Important Product Information

Transcription

1 Important Product Information April 15, 2009 READ THIS INFORMATION FIRST Product: IC693CPU366 CPU Module with PROFIBUS Master Upgrades IC693CPU366-CD with CPU Firmware Version PROFIBUS Firmware Version 1.02 No field upgrade is required or available for this hardware revision. An IC693CPU366 can be field upgraded to an IC693CPU366-xD using the firmware upgrade utility and upgrade kit 44A G04. Firmware upgrade kits can be downloaded at no cost from 1http://support.gefanuc.com/ or purchased. Firmware upgrades require the IC690ACC901 Miniconverter and Cable Kit. Functional Compatibility Battery Life Programmer Version Requirements PLC C Toolkit Version Requirements IC693CMM321 Ethernet Interface Version Requirements Series Hand-Held Programmer Compatibility IC693BEM340 FIP Bus Controller Version Requirements Series PROFIBUS Compatibility With the original cache RAM component, the battery life was 6 years 25 C and 1½ years at 60 C. The data retention current on the currently available part reduces the battery life to 10 months at 25 C and 5½ months at 60 C. The IC693CPU366 can be configured and programmed with Machine Edition Logic Developer PLC version 5.0 SP1 or later. Version 4.00 or later of the PLC C Toolkit must be used for C programming. All Ethernet Interface (IC693CMM321) modules used for programmer or HMI/SCADA communications with this CPU must be one of the following revision groups: IC693CMM321-CC or later IC693CMM321-AA or -BA upgraded to firmware version 1.11 or later The CPU366 does not support PROFIBUS configuration using the Hand-Held Programmer (HHP). IC693BEM340 firmware version 3.00 or later is required for this release of CPU 36x firmware. Users of the Series IC693PBM200 and IC693PBS201 PROFIBUS modules should review the Series CPU w/embedded PROFIBUS User s Manual, GFK There are operational differences between the PROFIBUS functionality of these CPU models and the PBM200/PBS201 modules, such as COMMREQ status words and data fields. These CPU models report more information than the PROFIBUS modules in some instances and less information in others.

2 2 Important Product Information DOIO Functionality DOIO functionality is not supported to the embedded PROFIBUS interface at this time. The DOIO function block does not return an error if it is executed using the embedded PROFIBUS as a target. Get Device Status COMMREQ The Get Device Status COMMREQ is used to get detailed status information about a particular device on the PROFIBUS network. In order to get the most up to date data, a change was made after the initial release to make this an active network command. In the first release, this information was returned to the user application based on buffered data. After the initial release, this data is actively requested from the network. If the user application uses the Get Device Status COMMREQ often, there is a potential to impact network performance. Total Configuration Size The various memory resources within the PLC CPU constrain the number and type of slave devices and the amount of data they can exchange with the master. The amount of memory available for the PROFIBUS configuration is affected by the number and type of slave modules in the network configuration. The CPU366 provides up to 8K bytes (physical memory) of resource data. This is defined by each slave module s GSD file, and can vary depending on the types of modules. PROFIBUS Data Sizes The amount of data that can be configured on the CPU 366 PROFIBUS network provides up to 2048 bytes input and 2048 bytes output. Problems Resolved by this Hardware Revision The original cache RAM component is obsolete and no longer available. The new component is the lowest power part currently available. Problems Resolved by Firmware Revisions in this Release CPU Issues Resolved (Revision 10.74) Loss/add of module faults with IC693ALG222/223 modules in CPU366 PLC In previous CPU366 firmware versions, when two or more high-density analog input modules (IC693ALG222 or IC693ALG223) are installed in the CPU rack, and all 16 input channels are active in the modules, loss of module and addition of module faults for one of the analog modules may occur when the CPU rack is powered on. This issue is corrected in version

3 Important Product Information 3 PROFIBUS Issues Resolved (Revision 1.02) No PROFIBUS Loss/Add Faults In stop mode Slave Diagnostic Status Word Get Device Diagnostics COMMREQ COMMREQ Response Memory Data Types Format Of Loss/Add Faults In the I/O Table No Fault In Fault Table If PROFIBUS Configuration Is Rejected Validation Of Reference Table Sizes With COMMREQ Return Data Extra Addition of Device faults LED Operation With Failed CPU Loss of module and Addition of module faults are now logged correctly when the CPU is in STOP mode. The Slave Diagnostic Status Word now provides only the addresses of slaves that have a diagnostic message to report. This status word no longer erroneously reports the addresses of slaves that have a physical network error. The CPU366 Get Device Diagnostics now returns the standard diagnostics data, as well as the extended diagnostic data. This operation is consistent with other GE Fanuc PROFIBUS products. The %I, %Q, %M and %T memory types can now be used for the PROFIBUS COMMREQ response data. In previous releases, the CPU366 did not use the offset correctly when returning data using the BYTE offset segments associated with these memory types. This problem has been corrected in release The location of a Loss Of Device or Addition Of Device fault is now reported correctly in the IO Fault table. In addition, the slave address is listed in byte 5 of the fault extra data. The reference address indicated in the IO Fault table always shows the reference associated with the lowest configured slave in the PROFIBUS network. If the CPU366 rejects a PROFIBUS configuration after a download has completed, as of PROFIBUS firmware 1.02, the following fault will be logged Unable to deliver configuration to module due to configuration mismatch. The slave status bits will not be set, and the LED pattern will be SYS off, and COM blinking green. This indicates that the PROFIBUS daughterboard is not configured. The COMMREQ status word now correctly returns a value of 4 indicating Command Terminated invalid command data when an invalid memory reference type is used in a COMMREQ is used to read PROFIBUS information. In previous releases, if an invalid identifier was used, no data was returned to the reference table yet the status word would indicate a value of OK (1). In previous releases, an Addition of Device fault was reported for each device in the PROFIBUS network configuration either after a download or on the transition to run. This issue has been corrected in release The PROFIBUS Master LEDs now correctly indicate the network is in clear mode if the CPU mother board fails. In this situation, the power supply s OK LED will be off, indicating the CPU is non-operational.

4 4 Important Product Information ABB GSD file and SIEMENS SIMOCODE GSD file do not work on CPU366 CPU366 PROFIBUS master "Module Busy" COMMREQ Status Word response does not work PROFIBUS Master can't send DPV1 Write data for odd byte sizes PROFIBUS DP-V1 Communications: Slave Failure To Respond Causes Repeated Error Status In previous versions, downloading a project with one or more GSD files for either an ABB slave (model PDP22-FBP (V1)) or Siemens slave (model SIMCODE) to a CPU 366 would result in COM LED indicator flashing green & SYS LED indicator off. Neither the slave bit, nor the master bit (in the slave status bit array) would be set on and no fault was logged in the fault table. This issue is corrected in version When two of the same COMMREQS are sent at the same time (i.e. status word from 1 st COMMREQ has not been received) previous versions of firmware may erroneously result in a status of COMMREQ COMPLETE (COMMREQ Status Word = 1). With PROFIBUS firmware v1.02 (and later) a status word of MODULE BUSY (COMMREQ Status Word=2) will be returned when two of the same COMMREQS are sent at the same time. for Word 14 of the DP-V1 Write request COMMREQ should be: Length x of data to be written in words or bytes. The uppermost bit determines whether the size value is interpreted as words or bytes. For example, a value of 0x0005 indicates a data size of five words while a value of 0x8005 indicates a data size of five bytes. In previous versions, if the CPU366 timed out waiting for a response from a slave to a DP-V1 Read or Write request COMMREQ, it reported a DP-V1 Request Status of 130 decimal Master has stopped DP-V1 communication automatically. After receiving this error, subsequent DP-V1 COMMREQs could report DP-V1 Request Status 129 decimal Master is about to stop DP-V1 communication or DP-V1 is not in Open state. In order to clear this state, download a new hardware configuration to the CPU366 or, turn the CPU366 off and back on. This issue is corrected in version 1.02.

5 Important Product Information 5 CPU Restrictions and Open Issues Timing Issue with ALG220/221-F or earlier modules may result in incorrect %AI values read by CPU The CPU may generate a fatal fault if logic containing a DOIO function block call to a smart module is repeatedly transitioned between RUN and STOP modes. CPU may generate a Fatal Fault during store of folders with large configurations Reading corrupted data from flash memory may cause a Watch Dog Timeout The CPU may generate a fatal fault when configuring a module with the HHP following a store to the PLC that exhausts user memory Firmware Update fails following power-up with Clear M/T and a write to flash The %AI values reported by an IC693ALG220/221-F or earlier module revision may be incorrect and exhibit erratic behavior. Certain current or voltage levels within the input range applied to the module can cause the %AI values to be reported incorrectly. The problem stems from the use of particular opto-couplers that may exhibit timing issues with CPU 35x/36x modules. This issue does not occur with IC693ALG220/221-G and later module revisions. Storing program logic that contains a call to a DOIO function block may cause the CPU to run out of system memory. This can occur when the PLC transitions between RUN and STOP modes several times. Storing the hardware configuration will cause the system memory to be freed, and the PLC will resume normal operation. The CPU may generate a fatal fault during a store of a folder with a very large configuration. This may be made worse by storing logic and configuration at the same time, or by read requests for reference table data from a programmer or HMI during the store. See Storing Large Configurations on page 2H6 for recommendations. If corrupted data is read from flash memory, the Watch Dog Timer on the PLC may be triggered. This can be corrected by completing a valid flash store. The PLC CPU may generate a fatal fault when the user attempts to configure a module with the HHP after a store to the PLC that exhausts user memory. A firmware upgrade may fail after the user presses the Clear and M/T keys on the HHP during power-up and then performs a write to flash. Cycling power on the PLC will enable the upgrade to proceed. CPU366 PROFIBUS Master Restrictions and Open Issues Reference Address in Loss/Add Faults from CPU366 Incorrect The IO Fault table shows the reference associated with the slave that has the lowest network address configured in the PROFIBUS network

6 6 Important Product Information CPU Operational Notes PROFIBUS interface does not start after downloading configuration User Flash Contents Writing Flash Memory If the CPU366 is power cycled and a configuration is then downloaded into Flash, the PROFIBUS interface will stop working when the CPU366 is transitioned to Run mode. When this happens, the SYS LED on the CPU366 blinks, alternating between green and red. To correct this condition, stop the CPU366, download configuration into RAM and then start the CPU366. The SYS LED on CPU366 should be green and PROFIBUS network should return to operation. The user program, configuration, CPU ID (used for SNP communication), and reference memory tables stored in RAM will automatically be cleared when the CPU firmware in flash memory is changed. You will need to restore these when upgrading from a previous firmware version. The user program, configuration, and reference memory (%R, %AI, %AQ, %I, %Q, %T and %M) tables can be restored from a PLC programmer folder or from flash. The SNP ID must be set separately, using the PLC programmer or the HHP. The faults, overrides and transition tables cannot be stored to flash. The overrides may be restored from the programmer or folder, but the faults and transitions are lost. When writing very large programs to flash, you may need to increase the request timeout value in the programming software to avoid receiving a request timeout message. An upper bound of 25 seconds is typically satisfactory. Storing Large Configurations A Series PLC using a CPU 36x supports a maximum of 32 DSM314 or DSM324 modules. This number is reduced when other intelligent modules are used in the PLC, such as APM and GBC modules. It may also be reduced when: The number of racks in the PLC increases; The total size of logic, motion and AUP files increases; The application uses C logic blocks or a C logic program; and Connected programmers or HMI devices are used to read reference memory or fault tables. In some cases it may be possible to increase the number of DSM314 or DSM324 modules that the CPU will accept in the hardware configuration by storing logic first and then storing the configuration separately. CPU366 Does Not Support Hardware Configurations for CPU31x/32x/33x/34x/374 Simultaneous Load and Store Transition Tables are not cleared when the reference tables are cleared. An application that contains any CPU35x or CPU36x model in the hardware configuration can usually be stored to any other release 9.00 or later CPU35x or CPU36x model and then executed. However, attempting to store a hardware configuration that contains a CPU31x, 32x, 33x, 34x or 374 to a CPU366 will fail. When operating with multiple programmers attached, initiating a store operation from one programmer during a load operation from another programmer will cause the load to fail. The transition tables are not cleared when the reference tables are cleared through the programming software.

7 Important Product Information 7 CPU366 PROFIBUS Master Operational Notes PROFIBUS interface does not start after downloading configuration PROFIBUS Read/Write Request COMMREQ Data Size Daughterboard States LED Operation with Short Circuit Bus See description on page 3H6. The size of data transferred by the Read Request and Write Request COMMREQs is always specified in words. The IC693CPU366 cannot transfer data with a byte size that is not evenly divisible by two. If the PROFIBUS daughterboard receives an invalid configuration from Machine Edition, the daughterboard state may end up in CONFIG_FAILED, which can only be recovered from by a power cycle. The PROFIBUS LED will continue to blink, indicating that no configuration exists. When the A and B lines of the PROFIBUS system are shorted together a bus short circuit condition will occur within the PROFIBUS Master. This condition will be indicated by the COM and SYS LEDs located on the front of the module. The SYS LED will be Solid Red as long as a bus short remains. The COM LED will be Green and Flash RED depending on the severity of the short. The reason for this is that the bus controller is still attempting to communicate. Short circuit conditions that can occur when the PLC is in Run and actively communicating with at least one slave. Type of Short SYS LED COM LED A and B Shorted Together RED GREEN flashing RED A shorted to Ground B Open GREEN GREEN B shorted to Ground A Open GREEN GREEN A and B Shorted to Ground RED GREEN flashing RED CPU366 Warm power-up exceeds 5 second warm power up time Loss Of Daughterboard After Rapid HW Config Stores The CPU366 exceeds the 5-second warm power up time. The average warm power up time observed with the CPU366 is approximately 7 seconds. Repeatedly downloading a hardware configuration faster than the daughterboard can process the PROFIBUS configuration (before the LEDs indicate network OK), can eventually lead to a loss of daughterboard fault. Should this occur, power cycle the CPU to recover.

8 8 Important Product Information Product Documentation Series CPU with Embedded PROFIBUS Master User s Manual, GFK-2334 Series Installation and Hardware Manual, GFK-0356 Series 90-30/20/Micro CPU Instruction Set Reference Manual, GFK-0467 Documentation Errata Battery Life The new cache RAM component reduces the battery life as shown in the following table. This information will be included in the next scheduled update of the Series CPU Reference Manual. Hardware Version Estimated Battery Life at 25 C at 60 C IC693CPU366-Bx and earlier 6 years 1½ years IC693CPU366-Cx and later 10 months 5½ months PID Derivative Term The following changes will be made to the Series 90-30/20/Micro PLC CPU Instruction Set Reference Manual, GFK-0467M, at its next revision: In Chapter 12, Control Functions, Section PID Algorithm Selection (PIDISA or PIDIND) and Gains The description of the Derivation term should be replaced with this text: The Derivative term is the time rate of change of the Error term in the interval since the last PID solution. Derivative = ΔError / dt = (Error previous Error) / dt, where dt = Current PLC elapsed time - PLC elapsed time at previous PID solution. In normal mode (that is, without Reverse-Action mode), this is the change in the error term. (Error previous Error) = (SP PV) (previous SP previous PV) = (previous PV PV) (previous SP SP) However, when the Error Polarity bit (bit 0) in the Config Word is set, the sign of the change in the error term is reversed. (Error previous Error) = (PV SP) (previous PV previous SP) = (PV previous PV) (SP previous SP) The change in the error term depends on changes in both the Set Point and the Process Variable. If the Set Point is constant, the difference between SP and the previous SP is zero and has no effect on the output. However, Set Point changes can cause large transient swings in the derivative term and hence the output. Loop stability may be improved by eliminating the effect of Set Point changes on the derivative term. Set the third bit (bit 2) of the Config Word to 1 to calculate the Derivative based only on the change in PV. For bit 2 set in normal mode (bit 0 = 0), (Error previous Error) = (previous PV PV), and with bit 2 set in Reverse-Action mode (bit 0 = 1), (Error previous Error) = (PV previous PV).

9 Important Product Information 9 In table on page of GFK-0467M, the Config Word row should be replaced with: %Ref+0012 Config Word Low 6 bits used Bit 0: Error Polarity. When this bit is 0, the error term is SP - PV. When this bit is 1, the error term is PV - SP. Setting this bit to 1 modifies the standard PID Error Term from the normal (SP PV) to (PV SP), reversing the sign of the feedback term. This is for reverse acting controls where the CV must go down when the PV goes up. Bit 1: Output Polarity. When this bit is 0, the CV output represents the output of the PID calculation. When it is set to 1, the CV output represents the negative of output of the PID calculation. Setting this bit to 1 inverts the Output Polarity so that CV is the negative of the PID output rather than the normal positive value. Bit 2: When this bit is 1, the setpoint is removed from derivative calculation. For details, see the discussion on page 15. Bit 3: Deadband action. When the Deadband action bit is 0, no deadband action is chosen. If the error is within the deadband limits, the error is to be zero. Otherwise the error is not affected by the deadband limits. If the Deadband action bit is 1, deadband action is chosen. If the error is within the deadband limits, the error is forced to be zero. If, however, the error is outside the deadband limits, the error is reduced by the deadband limit (error = error deadband limit). Bit 4: Anti-reset windup action. When this bit is 0, the anti-reset windup action uses a reset back calculation. When the output is clamped, this replaces the accumulated Y remainder value with whatever value is necessary to produce the clamped output exactly. When the bit is 1, this replaces accumulated Y term with the value of the Y term at the start of the calculation. In this way, the pre-clamp Y value is held as long as the output is clamped. Bit 5: Enable derivative filtering. When this bit is set to 0, no filtering is applied to the derivative term. When set to 1, a first order filter is applied. This will limit the effects of higher frequency process disturbances on the derivative term.

10 10 Important Product Information CPU with Embedded PROFIBUS Interface User s Manual The following corrections will be included in the next revision (version B) of the Series CPU with Embedded PROFIBUS Interface User s Manual, GFK Appendix A In Appendix A of GFK-2334 (COMMREQ operation) COMMREQ Status Word, a COMMREQ status word of 5 is not used with the CPU366 or CPU367. The description of status word 7 will be revised to include conditions typically reported with a status word value of 5. COMMREQ Status Word The following table defines the state codes that can be returned in the COMMREQ status word. Dec Value (Hex) 0 (0000) Device has not yet processed the COMMREQ. 1 (0001) Command Complete Note: This status does not necessarily mean success. Some commands have reply data that must also be checked. 2 (0002) Command Terminated module busy 3 (0003) Command Terminated invalid command 4 (0004) Command Terminated invalid command data 5 (0005) Not used 6 (0006) Not used 7 (0007) Command Terminated not enough data or not enough memory in reply area The command did not specify sufficient PLC memory for the reply. Command will be ignored. 8 (0008) Command Terminated command-specific error. See AdditionalCode in the Status Block for more information.

11 Important Product Information 11 Chapters 5 and 6 Get Device Status Communication Requests Chapter 5 (PROFIBUS Master Status and Diagnostics) and Chapter 6 (PROFIBUS Slave Status and Diagnostics), Communication Requests Table of valid reference memory needs to include units for each of the reference memory types. Memory Type Abbreviation Decimal code to Memory Type enter %I Discrete Input table 16 Bytes %Q Discrete Output table 18 Bytes %R Register memory 08 Word (2 bytes) %AI Analog Input table 10 Word (2 bytes) %AQ Analog Output table 12 Word (2 bytes) %T %M Discrete temporary memory Discrete Input memory 20 Byte 22 Byte Units of Reference memory COMMREQ status word address, maximum size of response area, and starting addresses (in all COMMREQ command blocks defined in this manual) should be expressed in units of the reference memory being used. Examples: In the Get Device Status Command Block, if %R memory is used for the COMMREQ status word (Word 03 = 0008), then the COMMREQ status word address (Word 04) uses WORD units. If the response will be written to %R memory, (Word 08 = 0008), then the starting address (Word 09) and maximum size of the response area (Word 10) use WORD units. In the Get Device Status Command Block, if %M memory is used for the COMMREQ status word (Word 03 = 0022), then the COMMREQ status word address (Word 04) uses BYTE units. If the response will be written to %M memory (Word 08 = 0022), then the starting address (Word 09) and the maximum size of the response area (Word 10) use BYTE units. DP-V1 Write Request A description of the DP-V1 Write request COMMREQ should be added to the Series CPU with Embedded PROFIBUS Interface User s Manual, GFK For details, refer to 4HPROFIBUS Master can't send DPV1 Write data for odd byte sizes on page 5H4.

12 12 Important Product Information Installation in Hazardous Locations The following information is for products bearing the UL marking for Hazardous Locations: WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2; WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES; AND WARNING - EXPLOSION HAZARD - DO NOT CONNECT OR DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS. EQUIPMENT LABELED WITH REFERENCE TO CLASS I, GROUPS A, B, C & D, DIV. 2 HAZARDOUS LOCATIONS IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D OR NON-HAZARDOUS LOCATIONS ONLY.