Book of Implementation Guidelines AVI/VMS DeviceNet Reader Installation & Configuration for PLC-5

Transcription

1 Advance Manufacturing Engineering Book of Implementation Guidelines AVI/VMS DeviceNet Reader Installation & Configuration for PLC-5 AMS 0220 Section Revision Date: 08/01/07 Page 1 of 44 Revision: 1.3

2 Proprietary Notice This document comprises legally protected subject matter proprietary to Chrysler, and is loaned on the basis of confidential relationship. All use and disclosure is strictly controlled. Reproduction is prohibited without the permission of Chrysler. Documentation Standards, Version 2.0 Copyright 2007, Chrysler. All Rights Reserved. Revision Date: 08/01/07 Page 2 of 44 Revision: 1.3

3 TABLE OF CONTENTS 1.0 GENERAL PURPOSE SCOPE USERS DEFINITIONS OVERVIEW AVI DEVICENET FUNDAMENTALS AVI DEVICENET ARCHITECTURE HARDWARE OVERVIEW HARDWARE DEVICES CONFIGURE CDN108 MODULE RSNETWORX CONFIGURATION REVIEW AVI DATA MAPPING SPECIFICATIONS ONLINE CONFIGURATION PLC CONFIGURATION DEVICENET PLC CONFIGURATION FUNCTIONAL OPERATION OVERVIEW DATA FLOW TROUBLESHOOTING CDN108 DEVICENET STATUS LEDS CDN108 SERIAL CHANNEL STATUS LEDS CDN108 TROUBLESHOOTING...38 APPENDIX A: AVI SICK READER /DEVICENET WIRING DIAGRAM...40 APPENDIX B: SUPPORTING DOCUMENTATION...43 APPENDIX C: GLOSSARY & CONDITIONS...43 TERMS & CONVENTIONS...43 REVISION HISTORY...44 Revision Date: 08/01/07 Page 3 of 44 Revision: 1.3

4 TABLE OF TABLES Table 1: Hardware Overview...9 Table 2: DeviceNet Baud Rate Switch Settings...11 Table 3: MAC ID Switches (Node Number Settings)...11 Table 4: Example Configuration 1 Reader Connected to DNET...23 Table 5: Example Configuration 2 Readers Connected to DNET (Main & Backup)...23 Table 6: Example Configuration 2 Readers Connected to DNET (2 separate points)...23 Table 7: Example Configuration 2 Readers (1 st is RB/DB, 2 nd is DNET)...24 Table 8: Example Configuration 4 Readers (1 st DNET, 2 nd is RB/DB, 3 rd is DNET, 4 th is RB/DB, 5 TH is DNET)...24 Table 9: 23 Output and 33 Input Bytes...31 Table 10: CDN108 DeviceNet Status LEDs...37 Table 11: CDN108 Module Status LEDs...37 Table 12: CDN108 Serial Channel Transmit Status LEDs...37 Table 13: CDN108 Serial Channel Receive Status LEDs...38 Table 14: CDN108 Troubleshooting...38 Table 15: Supporting Documentation...43 Table 16: Terms & Conventions...43 Revision Date: 08/01/07 Page 4 of 44 Revision: 1.3

5 TABLE OF FIGURES Figure 1: AVI DeviceNet Architecture - PLC-5 with 1771-SDN Module...8 Figure 2: CDN108 Physical Layout...10 Figure 3: 1771 Scanlist...12 Figure 4: General Tab - CDN108 Configurations...13 Figure 5: EDS File Tab - CDN108 Configurations...14 Figure 6: 1771 Device Properties Window with CDN108 in the Scanlist...15 Figure 7: 1771 Device Properties I/O Parameters...16 Figure 8: PLC Interface Addresses...17 Figure 9: 1771 Device Properties Window Input Tab Example Reader 1 Node Configure...18 Figure 10: 1771 Device Properties Window Input Tab Example Reader 2 Node Configure...19 Figure 11: 1771 Device Properties Window Output Tab Example Reader 1 Node Configure...20 Figure 12: 1771 Device Properties Window Output Tab Example Reader 1 Node Configure...20 Figure 13: 1771 DeviceNet PLC Configuration - DeviceNet BTR & BTW for BT length 57 Rung Example...22 Figure 14: Example Rung for 1 DeviceNet Reader Rung Figure 15: Example Rung for 1 DeviceNet Reader Rung Figure 16: Example Rung for 1 DeviceNet Reader Rung Figure 17: Example Rung for 2nd DeviceNet Reader Rung Figure 18: Example Rung for 2nd DeviceNet Reader Rung Figure 19: Example Rung for 2nd DeviceNet Reader Rung Figure 20: Gateway Interface to Serial Device and DeviceNet Scanner...30 Figure 21: Beam On Message to Barcode Reader...32 Figure 22: Beam On Ack Message to PLC...33 Figure 23: Read Data Message to PLC...34 Figure 24: Good Read Message to Barcode Reader...35 Figure 25: Good Read Ack Message to PLC...36 Figure 26: AVI SICK Reader /DeviceNet Wiring Diagram...40 Figure 27: AVI Handheld Reader / DeviceNet Panel Layout Diagram...41 Figure 28: AVI Handheld Reader / DeviceNet Wiring Diagram...42 Revision Date: 08/01/07 Page 5 of 44 Revision: 1.3

6 1.0 GENERAL 1.1 PURPOSE This document is intended to help facilitate the installation and configuration of AVI readers using the DeviceNet communication platform for all Chrysler - North American Operation installations. 1.2 SCOPE The content will detail the use of AVI readers using DNET only or the combination of DNET readers in conjunction with readers using the RB/DB communication platform. This document is not intended to be a tutorial on PLC-5 s, DeviceNet, or RSNetworx. 1.3 USERS - Suppliers (e.g. OEMs, Integrators, Vendors) - Chrysler (e.g. Launch Engineers, Control Engineers, Process Engineers) - Any individual and / or organization involved in the design and installation of control systems for Chrysler. 1.4 DEFINITIONS Usage of the words Shall, May and Should The word shall is understood as a requirement. The word should is understood as a recommendation or preference. The word may is understood to specify a specification that is condition dependent. The designer or vendor may be required to justify a deviation from the standard, and may be required by an authorized Chrysler representative to make alterations so as to conform. Revision Date: 08/01/07 Page 6 of 44 Revision: 1.3

7 2.0 OVERVIEW The AVI readers currently use ASCII interface modules (RB & DB) to communicate with the AVI driver. The communication methodology has been changed to employ a plant floor network system called DeviceNet which will allow the AVI readers to communicate with the AVI driver over this network. 2.1 AVI DEVICENET FUNDAMENTALS All devices on DeviceNet have node numbers All devices will communicate with the PLC via the 1771-SDN Scanner Module. The 1771-SDN dip switches will comply to document AMS 0220 Section 5.4.2, Design & Installation Guidelines for DeviceNet Networks. (The SDN is typically node 0) AVI Reader DeviceNet Gateways will be assigned node numbers between per SDN channel. Refer to AMS 0220 Section 5.4.2, Design & Installation Guidelines for DeviceNet Networks All Reader DeviceNet Gateways will be configured as Change of State only All data mapping will comply with AMS 0220 Section 5.4.2, Design & Installation Guidelines for DeviceNet Networks and the spreadsheet file AVI_DeviceNet_Map.xls. AVI data mapping is detailed in Section All AVI readers will use a RS232 to DNET Converter tagged the CDN108 Gateway Any CPU with greater then 2 readers on DeviceNet will require a design review with the AVI Project Engineer A 10ms network response type parameter is assigned to each reader. This will be utilized during the network design phase It is recommended the AVI reader node be placed- if possible- on the channel with the least consumed bandwidth A separate specification will cover QAS Installations. Revision Date: 08/01/07 Page 7 of 44 Revision: 1.3

8 2.2 AVI DEVICENET ARCHITECTURE Barcode Reader (SICK or Intermec) Barcode Reader (SICK or Intermec) CDN108 Gateway (Node 41) CDN108 Gateway (Node 42) OEM Node PC running Rockwell RSNetworx communicating with the DeviceNet network using 1771-PCD card Figure 1: AVI DeviceNet Architecture - PLC-5 with 1771-SDN Module Revision Date: 08/01/07 Page 8 of 44 Revision: 1.3

9 3.0 HARDWARE OVERVIEW 3.1 HARDWARE DEVICES The hardware shall comply with the following version: Table 1: Hardware Overview DeviceNet Gateway Revision # Date Notes Product Part Number CDN108 Hardware Version Firmware Version EDS File Version Jun-02 Product Part Number Hardware Version 1771-SDN Series C Firmware Version Fixed Readers (SICK) All versions of SICK Readers (260,265,290,295,490,490HD) can communicate using DeviceNet. This is facilitated by each type having the ability to communicate via RS232. There will be no support of RS422 to DNET communication. (See Appendix A for wiring diagram). The new SICK DeviceNet Ready reader hub will be pre-wired with the CDN108 Gateway and a connector cable for network connection. The hub reader is identified as a Chry-04 hub. A retrofit kit (including wiring diagrams) will be provided for all existing readers that need to be converted for DNET connectivity Hand Held Readers (Intermec) The wired and cordless Intermec readers will be supported on DeviceNet An interface box will be used with all hand held readers (refer to Appendix A). This interface is currently manufactured by McNaughton-McKay (MCMC-DCX-DNET-BC). Revision Date: 08/01/07 Page 9 of 44 Revision: 1.3

10 3.1.3 CDN108 (D.I.P) DeviceNet Gateway Module This module converts RS232 data into DeviceNet compatible data (CAN Protocol) It is a full duplex gateway It requires 50 milliamps at 24 volts DC The node number is assigned to the CDN, not the actual reader It has a dedicated EDS file identified as 108-3eds_rev1.0 Chrysler will supply the EDS file for this module The EDS file shall not be modified in ANY way without the written approval of the Chrysler Specifying Authority There will be a hardware/firmware version number for this module that must correspond to Chrysler specifications Serial Status LEDs (RX, TX) Isolated Serial Channel (Male DB9 connector) Mounting Holes DeviceNet MAC ID Rotary Switches DeviceNet Status LEDs (NET, MOD) DeviceNet Baud Rate Rotary Switch DeviceNet Channel (Male 5-pin micro connector) Figure 2: CDN108 Physical Layout 3.2 CONFIGURE CDN108 MODULE Set the DeviceNet Baud Rate and MAC ID Address using the rotary switches. Configure switches before connecting to the DeviceNet network. There is either a small triangular indicator or white indicator on the switch. Use a small screwdriver to align that indicator with the desired setting. AVI specifications allow nodes per channel, see Point Spec document for actual. Revision Date: 08/01/07 Page 10 of 44 Revision: 1.3

11 3.2.1 DeviceNet Baud Rate Switch Valid settings are 125K, 250K, 500K, or PGM. The settings will be based on the document AMS 0220 Section 5.4.2, Design & Installation Guidelines for DeviceNet Networks. Table 2: DeviceNet Baud Rate Switch Settings Position Setting Position Setting Kbps 5 Invalid Kbps 6 Invalid Kbps 7 Invalid 3 Invalid 8 Invalid 4 Invalid 9 PGM (Do Not Use) MAC ID Switches (Node Number Settings) The two MAC ID switches represent decimal numbers from 00 to 99. The LSB switch selects the Ones digit and the MSB switch selects the Tens digit. Valid MAC IDs are 00 to 63. This number should be set between 41 and 45 for AVI readers (see Point Spec). Table 3: MAC ID Switches (Node Number Settings) MSB LSB Address 0 0 to 9 00 to to 9 10 to to 9 20 to to 9 30 to to 9 40 to to 9 50 to to 9 Do Not Use 7 0 to 9 Do Not Use 8 0 to 9 Do Not Use 9 0 to 9 Do Not Use Revision Date: 08/01/07 Page 11 of 44 Revision: 1.3

12 4.0 RSNETWORX CONFIGURATION 4.1 REVIEW AVI DATA MAPPING SPECIFICATIONS Review the spreadsheet file AVI_DeviceNet_Map.xls. This file is available from the Chrysler Specifying Authority. 4.2 ONLINE CONFIGURATION Start up RSNetworx and connect to the SDN module using either the PCS Card or the KFD Module Browse the network and confirm the SDN module and the CDN are recognized Make sure the CDN108 is not in the 1771-SDN Scanlist. To remove from scan list, use RSLogix or keyswitch to place the CPU in Program mode In RSNetworx double click on the 1771-SDN icon to open its device properties window Click on Scanlist tab, and select Upload when prompted to upload the Scanlist from the 1771-SDN Click on CDN108 to select it, then click on < to move it from right to left side of window Click Apply to download changes to 1771-SDN and OK to close this window Figure 3: 1771 Scanlist Revision Date: 08/01/07 Page 12 of 44 Revision: 1.3

13 4.2.4 Register the cdn108.eds file in RSNetworx. Select the EDS Wizard from the RSNetworx Tools menu. Follow the directions in the EDS Wizard window From the RSNetworx network menu, select Online. When prompted, select OK to upload the network configuration and browse the network for active DeviceNet nodes Using RSNetworx, download the cdn108.eds file to the CDN108. This version of the EDS file is configured specifically for this application. Double click the CDN108 icon to open its device properties window, and select Download when prompted. Note that Download will copy the RSNetworx CDN108 configuration image to the actual device, and Upload will copy the CDN108 configuration into RSNetworx. RSNetworx gets its default CDN108 image from the EDS file. However, uploading the CDN108 image will overwrite the RSNetworx CDN108 image in the current RSNetworx file. Upload does not corrupt the CDN108 EDS file Verify the CDN108 configuration in the CDN108 device General properties window, which pops up when the Download is complete. (Note the Revision 2.004) Figure 4: General Tab - CDN108 Configurations Revision Date: 08/01/07 Page 13 of 44 Revision: 1.3

14 4.2.8 Click on the EDS File tab. Make sure the CDN108 EDS File Version Figure 5: EDS File Tab - CDN108 Configurations Revision Date: 08/01/07 Page 14 of 44 Revision: 1.3

15 4.2.9 Double click on 1771-SDN icon to open its device properties window. Click on the CDN108, and click on > to add it to the Scanlist. Figure 6: 1771 Device Properties Window with CDN108 in the Scanlist Revision Date: 08/01/07 Page 15 of 44 Revision: 1.3

16 With the CDN108 still highlighted, click on the Edit I/O Parameters button. The Edit I/O Parameters window pops up for CDN108. Uncheck the Polled: box, and check the Change of State / Cyclic box. Select the Change of State button Set the Rx Size: to 33 bytes, and the Tx Size to 23 bytes. THESE VALUES MATCH THE CDN108 CONFIGURATION. If you change the CDN108 configuration, you must also change the Rx and Tx Sizes. The formulas for calculating the Rx Size and Tx Size are as follows: o Rx Size = RX Inst 1 Data Size + 2 bytes (2 overhead bytes are TX Ack, RX Toggle bytes) o Tx Size = TX Inst 1 Data Size + 2 bytes (2 overhead bytes are TX Toggle, RX Ack bytes) Figure 7: 1771 Device Properties I/O Parameters The Heartbeat Rate is not used by the CDN108. Click OK to save edits Revision Date: 08/01/07 Page 16 of 44 Revision: 1.3

17 Map the CDN108 input and output bytes into the 1771-SDN Block Transfer input and output bytes. To add an AVI Reader, configure the following as shown: The example covered below contains 2 readers and uses BT57 (57 is length value). The CDN node numbers are shown as 2 and 7- (The AVI specification dictates the nodes to be between 41 and Go to PLC Interface addresses and configure BT57 as shown below. Figure 8: PLC Interface Addresses Revision Date: 08/01/07 Page 17 of 44 Revision: 1.3

18 Go to Input Tab and configure 1 st node as shown below Example: Reader 1 (Listed as A02 (Node 2), CDN108) Figure 9: 1771 Device Properties Window Input Tab Example Reader 1 Node Configure Revision Date: 08/01/07 Page 18 of 44 Revision: 1.3

19 Example: Reader 2 (Listed as A07 (Node 7), CDN108) Go to Input Tab and configure 2nd node as shown below (if required) Figure 10: 1771 Device Properties Window Input Tab Example Reader 2 Node Configure Revision Date: 08/01/07 Page 19 of 44 Revision: 1.3

20 Go to Output Tab and configure 1 st node as shown below Example: Reader 1 (Listed as A02, CDN108) Figure 11: 1771 Device Properties Window Output Tab Example Reader 1 Node Configure Figure 12: 1771 Device Properties Window Output Tab Example Reader 1 Node Configure Revision Date: 08/01/07 Page 20 of 44 Revision: 1.3

21 If more then 2 readers are required on this CPU, consult with the AVI Project Engineer for a design review to determine how to allocate the additional readers (via Channel BT SDN). The general rules are as follows: Capturing the BT58 (if complete dedication is available) There will be no partial usage of BT allocation Adding a SDN Module Compliance to the AME DeviceNet Specifications. See Doc x.y All data mapping must follow the APICS specifications detailed in Item 1 in Section When finished editing the 1771-SDN device properties, click Apply to download the changes to the 1771-SDN, and OK to close the window Verify that the CDN108 MOD LED changes from flashing green (idle) to solid green (allocated to DeviceNet master). Make sure the 1771-SDN scanner DeviceNet LEDs are green, and there are no error codes being reported on the LED display. Revision Date: 08/01/07 Page 21 of 44 Revision: 1.3

22 5.0 PLC CONFIGURATION 5.1 DEVICENET PLC CONFIGURATION AVI Driver Configuration Load in the AVI Driver per standard procedure (see docxx) All configurations referring to the DB or RB Module will be replaced by DeviceNet configuration. (Utilize USC for all other configuration) Configure the DeviceNet Enable bit in the N286 reader block. This is done by setting Word 1, Bit 4 equal to 1 (ON) in each DeviceNet reader block. First Reader- N286:11/4=1, Second Reader- N286:61/4=1, Third Reader- N286:111/4=1, etc Add additional DeviceNet logic blocks to OEM program file 80 as needed (three extra rung required per DeviceNet block) Verify the DeviceNet BTR & BTW for BT length 57 are inserted at the end of file 2 Figure 13: 1771 DeviceNet PLC Configuration - DeviceNet BTR & BTW for BT length 57 Rung Example Revision Date: 08/01/07 Page 22 of 44 Revision: 1.3

23 5.1.2 Example Configurations: 1 reader only connected to DNET Table 4: Example Configuration 1 Reader Connected to DNET Reader 1 N275:10 - N275:19=0 N286:11/0=1 N286:11/1=0 N286:11/4=1 N286:14=1 N286:15=0 2 readers only connected to DNET (Main & Backup) Table 5: Example Configuration 2 Readers Connected to DNET (Main & Backup) Reader 1 Reader 2 N275:10 - N275:19=0 N275:20 - N275:29=0 N286:11/0=1 N286:61/0=0 N286:11/1=0 N286:61/1=1 N286:11/4=1 N286:61/4=1 N286:14=1 N286:64=2 N286:15=0 N286:65=0 2 readers only connected to DNET (2 separate points) Table 6: Example Configuration 2 Readers Connected to DNET (2 separate points) Reader 1 Reader 2 N275:10 - N275:19=0 N275:20 - N275:29=0 N286:11/0=1 N286:61/0=1 N286:11/1=0 N286:61/1=0 N286:11/4=1 N286:61/4=1 N286:14=1 N286:64=2 N286:15=0 N286:65=0 Revision Date: 08/01/07 Page 23 of 44 Revision: 1.3

24 2 readers (1 st is RB/DB, 2 nd is DNET) Table 7: Example Configuration 2 Readers (1 st is RB/DB, 2 nd is DNET) Reader 1 Reader 2 N275:20 - N275:29=0 N286:11/0=1 N286:61/0=1 N286:11/1=0 N286:61/1=0 N286:11/4=0 N286:61/4=1 N286:14=1 N286:64=1 N286:15=0 N286:65=0 4 readers (1 st DNET, 2 nd is RB/DB, 3 rd is DNET, 4 th is RB/DB, 5 TH is DNET) Table 8: Example Configuration 4 Readers (1 st DNET, 2 nd is RB/DB, 3 rd is DNET, 4 th is RB/DB, 5 TH is DNET) Reader 1 Reader 2 Reader 3 Reader 4 Reader 5 N275:10 - N275:19=0 N275:30 - N275:39=0 N275:50 - N275:59=0 N286:11/0=1 N286:61/0=1 N286:111/0=1 N286:161/0=1 N286:211/0=1 N286:11/1=0 N286:61/1=0 N286:111/1=0 N286:161/1=0 N286:211/1=0 N286:11/4=1 N286:61/4=1 N286:111/4=1 N286:161/4=1 N286:211/4=1 N286:14=1 N286:64=1 N286:114=1 N286:164=1 N286:214=1 N286:15=0 N286:65=0 N286:115=0 N286:165=0 N286:215= For 1 DeviceNet reader add the following 3 rungs below xxx. Figure 14: Example Rung for 1 DeviceNet Reader Rung 1 Revision Date: 08/01/07 Page 24 of 44 Revision: 1.3

25 Figure 15: Example Rung for 1 DeviceNet Reader Rung 2 Revision Date: 08/01/07 Page 25 of 44 Revision: 1.3

26 Figure 16: Example Rung for 1 DeviceNet Reader Rung 3 Revision Date: 08/01/07 Page 26 of 44 Revision: 1.3

27 5.1.4 For the addition of a second reader add the following 3 rungs below xxx. (Details on the second DNET reader? 3 rd DNET after a second Rb? Etc??) Figure 17: Example Rung for 2nd DeviceNet Reader Rung 1 Revision Date: 08/01/07 Page 27 of 44 Revision: 1.3

28 Figure 18: Example Rung for 2nd DeviceNet Reader Rung 2 Revision Date: 08/01/07 Page 28 of 44 Revision: 1.3

29 Figure 19: Example Rung for 2nd DeviceNet Reader Rung 3 Revision Date: 08/01/07 Page 29 of 44 Revision: 1.3

30 6.0 FUNCTIONAL OPERATION OVERVIEW The following diagram shows how gateway interfaces to serial device and DeviceNet scanner. Input File BTR Inputs DeviceNet COS Response Input data Receive Message Packet Outputs Output File BTW DeviceNet COS Command Output data Transmit Message Packet Application Program 1771-SDN DNET Scanner BC Reader CDN108 Gateway DeviceNet network Figure 20: Gateway Interface to Serial Device and DeviceNet Scanner 6.1 DATA FLOW The following diagram shows how the 1771-SDN input and output bytes map into the DeviceNet Changeof-State (COS) Response and Change-of-State Command messages (byte-swap option enabled). The user should not be concerned with the byte swapping as this is transparent to the functionality the user is concerned with. The CDN108 expects 23 output bytes in a COS Command message received from 1771-SDN, and returns 33 input bytes in a COS Response message to 1771-SDN. The 23 and 33 byte values are user-configured, and were selected to support the maximum expected serial message sizes and minimize total number of DeviceNet I/O bytes. Revision Date: 08/01/07 Page 30 of 44 Revision: 1.3

31 6.1.1 The following tables define the 23 output bytes and 33 input bytes for this application SDN Outputs (23 bytes or 11 words) Table 9: 23 Output and 33 Input Bytes 1771-SDN Inputs (33 bytes or 17words) Word Byte Function Word Byte Function N268:10 0 HB bit 0 Transmit Toggle bit N267:10 0 HB bit 0 Transmit Acknowledge bit 1 LB bit 0 Receive Acknowledge bit 1 LB bit 0 Receive Toggle bit N268:11 2 HB TX message length N267:11 2 HB RX message length 3 LB TX message data byte 0 3 LB RX message data byte 0 N268:12 4 HB TX message data byte 1 N267:12 4 HB RX message data byte 1 5 LB TX message data byte 2 5 LB RX message data byte 2 N268:13 6 HB TX message data byte 3 N267:13 6 HB RX message data byte 3 7 LB TX message data byte 4 7 LB RX message data byte 4 N268:14 8 HB TX message data byte 5 N267:14 8 HB RX message data byte 5 9 LB TX message data byte 6 9 LB RX message data byte 6 N268:15 10 HB TX message data byte 7 N267:15 10 HB RX message data byte 7 11 LB TX message data byte 8 11 LB RX message data byte 8 N268:16 12 HB TX message data byte 9 N267:16 12 HB RX message data byte 9 13 LB TX message data byte LB RX message data byte 10 N268:17 14 HB TX message data byte 11 N267:17 14 HB RX message data byte LB TX message data byte LB RX message data byte 12 N268:18 16 HB TX message data byte 13 N267:18 16 HB RX message data byte LB TX message data byte LB RX message data byte 14 N268:19 18 HB TX message data byte 15 N267:19 18 HB RX message data byte LB TX message data byte LB RX message data byte 16 N268:20 20 HB TX message data byte 17 N267:20 20 HB RX message data byte LB TX message data byte LB RX message data byte 18 N268:21 22 HB TX message data byte 19 N267:21 22 HB RX message data byte LB unused 23 LB RX message data byte 20 N267:22 24 HB RX message data byte LB RX message data byte 22 N267:23 26 HB RX message data byte LB RX message data byte 24 N267:24 28 HB RX message data byte LB RX message data byte 26 N267:25 30 HB RX message data byte LB RX message data byte 28 N267:26 32 HB RX message data byte LB unused Revision Date: 08/01/07 Page 31 of 44 Revision: 1.3

32 6.1.2 PLC sends Beam ON message to Barcode Reader. PLC BTW 23 output bytes with Beam ON command & T X Toggle to 1771-SDN 1771-SDN sends 23 output bytes to CDN366 (COS Command mess age) SDN Outputs (23 bytes or 11 words) 1771-SDN Inputs (33 bytes or 17 words) N268:10 B yte 0 0x01 TX Toggle (toggled) N267:10 Byte 0 0x01 TX Ack (toggled) B yte 1 0x00 RX Ack ( unchanged) Byte 1 0x00 RX Toggle (unchanged) N268:11 B yte 2 0x04 Length = 4 N267:11 Byte 2 0x00 Length = 0 Byte 3 0x02 STX Byte 3 xx undefined N268:12 B yte 4 0x32 2 N267:12 Byte 4 xx undefined Byte 5 0x31 1 Byte 5 xx undefined N268:13 B yte 6 0x03 ETX N267:13 Byte 6 xx undefined Byte 7 xx undefined Byte 7 xx undefined N268:14 Byte 8 xx undefined N267:14 Byte 8 xx undefined Byte 9 xx undefined Byte 9 xx undefined N268:15 Byte 10 xx undefined N267:15 Byte 10 xx undefined B yt e 11 xx unde fined Byte 11 xx undefined N268:16 Byte 12 xx undefined N267:16 Byte 12 xx undefined B yt e 13 xx unde fined Byte 13 xx undefined N268:17 Byte 14 xx undefined N267:17 Byte 14 xx undefined B yt e 15 xx unde fined Byte 15 xx undefined N268:18 Byte 16 xx undefined N267:18 Byte 16 xx undefined B yt e 17 xx unde fined Byte 17 xx undefined N268:19 Byte 18 xx undefined N267:19 Byte 18 xx undefined B yt e 19 xx unde fined Byte 19 xx undefined N268:20 Byte 20 xx undefined N267:20 Byte 20 xx undefined B yt e 21 xx unde fined Byte 21 xx undefined N268:21 Byte 22 xx undefined N267:21 Byte 22 xx undefined Byte 23 unused Byte 23 xx undefined N267:22 Byte 24 xx undefined Byte 25 xx undefined N267:23 Byte 26 xx undefined Byte 27 xx undefined N267:24 Byte 28 xx undefined Byte 29 xx undefined N267:25 Byte 30 xx undefined Byte 31 xx undefined N267:26 Byte 32 xx undefined Byte 33 unused CDN366 transmits serial message to BC Reader, toggles TX Ack when done. STX 2 1 ETX 0x02 0x32 0x31 0x03 Serial M essage transmitted to BC Reader 1771-SDN receives 33 input bytes from CDN366 (COS Response message) PLC BTR 33 input bytes, with TX Ack toggled. Ready for next TX message. Figure 21: Beam On Message to Barcode Reader Revision Date: 08/01/07 Page 32 of 44 Revision: 1.3

33 6.1.3 Barcode Reader returns Beam ON Ack message to PLC. CDN366 receives & saves serial message from BC Reader, toggles RX Toggle. STX 2 1 ETX 0x02 0x32 0x31 0x03 Serial Message received from BC Reader 1771-SDN receives 33 input bytes from CDN366 (COS Response message) PLC BTR 33 input bytes, with RX Toggle toggled, indicating new RX message. PLC processes new RX message, toggles RX Ack when done (RX sync mode only) PLC BTW 23 output bytes with RX Ack to 1771-SDN SDN sends 23 output bytes to CDN366 (COS Command message) 1771-SDN Outputs (23 bytes or 11 words) N268:10 UB Byte 0 0x01 TX Toggle (unchanged) Byte 1 0x01 RX Ack (toggled) N268:11 Byte 2 0x04 Length = 4 Byte 3 0x02 STX N268:12 Byte 4 0x32 2 Byte 5 0x31 1 N268:13 Byte 6 0x03 ETX Byte 7 xx undefined N268:14 Byte 8 xx undefined Byte 9 xx undefined N268:15 Byte 10 xx undefined Byte 11 xx undefined N268:16 Byte 12 xx undefined Byte 13 xx undefined N268:17 Byte 14 xx undefined Byte 15 xx undefined N268:18 Byte 16 xx undefined Byte 17 xx undefined N268:19 Byte 18 xx undefined Byte 19 xx undefined N268:20 Byte 20 xx undefined Byte 21 xx undefined N268:21 Byte 22 xx undefined Byte 23 unused 1771-SDN Inputs (33 bytes or 17 words) N267:10 Byte 0 0x01 TX Ack (unchanged) Byte 1 0x01 RX Toggle (toggled) N267:11 Byte 2 0x04 Length = 4 Byte 3 0x02 STX N267:12 Byte 4 0x32 2 Byte 5 0x31 1 N267:13 Byte 6 0x03 ETX Byte 7 xx undefined N267:14 Byte 8 xx undefined Byte 9 xx undefined N267:15 Byte 10 xx undefined Byte 11 xx undefined N267:16 Byte 12 xx undefined Byte 13 xx undefined N267:17 Byte 14 xx undefined Byte 15 xx undefined N267:18 Byte 16 xx undefined Byte 17 xx undefined N267:19 Byte 18 xx undefined Byte 19 xx undefined N267:20 Byte 20 xx undefined Byte 21 xx undefined N267:21 Byte 22 xx undefined Byte 23 xx undefined N267:22 Byte 24 xx undefined Byte 25 xx undefined N267:23 Byte 26 xx undefined Byte 27 xx undefined N267:24 Byte 28 xx undefined Byte 29 xx undefined N267:25 Byte 30 xx undefined Byte 31 xx undefined N267:26 Byte 32 xx undefined Byte 33 unused CDN366 gets toggled RX Ack. Ready for next RX message (RX sync mode only). Figure 22: Beam On Ack Message to PLC Revision Date: 08/01/07 Page 33 of 44 Revision: 1.3

34 6.1.4 Barcode Reader sends 20 byte Read Data message to PLC, when it reads a barcode label. CDN366 receives & saves serial message from BC Reader, toggles RX Toggle. STX 9999_ ETX 0x02 0x39 0x39 0x39 0x39 0x5F 0x35 0x35 0x35 0x31 0x32 0x33 0x34 0x35 0x36 0x37 0x38 0x03 Serial Message received from BC Reader 1771-SDN receives 33 input bytes from CDN366 (COS Response message) PLC BTR 33 input bytes, with RX Toggle toggled, indicating new RX message. PLC processes new RX message, toggles RX Ack when done. (RX sync mode only). PLC BTW 23 output bytes with RX Ack to 1771-SDN SDN sends 23 output bytes to CDN366 (COS Command message) 1771-SDN Outputs (23 bytes or 11 words) N268:10 UB Byte 0 0x01 TX Toggle (unchanged) Byte 1 0x00 RX Ack (toggled) N268:11 Byte 2 0x04 Length = 4 Byte 3 0x02 STX N268:12 Byte 4 0x32 2 Byte 5 0x31 1 N268:13 Byte 6 0x03 ETX Byte 7 xx undefined N268:14 Byte 8 xx undefined Byte 9 xx undefined N268:15 Byte 10 xx undefined Byte 11 xx undefined N268:16 Byte 12 xx undefined Byte 13 xx undefined N268:17 Byte 14 xx undefined Byte 15 xx undefined N268:18 Byte 16 xx undefined Byte 17 xx undefined N268:19 Byte 18 xx undefined Byte 19 xx undefined N268:20 Byte 20 xx undefined Byte 21 xx undefined N268:21 Byte 22 xx undefined Byte 23 unused 1771-SDN Inputs (33 bytes or 17 words) N267:10 Byte 0 0x01 TX Ack (unchanged) Byte 1 0x00 RX Toggle (toggled) N267:11 Byte 2 0x12 Length = 18 Len=28 Byte 3 0x02 STX VIN= STX N267:12 Byte 4 0x Byte 5 0x N267:13 Byte 6 0x Byte 7 0x N267:14 Byte 8 0x5F Byte 9 0x N267:15 Byte 10 0x Byte 11 0x N267:16 Byte 12 0x Byte 13 0x N267:17 Byte 14 0x Byte 15 0x N267:18 Byte 16 0x Byte 17 0x N267:19 Byte 18 0x Byte 19 0x N267:20 Byte 20 0x03 ETX A Byte 21 xx undefined B N267:21 Byte 22 xx undefined Yr Code Byte 23 xx undefined Pl Code N267:22 Byte 24 xx undefined 1 Byte 25 xx undefined 2 N267:23 Byte 26 xx undefined 3 Byte 27 xx undefined 4 N267:24 Byte 28 xx undefined 5 Byte 29 xx undefined 6 N267:25 Byte 30 xx undefined ETX Byte 31 xx undefined N267:26 Byte 32 xx undefined Byte 33 unused CDN366 gets toggled RX Ack. Ready for next RX message (RX sync mode only). Figure 23: Read Data Message to PLC Revision Date: 08/01/07 Page 34 of 44 Revision: 1.3

35 6.1.5 PLC sends Good Read message to Barcode Reader. PLC BTW 23 output bytes with Good Read & TX Toggle to 1771-SDN 1771-SDN sends 23 output bytes to CDN366 (COS Command message) 1771-SDN Outputs (23 bytes or 11 words) 1771-SDN Inputs (33 bytes or 17 words) N268:10 UB Byte 0 0x00 TX Toggle (toggled) N267:10 UB Byte 0 0x00 TXAck (toggled) Byte 1 0x00 RXAck (unchanged) Byte 1 0x00 RX Toggle (unchanged) Word 1 Byte 2 0x0C Length = 12 Word 1 Byte 2 0x12 Length = 18 Byte 3 0x02 STX Byte 3 0x02 STX Word 2 Byte 4 0x32 2 Word 2 Byte 4 0x39 9 Byte 5 0x38 8 Byte 5 0x39 9 Word 3 Byte 6 0x30 0 Word 3 Byte 6 0x39 9 Byte 7 0x30 0 Byte 7 0x39 9 Word 4 Byte 8 0x30 0 Word 4 Byte 8 0x5F _ Byte 9 0x30 0 Byte 9 0x35 5 Word 5 Byte 10 0x30 0 Word 5 Byte 10 0x35 5 Byte 11 0x30 0 Byte 11 0x35 5 Word 6 Byte 12 0x31 1 Word 6 Byte 12 0x31 1 Byte 13 0x31 1 Byte 13 0x32 2 Word 7 Byte 14 0x03 ETX Word 7 Byte 14 0x33 3 Byte 15 xx undefined Byte 15 0x34 4 Word 8 Byte 16 xx undefined Word 8 Byte 16 0x35 5 Byte 17 xx undefined Byte 17 0x36 6 Word 9 Byte 18 xx undefined Word 9 Byte 18 0x37 7 Byte 19 xx undefined Byte 19 0x38 8 Word 10 Byte 20 xx undefined Word 10 Byte 20 0x03 ETX Byte 21 xx undefined Byte 21 xx undefined Word 11 Byte 22 xx undefined Word 11 Byte 22 xx undefined Byte 23 unused Byte 23 xx undefined Word 12 Byte 24 xx undefined Byte 25 xx undefined Word 13 Byte 26 xx undefined Byte 27 xx undefined Word 14 Byte 28 xx undefined Byte 29 xx undefined Word 15 Byte 30 xx undefined Byte 31 xx undefined Word 16 Byte 32 xx undefined Byte 33 unused CDN366 transmits serial message to BC Reader, toggles TX Ack when done. STX ETX 0x02 0x32 0x38 0x30 0x30 0x30 0x30 0x30 0x30 0x31 0x31 0x03 Serial Message transmitted to BC Reader 1771-SDN receives 33 input bytes from CDN366 (COS Response message) PLC BTR 33 input bytes, with TX Ack toggled. Ready for next TX message. Figure 24: Good Read Message to Barcode Reader Revision Date: 08/01/07 Page 35 of 44 Revision: 1.3

36 6.1.6 Barcode Reader returns Good Read Ack message to PLC. CDN366 receives & saves serial message from BC Reader, toggles RX Toggle. STX ETX 0x02 0x32 0x38 0x30 0x30 0x30 0x30 0x30 0x30 0x31 0x31 0x03 Serial Message received from BC Reader 1771-SDN receives 33 input bytes from CDN366 (COS Response message) PLC BTR 33 input bytes, with RX Toggle toggled, indicating new RX message. PLC processes new RX message, toggles RX Ack when done (RX sync mode only). PLC BTW 23 output bytes with RX Ack to 1771-SDN SDN Outputs (23 bytes o r 11 words) N268:10 UB Byte 0 0x00 TX Toggle (unchanged) Byte 1 0x01 RX Ack (toggled) Word 1 Byte 2 0x0C Length = 12 Byte 3 0x02 STX Word 2 B yt e 4 0x32 2 Byte 5 0x38 8 Word 3 B yt e 6 0x30 0 Byte 7 0x30 0 Word 4 B yt e 8 0x30 0 Byte 9 0x30 0 Word 5 Byte 10 0x30 0 Byte 11 0x30 0 Word 6 Byte 12 0x31 1 Byte 13 0x31 1 Word 7 Byte 14 0x03 ETX Byte 15 xx undefined Word 8 Byte 16 xx undefined Byte 17 xx undefined Word 9 Byte 18 xx undefined Byte 19 xx undefine d Word 10 Byte 20 xx undefined Byte 21 xx undefined Word 11 Byte 22 xx undefined Byte 23 unused 1771-SDN Inputs (33 bytes or 17 words) N267:10 UB Byte 0 0x00 TX Ack (unchanged) Byte 1 0x01 RX Toggle (toggled) Word 1 Byte 2 0x0C Length = 12 Byte 3 0x02 STX Word 2 Byte 4 0x32 2 Byte 5 0x38 8 Word 3 Byte 6 0x30 0 Byte 7 0x30 0 Word 4 Byte 8 0x30 0 Byte 9 0x30 0 Word 5 Byte 10 0x30 0 Byte 11 0x30 0 Word 6 Byte 12 0x31 1 Byte 13 0x31 1 Word 7 Byte 14 0x03 ETX Byte 15 xx undefined Word 8 Byte 16 xx undefined Byte 17 xx undefined Word 9 Byte 18 xx undefined Byte 19 xx undefined Word 10 Byte 20 xx undefined Byte 21 xx undefined Word 11 Byte 22 xx undefined Byte 23 xx undefined Word 12 Byte 24 xx undefined Byte 25 xx undefined Word 13 Byte 26 xx undefined Byte 27 xx undefined Word 14 Byte 28 xx undefined Byte 29 xx undefined Word 15 Byte 30 xx undefined Byte 31 xx undefined Word 16 Byte 32 xx undefined Byte 33 unused 1771-SDN sends 23 output bytes to CDN366 (COS Command message) CDN366 gets toggled RX Ack. Ready for next RX message (RX sync mode only). Figure 25: Good Read Ack Message to PLC Revision Date: 08/01/07 Page 36 of 44 Revision: 1.3

37 7.0 TROUBLESHOOTING 7.1 CDN108 DEVICENET STATUS LEDS The CDN360 gateway has two bi-color status LEDs (NET and MOD) that indicate operational status. During power-up, the LEDs cycle through a sequence of alternating red and green. After power-up, the NET LED should be flashing green (or solid green if allocated to a DeviceNet master) and the MOD LED should be solid green. If this does not occur, disconnect from DeviceNet and verify all the switch settings. Table 10: CDN108 DeviceNet Status LEDs State Off Flashing Red Solid Red Flashing Green Solid Green DeviceNet Status LED (NET) No power Configuration error, Check DeviceNet switch settings Unrecoverable error. Device not allocated to a DeviceNet master Normal runtime, device allocated as a slave Table 11: CDN108 Module Status LEDs State Off Flashing Red Solid Red Flashing Green Solid Green Module Status LED (MOD) No power Configuration error, Check object attribute settings Unrecoverable error. Not defined Normal operation 7.2 CDN108 SERIAL CHANNEL STATUS LEDS The gateway has two bi-color LEDs to indicate serial channel activity. The TX LED flashes green when a packet is being transmitted. The RX LED flashes green when a packet is being received. A fault is indicated by solid red. After power-up, both LEDs should be off. Table 12: CDN108 Serial Channel Transmit Status LEDs State Off Flashing Red Solid Red Flashing Green Solid Green Transmit Status LED (TX) No data being transmitted Not defined Transmit error (parity or overrun error) Data being transmitted Not defined Revision Date: 08/01/07 Page 37 of 44 Revision: 1.3

38 Table 13: CDN108 Serial Channel Receive Status LEDs State Off Flashing Red Solid Red Flashing Green Solid Green Receive Status LED (RX) No data being received Not defined Receive error (parity or overrun error) Data being received Not defined 7.3 CDN108 TROUBLESHOOTING Table 14: CDN108 Troubleshooting Problem DeviceNet Configuration Program does not recognize Gateway. DeviceNet Configuration Program does not recognize Gateway after loading EDS file. Gateway does not appear on DeviceNet network. After setting Gateway MAC ID, DeviceNet Master does not recognize Gateway. NET LED is flashing red. Possible Cause Register Gateway EDS file with Configuration Program Check Major and Minor Revisions for Gateway and EDS file, to see if you have correct EDS file for your Gateway's firmware version Check wiring and cable connections Check DeviceNet power supply voltage Make sure Gateway baud rate matches network baud rate Verify Gateway baud rate is set from rotary switches or retentive memory value Make sure Gateway MAC ID is not used by another device Disconnect Gateway from network before changing MAC ID Make sure Gateway MAC ID is not used by another device Verify Gateway MAC ID is set from rotary switches or retentive memory value Verify DeviceNet baud rate Gateway is removed from DeviceNet Master scanlist or network. Power cycle Gateway to reset. NET LED is solid red. Make sure Gateway MAC ID is not used by another device. Possible DeviceNet network failure. NET LED is off. Check wiring and cable connections Check DeviceNet power supply voltage Make sure Gateway baud rate matches network baud rate Verify Gateway baud rate is set from rotary switches or retentive memory value MOD LED is flashing or solid red. Gateway has failed. Cycle power to reset. Replace Gateway if necessary RX LED does not flash green when data is sent to the Gateway. If Sync Enabled, make sure Receive Toggle and Receive Acknowledge bits are being toggled. If application does not toggle Receive Acknowledge, Gateway will not receive data. Verify data is being received in Receive Data. If Sync Enabled is disabled, verify data is being received in Receive Data Verify source device is transmitting data to Gateway Revision Date: 08/01/07 Page 38 of 44 Revision: 1.3

39 Problem RX LED is solid red after Gateway receives data. TX LED is solid red after receiving data from DeviceNet Master. TX LED does not flash green when Gateway should be transmitting data. 17xx-SDN Scanner displays error code 77. Possible Cause Check Serial Status for RX buffer Overflow or Parity Error. Reset Gateway or clear Serial Status error bit if necessary. Make sure parity is set to match transmitting device Check Serial Status for TX buffer Overflow or Parity Error. Reset Gateway or clear Serial Status error bit if necessary. Make sure parity is set to match receiving device configuration Make sure Transmit Toggle is being toggled. If application does not toggle Transmit Toggle, Gateway will not transmit data. Verify data is being saved in Transmit Data Gateway COS/Poll Produce Size and/or COS/Poll Consume Size value do not match 17xx-SDN COS/Poll Rx Size / Tx Size settings Revision Date: 08/01/07 Page 39 of 44 Revision: 1.3

40 APPENDIX A: AVI SICK READER /DEVICENET WIRING DIAGRAM Figure 26: AVI SICK Reader /DeviceNet Wiring Diagram Revision Date: 08/01/07 Page 40 of 44 Revision: 1.3

41 Figure 27: AVI Handheld Reader / DeviceNet Panel Layout Diagram Revision Date: 08/01/07 Page 41 of 44 Revision: 1.3

42 Figure 28: AVI Handheld Reader / DeviceNet Wiring Diagram Revision Date: 08/01/07 Page 42 of 44 Revision: 1.3

43 APPENDIX B: SUPPORTING DOCUMENTATION The Chrysler documents listed below are instrumental in defining AVI Points, and configuration. The user should have a good understanding of the following documents. Table 15: Supporting Documentation Doc. No. AMS AMS AMS AMS Title AVI/VMS Barcode Reader Placement Guidelines AVI/VMS Driver Installation & Configuration for PLC-5 AVI/VMS Reader Communications & Configuration for PLC-5 AVI/VMS Implementation Guidelines for PLC-5 APPENDIX C: GLOSSARY & CONDITIONS TERMS & CONVENTIONS Table 16: Terms & Conventions ASL AVI BOIG CLx Chrysler DNET N/A OEM Operator PFCS PFS PLC Specifying Authority WCC Approved Source List Automatic Vehicle Identification Book of Implementation Guidelines ControlLogix Chrysler - North American Operations DeviceNet Not Applicable Original Equipment Manufacturer The term operator is used generically to describe a support person. An operator may be production, maintenance or engineering personnel depending on the application. Plant Floor Communication System Performance Feedback System Programmable Logic Controller The Specifying Authority is the project individual or designated technical representative with the responsibility to make a decision on behalf of Chrysler. Work Cell Controller Revision Date: 08/01/07 Page 43 of 44 Revision: 1.3

44 REVISION HISTORY Date Revision Number Name Description 8/01/ J. E. Dupuie Changed document to reflect company name change. Added section 1.4 Definitions and moved Use of Shall, May and Should to subsection from Appendix C. Added.Table 16 to Appendix C. 8/01/ N. Bayan J. E. Dupuie Added Mc & Mc Order Numbers sec and Drawings Appendix A, Figures. Added Table of Tables, Table of Figures and their captions 1/05/ J. Tyson No content was changed. Updated footers to reflect new Revisions, Dates and Filenames. The document remained the same amount of pages. Reformatted table headers so they match other documents. 04/01/ Hetal Vyas Initial release. Revision Date: 08/01/07 Page 44 of 44 Revision: 1.3