steps: 1. If the RUN indicator on the CPU is on, stop the program using Concept (in the main menu Online). Result The RUN indicator is off, while the Ready indicator is on. 2. Start the Loader.exe file (in the Concept\dat directory). Result The installation program for the Executive file (EXEC) will start. 3. Select the option Communication Parameters. 4. Select the option MODBUS PLUS. 5. Select the ADAPTER #0 or ADAPTER #1 option, depending on LAN address setting in the config.sys file (parameter /n) 6. At Enter first Routing Path: the Modbus node address of your PLC module. 7. Acknowledge the query Enter second Routing Path: with <Return>. 8. Select the option TARGET PATH At Enter Software Interrupt > enter the interrupt (5c or 5d) selected in the config.sys file and confirm this with <Return>. 10. Select the option ACCEPT CHANGES. Result You will be returned to the main menu. 11. Select the option File Selection. 12. Select the EXEC file according to your Atrium PLC module: PLC module EXEC file 180 CCO atrium.bin 180 CCO atr586.bin 13. Confirm the entry with <Return>. 14. Select the option Load File to PLC Width: 185 mm Height: 230 mm

34 Initial startup when using Modbus Plus 15. Acknowledge the warning with Yes. Result The Executive file is downloaded to Flash RAM of the CPU and the message Node failed to enter normal mode will appear. 16. Confirm the message with <Return>. Result The message Download Operation Successful will appear. 17. Confirm the message with <Return>. 18. Select the option Exit Program Building the Software Link The software link from Concept to PLC module runs via an internal PC bus. Additional information for project creation, connection structure between programming unit and PLC, user program download into the PLC, and project documentation can be found in the Concept Installation Guide, as of version 2.1, in the Quick Start chapter

35 Module Description The module descriptions are arranged alphabetically. 31 Width: 185 mm Height: 230 mm

36 32

37 180 CCO / 180 CCO CCO / 180 CCO Modicon TSX Atrium PLC Module The 180 CCO 121/241 coprocessors are PLC CPUs with I/O and communication interface for use on a PC with an ISA (AT ) bus. The PLC module 180 CCO has a 386EX CPU with 2 MB RAM and the PLC module 180 CCO has a CCO 586 CPU with 4 MB RAM memory for application programs and data HighLowIRQ 10 1 Module components 1 Motherboard (see Page 36) 2 386EX CPU or CCO 586 CPU (see Page 40) 3 IBS PC 104 SC T (see Page 42) 4 Interface card (see Page 46) 5 Backup battery on motherboard (see page 45) 6 Backup battery on the CPU (180 CCO only (see page 45) 33 Breite: 185 mm Höhe: 230 mm

38 180 CCO / 180 CCO Features and Functions The PLC module is an open coprocessor for realtime PLC functions with an integrated Modbus Plus interface, an additional INTERBUS interface and separate power supply. The module operates by means of the separate power supply independent of the host PC, i.e. even if the PC fails, it will continue to operate. The module consists of the following components: Standard AT format motherboard with PC 104 interfaces and Modbus Plus interface CPU with 386 EX microprocessor (180 CCO ) or 80486DX5 133 microprocessor (180 CCO ) INTERBUS module of Generation 4 Interface card Operating system Programming environment 1.1 Motherboard The motherboard contains the interface for the PC (2 kb DPM), the Modbus Plus communication interface (1 kb DPM), two PC 104 interfaces for connecting a CPU and an INTERBUS module, an option for connecting a backup battery, address selection switches, reset button, LED indicators for diagnostics and management of the supply voltage on/off control. 1.2 CPUs CPU 386EX (180 CCO ) The 386EX CPU contains a 386 EX microprocessor, 1MB Flash memory, 2 MB battery backed SRAM for programs and data, a realtime clock and an option for connecting a backup battery. CCO 586 (180 CCO ) The CPU CCO 586 contains a 80486DX5 133 microprocessor, 1MB Flash memory, 4 MB battery backed SRAM for programs and data, a realtime clock and an option for connecting a backup battery. 1.3 IBS PC 104 SC T für INTERBUS (CRP 660 0x) The IBS PC 104 SC T is a standard PC module for INTERBUS Generation 4. The fieldbus connection is electrically isolated by means of an additional interface card. INTERBUS uses logical addressing as well as the PCP channel. An INTERBUS line can process a maximum of 256 I/O words. The number of actual I/O points is dependent on the INTERBUS modules used. If only discrete I/O are used, a maximum of 4096 inputs and 4096 outputs is possible. 1.4 Interface Card The interface card provides electrical isolation for INTERBUS. It also provides the interface connectors for INTERBUS and the CMD Tool RS 232 connection for INTERBUS configuration and individual diagnostics. 34

39 180 CCO / 180 CCO Operating System The module operating system is a Schneider Automation standard operating environment (standard EXEC in conjunction with the 32 bit IEC operating system). 1.6 Programming Environment The module is programmed using Concept Version 2.12 or later. CMD Tool is available for INTERBUS configuration and individual diagnostics. 35 Breite: 185 mm Höhe: 230 mm

40 180 CCO / 180 CCO Configuration Before start up, the following procedures should be carried out on the module: Set the Modbus Plus address (motherboard) Set the PC addresses used on the ISA bus (motherboard) Set the interrupt used (motherboard) Select the power supply interface (motherboard) Insert the backup battery for the data and program memory (motherboard or CPU (180 CCO only)) Set write protection for the memory (CPU) Set the INTERBUS interface port address (IBS PC 104 SC T) 2.1 Motherboard settings The following settings can be made on the motherboard: MB+ address PC interrupt PC address Selection of power supply Figure 1 Motherboard 6 HighLowIRQ Module elements: 1 Connector panel (see Page 37) 2 Modbus Plus addressing (see Page 37) 3 PC interrupt (see Page 38) 4 PC address (see Page 38) 5 Backup battery (see Page 45) 6 Selection of internal/external power supply (see Page 39) 7 Internal connection for power supply (see Page 43) 36

41 180 CCO / 180 CCO Connector panel for motherboard Figure 2 Connector panel RES 1 RDY RUN I/O MB+ 2 EXTERNAL POWER 3 Connector panel elements: 1 Reset button (see Page 50) 2 Diagnostic LEDs (see Page 49) 3 External connection for supply voltage (see Page 43) 4 Modbus Plus interface (see Page 48) 4 MB+ MB+ Address The Modbus Plus interface is addressed via two rotary switches on the motherboard (see Figure 3 and Table 1). Figure 3 Modbus Plus addressing 10 1 Table 1 Rotary switch for Modbus Plus addressing Device address Rotary switch 10 Rotary switch The Modbus Plus address factory preset is Breite: 185 mm Höhe: 230 mm

42 180 CCO / 180 CCO PC interrupt The PC interrupt is set via a rotary switch on the motherboard (see Figure 4 and Table 2). Figure 4 PC interrupt IRQ Table 2 Setting the PC interrupt (IRQ) PC interrupt IRQ rotary switch IRQ 10 0 IRQ 11 1 IRQ 9 2 IRQ 3 3 IRQ 4 4 IRQ 5 5 IRQ 6 6 IRQ 7 7 Polled mode 8 Polled mode 9 The PC interrupt factory preset is 9, Polled Mode. PC address The PC address is set via two Base Address rotary switches on the motherboard (see Figure 5 and Table 3). The first two digits have to be set via the switches, the last two digits are always 0. Note The PLC module occupies 4 kb of the PC memory from the PC address set. Figure 5 Setting the PC address High Low Table 3 Setting the PC address (preset) PC address High rotary switch (0... F) Low rotary switch (0... F) D000 D 0 38

43 180 CCO / 180 CCO Selecting the power supply This switch allows you to select the type of power supply required, either external or internal. The factory setting is shown (external power supply). Figure 6 Power supply switch Power supply external internal 39 Breite: 185 mm Höhe: 230 mm

44 180 CCO / 180 CCO EX CPU and CCO 586 CPU Settings The following settings can be made on the CPU: Activation of write protection for the application program memory Setting the communication parameters for the Modbus interface MB1(for service purposes) Figure 7 CPU MB2 6 MB LED 4 LED 3 LED 2 LED 1 OFF ON mem RTU ASCII LED 6 4 LED 5 Module elements: 1 Modbus MB1 interface communication parameters (for service purposes) (see Page 41) 2 Write protection switch for the memory (see Page 41) 3 Diagnostic LEDs (see Page 49) 4 Connection for external backup battery and diagnostic LED (see Page 45) 5 Backup battery and diagnostic LED (180 CCO only (see page 45) 6 Modbus Interfaces (for service purposes) 40

45 180 CCO / 180 CCO Modbus MB1 interface communication parameters (for service purposes) This switch on the CPU is used to set the communication parameters for the Modbus interface MB1. Figure 8 Setting the MB1 communication parameters MB1 mem = interface parameters are taken from the software configuration RTU = 9600 bauds, even parity, 8 data bits, 1 stop bit ASCII = 2400 bauds, even parity, 7 data bits, 1 stop bit The factory setting is shown (RTU mode). Memory write protection The mem prot memory protection switch on the CPU is used to specify whether the application program may or may not be modified. Figure 9 Setting write protection mem prot not used OFF = no write protection ON = write protection active The factory setting is shown (no write protection). 41 Breite: 185 mm Höhe: 230 mm

46 180 CCO / 180 CCO IBS PC 104 SC T Settings for INTERBUS The following settings can be made on the INTERBUS card: INTERBUS interface port address Figure 10 IBS PC 104 SC T 1 O F F 1 8 Module elements: 1 Port address setting (see Page 42) The INTERBUS interface port address is factory set on the INTERBUS card at 1Hex and the test modus is OFF (see Figure 11): Figure 11 INTERBUS port addressing OFF ON ON = test mode Significance 0 Hex Significance 100 Hex Significance 80 Hex Significance 40 Hex Significance Hex Significance 10 Hex Significance 8 Hex = 1 Hex = setting OFF Caution If you have set the test mode (switch 1 = ON), the INTERBUS system will not operate properly. The IBS PC 104 SC T controller does not correspond with the corresponding CPU (PLC CPU). 42

47 180 CCO / 180 CCO Supply Voltage The supply voltage connection for the module can be either external or internal, depending on the setting of the selector switch on the motherboard (see page 39). The supply voltage itself can be provided either via an external power supply unit or from the host PC supply unit. Supply voltage connection The external supply voltage connection is via the 8 pin connector on the motherboard connector panel. The internal supply voltage connection is via an 8 pin connector on the motherboard. Figure 12 Connection assignment for the 8 pin connector 8: 7: 6: Powerresn (In) (not with host PC supply) 5: Powerfail (In) (not with host PC supply) 4: 5 V 3: GND 2: GND 1: Caution There are two connectors to connect the supply voltage to the PLC module. You are only allowed to feed the power to one of both connectors (dependent on the position of the power selector switch). If you use both connectors at the same time, the PLC module will not start. Type of supply voltage The following types of supply voltage can be used: Power supply via an external power supply unit The TSX Quantum 140 CPS or power supply module acts as an external power supply unit, and is installed on the TSX Quantum 140 XBP motherboard with the power supply adaptor. Mit dem The power supply is connected to one of the two 8 pin connectors on the PLC module using the preassembled 180 XCA connection cable. 43 Breite: 185 mm Höhe: 230 mm

48 180 CCO / 180 CCO Caution The cable does not have any strain relief at the 8 pin female connector end for connection to the PLC module. You must fasten the cable with help of a suitable strain relief. If you don t fasten the cable, the power supply may be interrupted because of unwanted strain of the connector and the PLC breaks down. If this type of power supply is selected, the module will not be dependent on the host PC, i.e. even if the PC fails, the module will continue to operate. This means that your program will continue running if the PC is switched off. When using an external power supply, the backup battery is activated if the power supply unit shuts down when it receives the undervoltage warning signal from the power unit. Power supply via the host PC power supply unit If a power supply via the host PC internal power supply unit is selected, the module will be dependent on the host PC. The backup battery is not activated, as the required undervoltage warning signals are missing. STOP Warning If the module power is supplied via the host PC power supply unit, the module will be cut off when you shut down the PC. This will cause a loss of data on the CPU, and all application data will have to be reloaded into the PLC module when the PC is restarted. The 180 XCA power supply cable for connection to the host PC power supply unit must be ordered separately. Table 4 Power supply components Type Module Number Power supply module 140 CPS or 140 CPS Power supply adaptor 180 CPX 1 00 Backplane 140 XBP Connection cable for adapter 180 XCA Connection cable for PC power supply unit 180 XCA

49 180 CCO / 180 CCO Backup Battery Connection Data and application programs can be protected against loss of data when the module power supply is switched off by fitting a backup battery. Note The backup battery is only activated if power is supplied via an external power supply unit, otherwise the required undervoltage warning signals will not be issued. Two types of backup batteries can be used on the PLC module 180 CCO : The 990 XCP Modicon TSX Quantum battery can be fitted in a special support on the motherboard and the connection can be made to the CPU. This battery can be accessed easily and can be replaced without removing the module from the PC. This battery is fitted by the factory. An LED next to the connector on the CPU indicates whether the battery has undervoltage. The SL350 Modicon TSX Compact battery (A1, 984) can be fitted in a special support on the 386EX CPU. An LED next to the battery support indicates whether the battery has undervoltage. Note If both batteries are fitted, a larger backup reserve is possible. The battery backup switch is designed so that the battery on the CPU will supply battery current until it is exhausted. Once it is exhausted, the battery on the motherboard will take over the supply without interruption. The undervoltage message is only displayed in Concept only when both batteries are empty. The PLC module 180 CCO has only the backup battery on the motherboard. Caution Batteries can only be replaced without loss of data if the power supply is switched on or if the break in power supply is less than 1 minute. 45 Breite: 185 mm Höhe: 230 mm

50 180 CCO / 180 CCO Interfaces The PLC module has the following interfaces: INTERBUS interface on the interface card connector panel RS 232 interface on the interface card connector panel Modbus Plus interface on the motherboard connector panel Interface Card Figure 13 Interface Card 1 Connector panel elements: 1 INTERBUS interface (see Page 46) 2 RS 232 interface for CMD Tool (see Page 47) IBS 2 RS232 INTERBUS Interface The INTERBUS connection is electrically isolated via a separate interface card. The peripherals are connected using standard INTERBUS connectors. Remote bus cable connection to the interface labelled IBS. Figure 14 INTERBUS pin assignment INTERBUS Connection point occupied Connection point not occupied 46

51 180 CCO / 180 CCO Table 5 INTERBUS interface assignment Connector Signal Meaning 1 DO Data, direction of transmission (+), (Data Out) 2 DI Data, direction of reception (+), (Data In) 3 GND Reference conductor (Signal Ground) 4 GND Reference conductor (Signal Ground) 5 +5V +5 V for fiber optic adapter connection 6 DO Transmit negated data (Data Out negated) 7 DI Receive negated data (Data In negated) 8 +5V +5 V for fiber optic adapter connection RS 232 interface for CMD Tool CMD Tool for INTERBUS configuration and specific individual diagnostics can be connected via the RS 232 interface on the interface card. Use the 990 NAA 263 data cable (3 m long). Figure 15 RS232 C pin assignment RS 232 C Connection point occupied Connection point not occupied Table 6 RS 232 interface assignment Connector Signal Meaning 2 D2 (RXD) Received Data 3 D1 (TXD) Transmitted Data 5 E2 (GND) Reference conductor (Signal Ground) 7 S2 (RTS) Switch on transmission unit (Request to Send) 8 M2 (CTS) Ready for transmission (Clear to Send) 47 Breite: 185 mm Höhe: 230 mm

52 180 CCO / 180 CCO Modbus Plus Interface Communication with other devices is possible via the Modbus Plus interface on the motherboard. Figure 16 Modbus Plus pin assignment Modbus Plus Connection point occupied Connection point not occupied Table 7 Modbus Plus interface assignment Connector Signal Meaning 1 SHIELD Shield 2 SDATA LOW Data line 3 SDATA HIGH Data line, negated The standard Modbus Plus drop cable is recommended for connecting neighbouring Modbus Plus devices: 990 NAD (2.4 m long) 990 NAD (6m long) The following accessories are required for constructing a bus cable: 990 NAD Modbus Plus tap Modbus Plus cable (piece goods) Note The Modbus Plus cable shield must be connected electrically and in parallel to PG at the entry of the device enclosure. The maximum permissible distance from the ground point to the station cable connector is 30 cm. 48

53 180 CCO / 180 CCO Diagnostics The PLC module has 4 status LEDs and a reset button on the motherboard connector panel and 6 LEDs on the CPU. 3.1 Status LEDs on the Motherboard The motherboard connector panel has the following LEDs: Table 8 Meaning of LEDs LED Color Meaning RDY green Supply voltage present, processor running RUN green ON = application program running, Flashing = Error (see Table 11) I/O green Data exchange taking place via INTERBUS. MB+ green Modbus Plus communication (see Table 12) 3.2 Status LEDs on the CPUs 180 CCO The 386EX CPU has the following diagnostic LEDs: Table 9 Meaning of LEDs LED No. Color Meaning MB1 1 green Modbus Interface 1 (for service purposes) MB2 2 green Modbus Interface 2 (for service purposes) RUN 3 green ON = application program running Flashing = Error (see Table 11) RDY 4 green Supply voltage present, processor running BAT 5 green External battery undervoltage or battery not present (next to the external battery connector) BAT (next to the battery support) 6 green Internal battery undervoltage or battery not present 180 CCO The CCO 586 CPU has the following diagnostic LEDs: Table 10 Meaning of LEDs LED No. Color Meaning MB1 1 yellow Modbus Interface 1 (for service purposes) MB2 2 yellow Modbus Interface 2 (for service purposes) RUN 3 yellow ON = application program running Flashing = Error (see Table 11) RDY 4 yellow Supply voltage present, processor running BAT (next to the external battery connector) 5 red External battery undervoltage or battery not present 49 Breite: 185 mm Höhe: 230 mm