APNT#1208 GP-Pro EX to Allen Bradley RIO via Gateway. Explore Newer Solutions

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1 Application Note #1208: GP-Pro EX to Allen Bradley RIO via Gateway Explore Newer Solutions When upgrading your existing HMI consider updating the communications to current technology. Pro-face GP-Pro EX includes features that overcome limitations that traditionally required a remote I/O (RIO) connection to the PLC. These features often perform better, are simpler to implement, and can cost less than upgrading using an Remote I/O (RIO) solution. Limitations: Unlike the old Pro-face GP and QuickPanel hardware RIO adapters, RIO Gateways like ProLinx 5601-RIO-DFCM cannot access all I/O registers. They can only access their assigned I/O address block. In the case of the ProLinx adapter the first input word and output word assigned in the PLC to the gateway are also not accessible in the HMI. Pro-face does not offer the ProLinx adapter. Pro-face America provides technical support, and this document details, connecting GP-Pro EX to and reading and writing the memory in the ProLinx 5601-RIO-DFCM. Please contact ProLinx for all support for help on mapping and exchanging data between their device and your PLC. In most cases the following solutions will perform better at a lower overall project cost. Unlike an RIO solution, none of them require ladder programming to exchange data. Even when replacing an existing HMI on RIO, upgrading to one of these solutions may be a better choice: * Serial -- RS232 via the PLC CH0 programming port. RS-Linx PLC programming access via the Pro-face Pass-Through tool. Use the Pro-face Multi-link feature to connect additional displays. * Ethernet -- Add a 1761-NET-ENI module to the PLC for Ethernet access. Connect one or more displays. (Verify the PLC5 hardware and firmware versions are compatible with the NET- ENI module.) * Data Highway -- Adding a DH+ network does not require additions to the PLC program. We offer a DH+ gateway solution. Use the Pro-face Multi-link feature to connect additional displays. See APNT1188 for more information. 1 A typical RIO solution requires data handling PLC ladder programming and additional I/O startup costs. RIO requires more complex programming because it cannot read and write the same PLC register. Page 1 of 16

2 GP to Remote I/O Overview Pro-face GP-Pro EX can be connected to an Allen Bradley RIO using a ProLinx 5601-RIO- DFCM gateway. The Pro-face display communicates with the gateway using the standard GP- Pro EX Rockwell Automation DF1 serial driver. The gateway is connected to the PLC as remote I/O. A memory area in the gateway is used to store data for exchange between the PLC and the HMI. Configuration software provided with the gateway defines the data area and communications with the PLC and the Pro-face HMI display. This application note is an addendum to the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver. The like numbered sections in this guide provide additional helpful information to connect the gateway to a Pro-face AST/AGP. Refer to both documents as well as the ProLinx DF1 Mater/Slave manual dfcm_protocol_ manual.pdf to configure the DF1 side of the RIO-DF1 gateway. For help configuring the RIO side of the gateway and the PLC refer to the ProLinx Rockwell Automation Remote I/O Adapter manual rio_driver_manual.pdf. For technical support regarding the gateway any aspect of the RIO and PLC side of the gateway contact ProSoft at or support@prosoft-technology.com Note: The first input word and output word assigned in the PLC to the gateway are not accessible in the HMI. Example: Assume a gateway is configured as a full rack and it is assigned 8 inputs starting at I:10 and 8 output words starting at O:10 in the PLC I/O configuration. The first input word I:10 and output word O:10 are not accessible. The remaining 7 input words (I:11 I:17) and 7 output words (O:11 O:17) can be used. How the Gateway Works The PLC Remote I/O Scanner is connected to field I/O and the ProLinx gateway Remote I/O Adapter interface. A limited amount data (up to 7 words in and 7 words out) can be exchanged directly with the gateway at high speed as PLC I/O. To exchange additional data with the gateway ladder logic including BTR/BTW block transfer commands must be added to the PLC program. BTW/BTR commands can move up to 60 words of data in a single block on the RIO network. The Pro-face display is connected to the ProLinx gateway DF1 interface. The Pro-face DF1 driver automatically handles data exchanges between the gateway and the Pro-face display. All memory in the gateway, whether linked to the PLC as direct I/O or by block transfers, is accessible by DF1 protocol as N-files (integer) mapped in the gateway by the user. A shared user defined memory area (database) within the gateway is used to exchange data between the RIO interface and the DF1 interface. Output and BTW data are write only from the Page 2 of 16

3 PLC to the gateway so the HMI display can only read that data. The HMI display can write Input and BTR data to the PLC through the gateway. A limited amount of input and output (direct I/O) data is exchanged with the gateway every I/O scan providing the best performance. Slower block transfer (BTR and BTW) data exchanges require multiple ladder scans to update. Be aware that block transfer data exchanges can impact analog and word module updates. Hint: To legacy Quick Panel and GP-Pro users retrofitting displays with O, I, BTW, and BTR addressing: Consider creating your gateway addressing configuration first. Then convert the legacy project to DF1 and substitute the new N-file addressing before upgrading to GP-Pro EX The following numbered sections supplement the corresponding section in the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver. 1 System Configuration The system configuration in the case when the External Device of a Rockwell Automation PLC and the Display are connected is shown. * SLC 500 series PLCs require a 1747-ASB Remote I/O adapter module. 2 Selection of External Device Refer to the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver Section 2 Selection of External Device for a full explanation. To connect to the ProLinx gateway use these settings to select the Device/PLC: Manufacturer: Rockwell Automation, Inc. Series: DF1 Page 3 of 16

4 3 Example of Communication Setting 3.a Setting Example 1 Settings of GP-Pro EX * Communications Settings To display the setting screen, select [Device/PLC Settings] from [System setting window] in workspace. The Communication Settings selected should match settings in the ProSoft Configuration Builder. * Device Settings The device communication setting for the gateway should be SLC500 series. To display the setting screen, click the Settings icon of the external device you want to set from [Device-Specific Settings] of [Device/PLC Settings]. Page 4 of 16

5 3.b Setting Example 2 Settings of GP-Pro EX * Communications Settings To display the setting screen, select [Device/PLC Settings] from [System setting window] in workspace. The Communication Settings should match settings in the ProSoft Configuration Builder. * Device Settings The device communication setting for the gateway should be SLC500 series. To display the setting screen, click the Settings icon of the external device you want to set from [Device-Specific Settings] of [Device/PLC Settings]. Page 5 of 16

6 3.c Settings of External ProLinx Gateway Device (GP-Pro EX Setting Example 1 and 2) Use the ProSoft Configuration Tool to configure the gateway. * RIO Configuration RIO configuration defines the RIO interface to the PLC and where PLC data will be located in gateway memory. Refer to the ProSoft manual rio_driver_manual.pdf for instructions to configure the gateway, configure the PLC RIO interface, RIO cabling, and any required PLC programming. The illustration below shows the ProSoft RIO configuration used in our sample project. Note: The memory area used by BTR or BTW blocks is larger than the Register Count. Allow for a gap of at least several registers between BTR and BTW blocks. *DF1 Configuration Set the jumper on the back of the ProLinx gateway appropriately for either RS232 (default) or RS422 to match the GP-Pro EX setting. The gateway software configuration is the same for either RS232 and RS422. Page 6 of 16

7 The DF1 configuration sets the communication parameters to communicate with the Pro-face HMI. For details instructions refer to ProSoft dfcm_protocol_manual.pdf. Local Station ID should match the GP-Pro EX Individual Device Settings / Destination ID (Remote). Match the GP-Pro EX Communication Settings: Protocol, Local Station ID (DF1 mode), Termination Type (Error Detection), Baud Rate, and Parity. The default settings in the gateway for RTS on, RTS off, and Use CTS Line are suitable when GP-Pro EX Flow Control is set to ER(DTS/CTS) for RS232 or NONE for RS422, and the DF1 cabling shown in this document is used. The DF1 protocol uses SLC500 integer file addressing to exchange data with the gateway memory. The ProSoft Configuration Builder is used to map the gateway memory as N files. First File sets the starting file number. File Size defines the number of words per file. File Offset determines the gateway memory location of the first word in the first N-file file. Page 7 of 16

8 Note: The DF1 N-register addresses have no relationship to the PLC5 files. The File Size is not related to the BTW or BTR number of words. 4 Setup Items Refer to the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver Section 4. 5 Cable Diagrams Connection notes: The FG pin of the External Device body must be D-class grounded. Please refer to the manual of the External Device for more details. SG and FG are connected inside the display. When connecting SG to the External Device, design the system to not form short-circuit loop. Connect the isolation unit, when communication is not stabilized under the influence of noise etc. Cable Diagram 1 Display (Connection Port) PLC (Connection Port) Cable Diagram Remarks AGP (COM1) AST (COM1) GP4000 (COM1) SIO Type RS RIO-DFCM ProLinx Gateway * Port 0 - RS232 HMI-CAB-ST52 or HMI-CAB-ST52-30x or HMI-CAB-ST52-50x A Your own cable B A) When using the RS232 cable (HMI-CAB-ST52) by Pro-face America Page 8 of 16

9 B) When using your own cable Cable Diagram 2 Display (Connection Port) PLC (Connection Port) Cable Diagram Remarks AGP (COM1)* AGP3302B (COM2) GP4000 (COM2) AST (COM2) SIO Type RS422 4-wire 5601-RIO-DFCM ProLinx Gateway * Port 0 - RS422 Your own cable A AGP (COM2)* Your own cable B * All AGP models except AGP-3300 and AGP3302B Page 9 of 16

10 A) When using your own cable. AGP (COM1)*, AGP3302B (COM2), GP4000 (COM2) AST (COM2): B) When using your own cable. AGP (COM2)* * All AGP models except AGP-3300 and AGP3302B Page 10 of 16

11 6 Supported Device Range of supported device address is shown in the table below. 6.a ProLinx Gateway 7 Device Code and Address Code Refer to the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver Section 7 8 Error Messages Refer to the Pro-face PLC/Device connection manual Rockwell Automation DF1 Driver Section 8 Troubleshooting ** Errors displayed on the HMI display: Refer to the Pro-face documentation for an explanation of the error. Check the ProLinx gateway Port 0 status indicator lights. Check HMI to gateway cabling. Verify the addresses in the HMI project are only N file addresses and with-in the ranges defined in the gateway. Page 11 of 16

12 ** Wrong data or all zeros are displayed on the HMI. No error messages are displayed on HMI: Verify PLC values are being written into the gateway memory. Values in gateway memory can be viewed with the ProSoft Configuration Builder software (see note 1). a> If the data does not appear in the gateway memory as expected verify the PLC logic is sending the data. Check the gateway Remote I/O port status LEDs. Review the gateway RIO configuration. The number of registers between BTR Start and BTW Start should be greater than setting Register count. Refer to the ProSoft manual rio_driver_manual.pdf for help. If you still need assistance contact ProSoft for gateway configuration support or Rockwell Automation for PLC programming support. b> If the data appears in the gateway memory but does not appear on the Pro-face display verify the data at the expected gateway memory location. Look at the DF1 Port 0 configuration in the ProSoft Configuration Builder. Check the settings for First File, File Size, and File Offset to verify the N file address of the data in the gateway. If you still need assistance contact ProSoft or Pro-face America for technical support. ** Wrong data or no data read by the PLC. No error messages are displayed on HMI: Verify values from the HMI are at the expected locations in gateway memory. Values in gateway memory can be viewed with the ProSoft Configuration Builder software (see note 1). a> If the data is in the gateway memory but does not appear in the PLC verify the gateway RIO configuration and the BTW/BTR block transfer programming in the PLC. Check the gateway Remote I/O port status LEDs. Refer to the ProSoft manual rio_driver_manual.pdf for help. If you still need assistance contact ProSoft for gateway configuration support or Rockwell Automation for PLC programming support. b> If the data does not appear in the gateway memory at the expected locations Look at the DF1 Port 0 configuration in the ProSoft Configuration Builder. Check the settings for First File, File Size, and File Offset to verify the N file address of the data. If you still need assistance contact ProSoft or Pro-face America for technical support Note1: Open your ProSoft Configuration Builder project. From the menu at the top of the window select Project, then Module / Diagnostics. Establish a Connection to the gateway. Press D for database mode, then press [enter] to display a list of options. Example Project A tested set of projects is included with this application note. The set includes a RS-Logix v2.0 project for a PLC5, a ProLinx gateway project, and a GP-Pro EX v2.5 AGP3300 project. The file APNT1208_AB_PLC5_Project.pdf is a listing of the PLC project provided for your convenience. These items are needed to run the example project: 1. AGP3300 Pro-face display 2. HMI-CAB-ST52 Pro-face cable (or build your own using the diagram in this document) 3. GP-Pro EX Pro-face development software v2.5 or greater RIO-DFCM ProLinx gateway and cables 5. ProSoft Configuration Builder software 6. PLC5 series Allen Bradley programmable controller 7. Remote I/O cable assembly with terminating resistors on each end 8. RS Logix 5 Allen Bradley programming software v2.0 or later Page 12 of 16

13 The gateway is configured as a full rack. The PLC ladder logic section that executes the remote I/O data transfers (rungs 7 and 8) is sample code provided by ProSoft. It includes only the very basic components required for block transfers of data. The sequencing of the block transfers in the example is over simplified, but suitable for testing purposes. PLC configuration: The gateway is configured in RS-Logix as PLC Rack 1, Group 0, Full: The RS Logix configuration defines the gateway direct I/O addresses as The corresponding PLC ladder the I/O addresses are words I:010 I:017 and O:010 O:017. The I/O registers directly access the gateway every I/O scan without requiring PLC ladder programming. If additional data points are needed for the HMI application block transfers are implemented in the PLC ladder program. Page 13 of 16

14 Gateway RIO Interface Configuration: The ProSoft Configuration Builder is used to configure links between PLC I/O addresses and gateway memory. The first PLC input word (I:010) and output word (O:010) cannot be used. The remaining addresses are assigned like this: LC ProSoft Prolinx Address Configuration Memory Address I:010 Not used I:011 <- Input Word 1 : 511 I:012 <- Input Word 2 : 512 I:013 <- Input Word 3 : 513 I:014 <- Input Word 4 : 514 I:015 <- Input Word 5 : 515 I:016 <- Input Word 6 : 516 I:017 <- Input Word 7 : 517 O:010 Not Used O:011 -> Output Word 1 : 501 O:012 -> Output Word 2 : 502 O:013 -> Output Word 3 : 503 O:014 -> Output Word 4 : 504 O:015 -> Output Word 5 : 505 O:016 -> Output Word 6 : 506 O:017 -> Output Word 7 : 507 To exchange additional data, block transfer programming (BTW/BTR) is added to PLC ladder logic. Block transfers can move blocks of up to 60 words at a time between PLC data files and gateway memory. In the example 200 words are moved in blocks of up to 60 words at a time from the gateway memory to file N10 in the PLC by a Block Transfer Read (BTR) instruction. 200 words are moved in blocks of up to 60 words at a time from file N11 in the PLC by a Block Transfer Write (BTW) instruction to the gateway memory. (the example show how to do multiple block moves; for best performance minimize the number of block moves.) Memory locations in the gateway are linked to the BTR and BTW instructions in the ProSoft Configuration Builder: PLC ProSoft ProLinx Addresses Configuration Memory Address/Array Size N10:0 N10:199 <- BTR Start Register :600 BTR Register Count :200 N11:0 N11:199 -> BTW Start Register :1000 BTW Register Count :200 Page 14 of 16

15 Gateway DF1 interface Configuration The DF1 protocol locates data using a file number prefixed by the data type (example N11). The gateway is configured to simulate these files by mapping the gateway memory as a series of N-files equal in length. In the ProSoft Configuration Builder DF1 Port 0 parameter, First File = 7 sets N7:0 as the first address via the DF1 protocol. File size = 200 is the number of words allocated to all N files. File Offset = 0 defines the gateway address where the first N-file starts, in this case N7:0. Those two parameter settings create this DF1 mapping of gateway memory: ProLinx Memory Location DF1 Address 0 N7:0 200 N8:0 400 N9:0 600 N10:0 800 N11: N12: N13: N14:0 Etc. Addressing PLC memory in the Pro-face display: Although DF1 protocol can read and write the same address in the gateway, the data exchange with the PLC is only one way. Read/write (R/W) access to PLC memory is not possible through a RIO interface. Remote IO only allows either read only (inputs and BTR) or write only (outputs or BTW) access. The PLC I/O configuration and ladder program define the data exchange between the PLC and the gateway. In the example the accessible memory ranges and the data flow between the PLC and the Pro-face HMI are: PLC ProSoft ProLinx Pro-face HMI Pro-face HMI Address Configuration Memory DF1 Operation Address Address Possible I:011 I:017 <- Input Word 1-7 : <- N9:111 - N9:117 Write only O:011 O:17 -> Output Word 1-7 : > N9:101 - N9:107 Read only N10:0 N10:199 <- BTR Start Register : <- N10:0 N10:199 Write Only N11:0 N11:199 -> BTW Start Register : > N12:0 N12:199 Read only The GP-Pro EX project includes examples of direct I/O data and Block transfer data. Block transfers (BTR/BTW) require multiple PLC ladder scans for a full data exchange with the gateway. The PLC I/O register data is exchanged between the gateway and the PLC every I/O scan. In this example DF1 registers N9:101 N9:117 are linked in the gateway to PLC I/O registers making them ideal for push buttons and rapidly changing data displays and indicators. Page 15 of 16

16 Example Project Screens The main screen data display T4.0 ACC and all pushbuttons are linked in the gateway to PLC I/O registers. On the second screen the input (I:xx) and output (O:xx) data displays are also linked to PLC I/O registers. The remaining data displays on both screens are linked to PLC memory by block transfers (BTR/BTW). The second screen can be used as a diagnostic tool to view various PLC registers. All data displays on the second screen Indirect Memory Access are configured to indirectly address memory. Enter an Offset to select specific memory locations. The PLC address selected by the offset is displayed above the data. Each data display is configured to access a different file in the PLC For more information on Pro-face and our full line of HMI, Operator Interface and Industrial PC products please visit our web site at For technical support support@profaceamerica.com or call: Pro-face America. Specifications may change without notice. Pro-face is a registered trademark of Digital Corporation. Other brand or product names are the property of their respective owners. Page 16 of 16