Connecting to the MC³ from EtherNet/IP via ABC-EIP
Contents
1. Logical Physical W F Bits in the PLC Run Permission External Input 1 MC3 n Ctls 1 0 Load Simulator External Input 2 W MC3 n Ctls 1 1 Feeder Block Rack 1 Input 1 Belt Drive Ovrld Rack 1 Input 2 W Belt Drive Fail Rack 1 Input 3 F Digital output mapping Physical Logical W F Bits in the PLC Rack 1 Output 4 Fdr Drv Enable External Output 1 Fault MC3 n Status 1 0 External Output 2 Warning MC3 n Status 1 1 External Output 3 Ready MC3 n Status 1 2 External Output 4 Good Feedrate MC3 n Status 1 3 External Output 5 Hi Belt Load MC3 n Status 1 4 External Output 6 Hi Setpt MC3 n Status 1 5 External Output 7 HPAD Overload MC3 n Status 1 6 External Output 8 HPAD Underload Setting up the setpoint source Stopped CONNECT THE EIP TO THE MC2S AND CHECK COMMUNICATIONS example Action MC3fn Status 1 7 The MC Setpoint Method must be set to Serial See O amp M Page 27 The setpoint is taken from the PLC s MC3 0 CVars 0 in this If the distance between the EIP and the MC controllers is more then a few feet use a cable designed for RS 422 There should be two pairs individually shielded Belden 9368 or equivalent is a good alternative Connect the shields only at the ABC PDP to pin 5 of the DB9 P At the MC s connect the incoming and outgoing shields together only Add pull up and pull down2. MC3 Comm Valid Flag BOOL Decimal meat MC3 2 MC 4 gt A Monitor Tags A Edit Tags 4 CIBU CtI DNI onic Ext Int 0001 oo00 Feed F 1500002 001 nuu Sec iF O000002 000 8381112 002 Tagi HOW O000002 000 OOO00002 000 H uU 0000002 000 OO00002 000 Taga 0000002 000 00000 000 HOW 0000002 000 O000002 000 Ta35 H U 000000 000 15031 001 4947602 000 Herd ord 3183322 000 Int Frac 3319002 002 1 R3 BBH53He D5 R3 R3 1 R3 D21cznnnu Ta35 R3 1 n n n n 1 B 1 a40 m hms mc3 pdf Page 19 09 23 04 Lars Mennick Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Troubleshooting Setting up industrial networks can sometimes be a daunting task In this example four mapping layers are involved along with two different communication protocols Fortunately there are excellent troubleshooting tools available MC CPU boards Rev 1 and later have a set of LTD indicators Indicators 3 and 4 are connected to Comm 1 serial Receive Data and Transmit Data respectively Indicator 3 should blink four times as fast as indicator 4 since three out of four telegrams are intended for other controllers in this example The rightmost indicator in this picture is indicator The actual values in the
3. hms mc3 pdf Page 10 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved resistors at the EIP 221 between pins 6 and 1 Rx and 5V and pins 7 and 5 Rx and GND Add terminating resistors at the last MC 221 O Connect one between terminals 1 and 2 and one between terminals 3 and 4 The pin numbering on the MC is left to right There are two revisions of the MC controller old and new Refer the MC hardware manual It is available at the Merrick Web Site http www merrick inc com mct at the bottom of the page click on MC Hardware Reference Manual The different layouts are described in MC Connections MC 1 MC 2 MC 3 MC 4 DB9P Interface BELDEN Connect Connect 9368 Shields to ALL Shield terminal 5 together A New CPU board Rev 11 or later have two RS 485 ports built in You connect to the right port on the bottom board The DB9 P Pins connector to the right is the RS232 port for Comm 1 The two connectors on the left are for Comm 2 An Old CPU board did not have an RS 485 port so the port on the top board was used For a card stack with a New CPU board this port is not connected and does not work When you have connected and powered up the MC s and ABC PDP communication should
4. Connection Module Info Ethernet adapter you must Type ETHERNET MODULE Generic Ethemet Module first install the EDS file The Pe file itself is available at the arent Name r Connection Parameters HMS web site anyBus 4MC3 ve jid http Awww anybus com Description HMS ABC EIP to four Merick Instance Use the Rockwell Software EDS Hardware Installation Tool It is available in the MC3 Controllers Input fi 00 57 i 32 bit zl Dutput fi 50 fi E 32 bit Comm Format Data DINT z Configuration 1 p es i Address Host Name scis 21 1800 RSLinx start menu by default The configuration is Address ME x U 2 20 2250 Status Input described in detail in the HMS Application Note C Host Name Status Output Establishing iid id ces communication between AnyBys S EtherNet IP and hms mc3 pdf Page 17 09 23 04 Lars mm ICK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved ControlLogix5000 available on the HMS web site As you configure the module use DINTs for the Comm Format field This is how the Module Properties General tab look in this example You can calculate the sizes for n MC controllers Input Size 7 1 14n Output Size 1 4n Use a reasonable Requested Packet Interval in the Connection tab There is no reason the use the
5. 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved CONFIGURING THE MC Configuring the MC controllers include e Setting up communications parameters e Setting up register tags if you want to monitor special parameters other than Feedrate Belt Load Belt Speed Subtotal or Total e Configuring Warnings and Faults This configuration is done regardless if communications is used or not e Mapping external inputs and outputs Any logical input that you want to control from the PLC has to be mapped to an external input Any logical output you want to monitor has to be mapped to a logical output e Setting up the Setpoint Source so that the Setpoint is taken from the PLC The following menu references and screen shots were taken using the MC 20 20 EX A Belt Feeder Controller application The MC 20 20 EX Weigh Feeder Controller Operation and Maintenance Manual Version A O amp M is available at the Merrick Web Site http www merrick inc com mct at the bottom of the page click on MC Firmware Application Overview Setting the MC communications parameters Communi cations To get to the Communications screen from the main Baud Data Stop Parity screen touch Action Menu Settings Menu enter the T HI B password Inputs amp Outputs and finally Comm Settings Modbus RTU runs on COM 1 In this example the standard RTU line par
6. Name uc Name MC3 Description MC3 Related Data a Description Merrick MC3 Exhange Data Tag Base C Alias Data Type Size 124 C Produce 2 consumers C Consumed INT 8 Hex Bit Oriented Status data SVars REALNO Float Status Varibles Data MC 4 E e Ctls INT 2 Hex Bit Oriented Control data CV ars REAL 3 Fleat Control Variables Scope HMS_4Mc3 Comet COUNTER 2 Comm diags Comtm TIMER Z Comm timers Sue z Vaid BOOL Decimal Data Valid flag The MC User Defined Data Type defines the layout of the elements in MC3 n which is your interface to MC data After creating it you can add a tag of an array of MC The layout resembles the CIT table but the data types are choosen to make it easy to write ladder logic to monitor and control the MC s Status CIT elements 16 19 40 27 Status bit information from MC s to PLC Svars CIT elements 20 39 Variable information from MC s to PLC Ctls CIT elements 44 45 Control bit information from PLC to MC s Cvars CIT elements 46 51 Variable information from PLC to MC s ComCtr will count successful and failed communications go arounds ComTmr are internally used timers to monitor communications integrity Valid True when communications is running without errors ControlLogix l O Configuration To configure the EIP as a li io mods under the PLC
7. 43 are Read Only and intended for monitoring For performance reasons read a section starting with word 16 and as far along as you need The performance penalty for extending the read area length is small however you may find that you run out of space in the EIP s buffer if you have many MC s If you need to conserve EIP buffer space first determine how many variables you really need Typically for a belt feeder this would be Feedrate and Subtotal If this is the case you can read from word 16 23 You will then have to enter the MC register number for Feedrate in Tag 1 RegNo 251 for 20 20 EX A and for Subtotal in Tag 2 RegNo 181 for 20 20 EX A The Tag X RegNo values can be set in the MC by going to Action Menu Settings Menu enter the password Inputs amp Outputs Comm Settings Comm 1 Numeric Words 44 67 can be written to Note that the Tag n W value n 1 5 refers to the same internal MC register as the Tag n R value The Tag n RegNo is the internal MC register number for Tag n This Tagging scheme is in place to enable you to get to any variable within the MC You must have the Register Specification for the application and version you are working with You can find the register specifications at the Merrick Web Site http www merrick inc com mct at the bottom of the page click on MC Firmware Application Overview There is a risk here You can easily crash the MC if you for example write a value of ze
8. CIT exposed to Sse enn communications can be inspected in the MC by 1 8691832 002 000000 000 gt 2 DDDUbDe nbn touching Action Menu Diag Display Modbus Diag HAO ae eee Dat Note that the values are only updated on valid LE AU ME LE Modbus telegrams If no telegrams have been 18 Tasi R3 aga received most values are zero As you can see the 1 63 78502 005 R3 Hq 1 Ra layout follows the CIT exactly All integer values are Fs CPM Dent nan Tag Ra presented in hexadecimal format except the Tag register numbers The e format for the floating points can help troubleshooting FP transfers You are reading from all rows to the left and writing to the first five rows on the right in this example If you succeed with the integrity bit you should see bit 7 in the Sts DNI and CtI DNI toggle Check error counters in the Communication Diagnostic screen Hane aE Communications status statistics can be amp inspected in the MC by touching Action Menu Diag Display Modbus Diag The screen looks like this tas In this shot out of 1206 successful exchanges there was none lost to errors There were 1287 telegrams addressed to some other RTU device The last d command received was 16 Preset Multiple Regs Weng Er starting at word 44 4 words long Label Meaning rxlen Length in bytes of the las
9. R value position hms mc3 pdf Page 8 09 23 04 Lars Mennick Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Parameter Value Comment Tag Reg 2 Use 0 for unused tags Tag Reg 2 Tag Reg 3 Tag Reg 4 Tag Reg 5 Obviously to be able to tag other internal MC registers you need to have the register specification for the specific MC application you are using You can find the register specifications for most MC firmware applications at the Merrick Web Site http www merrick inc com mct at the bottom of the page click on MC Firmware Application Overview Configuring warnings and faults Warnings and Faults are qualifiers to logical inputs and outputs normally set by the user Warnings are considered to require attention Faults are considered to be fatal for the feeder operation and the controller will attempt to stop the feeder See O amp M page 55 In this example the warnings and faults are set up according to the following table Logical I O Qualifier Comment HPAD Overload Fault Invalid Load Cell Signal Bit Drive Fail Fault Signal from the belt motor VFD connected to an MC input Hi Setpoint Warning Setpoint above upper limit To detect floating point transfer problems Hi Belt Load Warning Too much material on the belt Ser Comm Lost Wa
10. Sot x Tag Name 2 Value Description Type Style Merick MC3 Exhange Data MC 4 MC3 1 MC Status Words INT 8 16 080 RO Status INT Hex 16 001c R1 Ex Outputs INT Hex 16 0000 R2 Warnings INT 16 0000 Faults 16 4340 R24 App Ver INT 16 b00 R25 Phys Inputs INT 16 021c R26 Phys Outputs Rack 1 2 INT 16 0000 R27 Phys Outputs R3 4 INT e Status Variables REAL 10 Float C3 0 SV ars U 0 07838111 Tag 1 Value AutaZero REAL Float C3 0 S Vars 1 0 0 Tag 2 Value Unused REAL Float H 0 5 2 0 0 Tag3 Value Unused REAL Float C3 0 S Vars 3 0 0 Tag 4 Value Unused REAL Float C3 0 SVars 4 0 0 Tag 5 Value Unused REAL Float C3 0 SVars 5 47 503143 Feedrate REAL Float 0 5 6 6 4947596 Belt Load REAL Float C3 0 S Vars 7 7 3183322 Belt Speed REAL Float C3 0 SV ars 8 233 19 Sub Total REAL Float C3 0 S Vars 9 126853 93 Grand Total REAL Float 4 Control Words INT 2 Hex 1680000 W0 Control INT Gg 1680001 W1 Ex Inputs INT EHMC3OLEVars Control Variables REAL 3 Float EMCSIOLCVarstO 47 5 Primary Setpoint REAL Float 8 C3 0 Cvars 1 0 0 Sec Setpoint Unused REAL Float C3 0 CVars 2 0 0 Tag 1 Value AutaZero REAL Float 1 Comm Counters Comm Timers TIMER 2 l PS
11. be mapped in three ways hms mc3 pdf Page 9 09 23 04 Lars Mennick Copyright 2004 Merrick Industries Inc All rights reserved Connecting to the MC from EtherNet IP via ABC EIP 1 Toa physical input or output In this example the logical input Belt Drive Overload is mapped to Rack 1 Input 3 which in turn is connected to the Overload output of the belt motor VFD The physical output Rack 1 Output 5 is mapped to the logical output Drive Enable The output is then connected to the Start input of the belt motor VFD 2 an external input or output In this example Run Permission logical input is mapped to External Input 1 This allows the PLC to start and stop the feeder through the External Inputs register CIT Word 45 bit 0 3 Unused Logical Inputs are typically connected to the Physical Inputs Always On or Always Off The PLC controls inputs to the MC as bits in the External Inputs register CIT Word 45 They are then mapped to Logical Inputs in the MC Note that the External Inputs are numbered 1 16 Bits in the External Inputs word are numbered 0 15 in the PLC In this example we use 5 inputs Two are physical connections from the VFD to the MC one is a physical connection to the emergency stop circuit Feeder Block and two are inputs controlled from the PLC Run Permission Load Simulator This is how the inputs have to be mapped in the MC where n is 1 4 for MC 1 4
12. default 5 mS It would cause unnecessary network traffic The turn around time is about 800 ms inside the EIP We used 100 ms in this example When you have completed the Scope HMS 4MC3 conro Show Show All Sot TagName configuration you will find three 7 Value Description brand new tags in the controller AnyBus 4MC3 C fies Unused Control _ Scope The tag names are derived ArgBus AMC3C Data tol from the name we gave the EIP at AnyBus_4MC3 1 Incoming configuration time kE AnyBus 4MC3 I Data To AnyBus_4MC3 0 Qutgoing AnyBus 4MC3 I Data is an array of AnyBus_4MC3 0 Data NEN 57 DINTS that holds the entire input 1 Merrick MC3 Exhange Data bufferin the EIP HE MC3 O 3 1 1 3 2 AnyBus 4MC3 O Data is an array of E MC3 2 _ 17 DINTS holds hold the entire output buffer in EIP WARNING Configuring the EIP as an I O device will generate UDP traffic on your EtherNet IP network If you use network switches to segment your traffic you will find that most switches will broadcast all the messages on all ports You can easily use up all your network bandwidth this way There is an alternative way Don t configure the EIP as an device at all and write generic messages instead That will generate TCP traffic rather th
13. start even without any EtherNet IP connection Check that all looks OK in the ModBus Diagnostic screen See page 20 Bench Testing Your System If you have access to the MC s and the EIP you can bench test your entire system by using the built in simulators in the MC The will behave as if a real feeder was connected to them although you will have to set up a belt load manually To put an MC 2020 in simulation mode 1 In Action Menu Settings Menu Tacho Settings push the lower left button until it reads Simulator 2 In Action Menu Settings Menu Inputs amp Outputs HPAD settings push the leftmost button until it reads None 3 Set the Load Simulator bit MC3 n Ctls 1 1 in the CLX You control the belt load by invisible touch pads on the upper row on the MC screen Increase the load with touch pad 6 from the left Decrease the belt load with touch pad 5 hms mc3 pdf Page 11 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved MC CIT FORMAT The format of the data structure exposed by the MC to communications is the same for Modbus ASCII Modbus RTU and DF 1 CIF read and write They are also common for all MC firmware applications The first 16 words are in place for legacy reasons and should not be used However reading and displaying words 8 15 can sometimes be useful for troubleshooting purposes Words 16
14. table CLX Adapter Buffer MC MC CIT AnyBus_4MC3 1 cam Registers INTs DINTs 1 0 0 1 _ Status EIP Internal SVars Memory Buffer Bytes 14 15 Ctls 43 44 CVars m 680 67 28 AnyBus 4MC3 O MC3 1 1 0 0x200 0 1 Status 15 16 SVars 5 4 Ctls 43 Mi 44 CVars 680 67 MC COM1 xd je CLX I O Ladder Logic Screen y Configuration COP Instructions or MSG Instructions Table transfer between MC and the PLC MC n data structures This block diagram shows a two MC set up clx_hms_mc3 pdf Page 2 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved CONFIGURATION EXAMPLE We used one Allen Bradley ControlLogix PLC CLX one EIP and four MC controllers A Read All Write some approach was taken meaning that as much information as possible was transferred from the MC s to the PLC and just enough was going the other way The CLX was configured to accept the EIP as an I O device on the EtherNet IP Network Some logic was added to monitor the EIP status to safeguard communications integrity and to extract and insert the MC data out of and in to useful data structures The EIP interface was configured to ma
15. to be different for each node and must be equal to the Controller Number setting in the corresponding MC See Configuring the MC on page 6 For each node you insert two transactions one for reading data from the MC and one for writing data to the MC The MC controllers support two transaction types Read Holding Registers Modbus Function 3 and Preset Multiple Regs Modbus Function 16 You use Read Holding Registers to retrieve data from the MC s and Preset Multiple Registers to write data to the MC s Each transaction has parameters for a Query and a Response They all have to be set correctly Most parameters can be summarily set according to the table below but the positioning of the data in the EIP data buffer table is critical and somewhat complex The configuration used here contains what you would need to monitor and control the MC controllers Referring to the MC CIT Format on page 10 you read from words 16 42 and write to words 44 51 This will allow you maximum monitoring capabilities and to set control bits external inputs the feedrate setpoint the batch setpoint when used and one multiplexable MC parameter hms mc3 pdf Page 5 09 23 04 Lars Mennick Copyright 2004 Merrick Industries Inc All rights reserved Ele MC3 1 nms ABC Config Tool D Aprojs AAACom EtherNet Tools View Help Connecting to the MC from EtherNet IP via ABC EIP
16. 0008 0 0 0 0 81 42 F9 FF 02081 0 42 0101 0 0 0408 0010 DO 40 0 0 1F 41 FE FF paro 0i 0j 0 0 0410 0018 FD 48 90 0 0 0 0218 0418 0020 81 42 F9 FF DO 40 0 0 0220 0420 0028 1F 41 FE FF FD 48 90 F 0228 0428 0030 47 BA SD 40 43 0 FB 0230 0430 Oise CI 2 Qi D 0238 0438 0040 0240 0440 0048 0248 0448 0050 0250 0450 0058 0258 0458 0060 0260 0460 0068 0268 0468 0070 0270 0470 nd rd sta 0088 0288 2110486 See ABCUM Chapter 10 With the Configurator online with the EP click on a node then the node monitor button You can inspect the data in hexadecimal format for the selected node Use the integrity bit In the PLC make the integrity bit MC3 n Ctls 0 7 the opposite of the echo bit MC3 n Status 0 7 If the echo bit stops toggling communications has failed and appropriate steps can be taken The integrity bit can be monitored in the MC Data Table screen in the EIP node monitor screen and in the CLX hms mc3 pdf Page 22 09 23 04 Lars
17. 02 0x03 0x04 Function 0x03 0x03 0x03 0x03 Byte Count Hex Always twice 0x0038 0x0038 0x0038 0x0038 the Number of points Data length 0x0038 0x0038 0x0038 0x0038 Data location 0x0004 0x003C 0x0074 0x00AC Byte Swap Swap 2 bytes Swap 2 bytes Swap 2 bytes Swap 2 bytes Checksum type Start Byte CRC 0x0000 CRC 0x0000 CRC 0x0000 CRC 0x0000 Preset Multiple Registers Query Parameter MC 1 MC 2 MC 3 MC 4 Slave Address Hex 0x01 0x02 0x03 0x04 Function Hex 0x10 0x10 0x10 0x10 Starting Address Hex Word 0x002C 0x002C 0x002C 0x002C Number of Registers Hex 0x0008 0x0008 0x0008 0x0008 Words Byte Count Hex Always twice 0x10 0x10 0x10 0x10 the Number of points Data length Hex bytes 0x0010 0x0010 0x0010 0x0010 Data location in the EIP table 0x0204 0x0214 0x224 0x234 Byte swap Swap 2 bytes Swap 2 bytes Swap 2 bytes Swap 2 bytes Checksum type Start Byte CRC 0x0000 CRC 0x0000 CRC 0x0000 CRC 0x0000 Preset Multiple Registers Response Parameter MC 1 MC 2 MC 3 MC 4 Slave Address 0x01 0x01 0x03 0x04 Function 0x10 0x10 0x10 0x10 Starting Address Hex Word 0x002C 0x002C 0x002C 0x002C Number of Registers Hex 0x0008 0x0008 0x0008 0x0008 Words Checksum type Start Byte CRC 0x0000 CRC 0x0000 CRC 0x0000 CRC 0x0000 Don t forget to download the configuration to the ABC PDP and to save the configuration file for future reference hms mc3 pdf Page 7
18. 13 Typically Batch Setpoint Register pointed t by Tag 1 RegNo for writing MC3 n CVars 2 Not written to in this example MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved CIT Ln Contains CIT Comment Structure member in MC3 n in Word it table Element Sr 54 2 j Tag3WVale 2 0004 56 2 Tag4WValue 3 0008 58 2 j Tag5WVale 4 0010 60 1 Write Protect Bts Set for write protection See note 3 61 1 Word Order Bits Set to reverse See note 4 62 invFracBits Set for Int Frac See note 5 63 1 TagfRegNo MC register number 64 1 TaggReNo 65 1 Tag3ReNo e6 TagdRegNo 67 1 TagppRegNo clx_hms_mc3 pdf Page 14 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Note 1 This is the bit assignment for words 16 and 44 corresponding to the first words read and written by the ABC PDP Bit Word 16 Function Word 44 Function Comment The MC will echo this bit from word 44 to word 16 Clear Warnings Clear Warnings Demand Used by PLC to clear all warnings Set Done the bit in word 44 and wait for the bit in word 16 to set Then clear the bit in word 44 EM Clear Subtotal Done Clear Subtotal Demand Same scheme as for Clear Warnings Lock Touchpad Lock To
19. MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Connecting to the MC from EtherNet IP via ABC EIP Using EtherNet IP as a transport between MC controllers and PLC s offers cost savings improved diagnostic capabilities better accuracy and tighter control A single EtherNet IP network replaces numerous analog and digital I O modules eliminates analog signal calibration and ensures data integrity Once the network is in place adding I O points and variables for monitoring is a matter of configuration rather than pulling cables and buying new I O modules The configuration described in this document is fully supported by Merrick Industries There is equipment on hand here to test user specific configurations and to deliver pre configured and tested solutions INTRODUCTION It is possible to exchange status and variables between MC controllers and EtherNet IP enabled PLCs using an ABC EIP protocol converter from HMS Industrial Networks AB EIP Communications replaces both analog and digital I O Full Floating Point accuracy is maintained for variables Up to 10 variables and 80 I O points can be configured per MC controller Newer versions of Merrick s MC controller support ModBus RTU serial communications and exposes a standardized Common Interface Table CIT ModBus functions 3 Read Holding Registers 16 Preset Multiple Regs and 8 sub function 0 Return Qu
20. ameters were selected 9600 baud 8 data bits 1 stop bit and Even parity These parameters must agree with the settings in the ABC PDP Sub Network settings on page 4 Refer to O amp M page 66 for more details Touching the Comm 1 Numeric button takes you to the Comm Numeric Params screen Set the parameters as follows Parameter Value Comment Controller 1to4 This is the Slave Address They must be different for each controller and correspond to the Slave Address hex parameters in the query and response parameter list in the ABC PDP configuration Start Char 10 Has no meaning for Modbus RTU End Char 13 Has no meaning for Modbus RTU Comm Timeout 5 0 The MC times incoming legal RTU telegrams and turns on the Ser Comm Lost logical output if this time expires You typically let this output qualify a Warning Also this will turn off all External Inputs Comm Protocol 2 Enter 2 for Modbus RTU Write Protect 3071 BFF hex All registers write protected except Primary Setpoint Word Order 0 All registers have normal word order This has to be found by trial and error The ControlLogix PLC has the word order for a floating point value straight as compared with a PLC 5 or SLC 5 Int Frac FP 0 Floating Point transfer is supported Integer Fraction is not needed Tag Reg 1 353 Internal MC Register Number for the Zero Tracking Load variable This will make the value show up in the Tag 1
21. amp amp amp 2 so EAA ABC Master Mode CLX_HMS_4MC3 The Sub Network related Devices Configuration Fieldbus ABC B e Sub EE C3 m Holding Registers LE Query E Response Preset Multiple Regs EX Query Ez Response T 4 parameters should be set according to the following table The settings are such that there is reasonable performance degradation for four connected controllers meaning that the communication turn around time is in the same order of magnitude as the internal MC update time Alphabetic Categorized El General Slave address 1 8 8 2004 3 36 PM onfig Line Parameter Setting Comment Offline Freeze Determines what happens to the write transactions on the Modbus options for Clear or side if EtherNet IP goes down Stop Scanning makes it impossible Fieldbus Stop to check communications between MC and EIP without a working Scanning EtherNet IP connection Use Freeze Offline Clear or Determines what happens to the read transactions on the options for Freeze EtherNet IP side if Modbus communications goes down Freeze is sub network an attractive solution since it does not disrupt data from all controllers if just one goes offline There are better means to monitor network integrity See Use the integrity bit on page 22 Update Cyclically There is no need
22. an UDP and the switches will behave as you expect them to There is a HMS publication that describes this Reading writing data from AnyBus S EtherNet IP using ControlLogix5000 MSG instruction available from the HMS website PLC logic to move the data The AnyBus 4MC3 tags are not suitable for ladder logic programming For that reason some data shuffling logic was added to move data between the AnyBus tags and the MC3 tag With this scheme there is a direct relation between the tag monitor in the CLX and the Modbus data diagnostic screen the MC MC3 MAIN holds off ladder execution for 20 seconds at boot sets the Data Valid bit for the Fieldbus side of the EIP calls the four communication routines for the four MC s and maintains the handshake confirmation bit for the EIP MC3 n Comm where n 1 4 are the individual communication handling routines for the four MC s It copies data between the AnyBus 4 tags and the MC3 n tag toggles the integrity bit maintains communications statistics and verifies that the communication is healthy Ladder listing files are available at the Merrick website hms mc3 pdf Page 18 09 23 04 Lars Mennick Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Here is a screen shot monitoring the MC3 0 tag elements Controller Tags HMS 4MC3 controller E am oj xi Scope JHMS_4MC3 contralh v Show Show All v
23. cting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved The EIP requires 24 V DC Connect according to ABCUM appendix C A serial interface cable must be purchased or manufactured Details can be found in ABCUM appendix C PC Connector Connect 24V and the PC Connector cable and start the configurator Configuration is described in ABCUM starting with chapter 4 You can skip Generic Data Mode chapter 5 You will be using Master Mode described in chapter 6 Fieldbus ABC Config Tool D AprojsAAAComEtherNeE Enter your IP address and subnet mask Make sure the CLX and the EIP are on the same subnet If you don t intend to route the traffic use 0 0 0 0 File Fieldbus Tools View Help Da ABC Master Mode CLX_HMS_4MC3 Erf ear as the Default Gateway IP address Alphabetic Categorized E Address mode Modbus address mode E Ethernet TCP IP configuration ERA Sub Network Disabled Communicator IP address 10 0 0 250 Default Gateway 10 0 0 1 Subnet Mask 255 255 255 0 El Fieldbus Fieldbus Type Ethemet 10 Sizes 10 Sizes Automatic Fieldbus 9 8 2004 2 42 PM infig Line 7 ABC Control Status byte should be set to Enable but no startup lock This enables you to check the RTU communication with the without havin
24. d The Sub network settings are global and should be set as follows for successful MC3 operation Parameter Settings Comment Bitrate 9600 or 19200 ModBus RTU standard is 9600 Data Bits 8 Mandatory Modbus RTU setting Parity Any Even is Modbus RTU standard Physical RS422 This is a four wire RS485 hook up From the Modbus Master s Standard point of view RS422 is the correct setting Start Bits 1 There are actually no options Stop Bits 1or2 Use 1 Message 1 10 ms Set to at least 1 There is no performance gain in setting this Delimiter parameter to O ABC Config Tool D Aprojs AAACom EtherNet_IP CLA HM HM loj File Sub Network Tools View Help MAFON EEIT PT ABC Master Mode CLX_HMS_4MC3 All MC serial parameter settings must agree with the parameters in this table Newer MC controllers support four wire RS485 and RS232 without re Devices Configuration configuration For older controllers and m Fieldbus Alphabetic Categorized if you connect to more than one c mmm E Communication controller you must use RS422 a Mord Skate Pes 2500 Under the Sub Network level insert MC3 3 Parity Even nodes one per MC you want to IT MC3 4 standard SOR connect This is a screen dump of our E Timing 4 node setup Message delimiter 10ms 1 Sub Network 9 8 2004 3 31 PM onfig Line 7 The slave Address has
25. egrams with CRC16 error counter rxfme Received telegrams with format error counter rxlfm Last format error encountered See note 2 Non supported command received counter timee Comm timeouts counter addr First register in received command Should toggle between 16 and 44 size Number of registers in received command Should toggle between 28 and 4 cmd Modbus command received Should toggle between 3 and 16 subf Subfunction in diagnostics command Only 0 Return Query Data supported retST Exception status of a received command causing a NAK RX Received telegram First 19 bytes in HEX format TX Transmitted telegram from this node First 19 bytes in hex format GpcOx Internal troubleshooting counters No useful information Note 1 This is the UART status register bit encoded Bit 0 Not Used Bit 1 Overrun error Bit 2 Parity error Bit 3 Framing error Bit 4 Break detected Note 2 Format errors have a decimal numerical value 1 Unsupported Modbus command 2 Read Holding Register telegram not 6 bytes long 3 Trying to read from non existing registers 4 Read Diagnostic telegram not 8 bytes long clx_hms_mc3 pdf Page 21 09 23 04 Lars ICK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved 5 Unsupported subfunction in Read Diagnostics telegram 6 Trying to write to non existing registers 7 Byte coun
26. ery Data are supported The EIP has an EtherNet IP interface one side and a Modbus Master interface on the other Many MC controllers can be connected to the EIP using the existing 4 wire RS 422 interface on the EIP and the existing 4 wire RS 485 interface on the MC controller The information in this document applies to the following MC firmware versions Firmware Used for Released Comm Ver 20 10 EX F Belt Feeder 03 28 02 1 20 20 EX All Belt Feeder 04 17 03 2 24 10 EX H and later Pressurized Coal Feeder 08 02 02 1 30 00 EX C and later Loss In Weight 04 25 02 1 30 10 EX E and later Enhanced Loss In 06 06 04 2 Weight 35 00 EX B and later Weigh Out Batcher 2 40 10 EX A and later Impact Flow Meter 04 14 03 2 90 10 EX Y and later MasterSet 01 02 03 2 Other Merrick firmware releases may also support ModBus RTU communications The EIP maintains a conversation with many MC controllers using Modbus RTU and then exposes one aggregated read and one aggregated write table to the PLC For real time control purposes a maximum of 4 per EIP can be used For monitoring only up to 16 MC s can be connected Data tables are transferred between the MC s and the EtherNet IP host PLC The positioning and content of the data elements in the tables must be tracked all the way from the internal MC register database to the data structures in the PLC This is done in several steps e Between the MC regi
27. g EtherNet IP connected ABC Config Tool D Aprojs 4A4ACom EtherNet File ABC Tools View Help Dg ABC Master Mode CLX HMS 4MC3 Devices Configuration 9 60 Fieldbus Alphabetic Categorized The Module Reset should be set to 4 Disabled The function of this setting x WM SubNetwok E Interface Physical Interface Serial is obscure E Module T Control Status Byte Enabled but no startup lock The Protocol setting must be Master Module Reset Disabled Mode meaning Modbus RTU master El Protocol ne Protocol Master Mode Statistics are useful for Modus RTU E Statistics troubleshooting Bytes 2 and 3 Receive Counter Location 0002 Statistics Enable Transmit Receive Counter unused eventual ly be Transmit Counter Location 0003 inspected from the PLC 3 8 2004 2 48 PM onfia Line 7 Sub Network The Sub Network is in reality the multi drop Modbus RTU network used to connect the MC controllers to the EIP This is where almost all configuration takes place There are settings for the overall Sub network for the individual slaves MC s in this case for the actions for each slave and for telegram parameters for each action hms mc3 pdf Page4 09 23 04 Lars MennicKk Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserve
28. intain a dialogue with four MC controllers aggregate the data and expose a Read and Write area to EtherNet IP The MC controllers were configured to accept control data and expose data for monitoring using Modbus RTU In the end the MC controllers become an integral part of the CLX I O with an easy to use programming interface in the form a single tag Equipment used e Laptop PC DELL Inspiron 8600 MS Windows XP Professional SP1 Rockwell Software RSLogix 5000 V10 00 00 Rockwell Software RSLinx V2 41 00 HMS Networks ABC Configurator version 2 00 rev 4 e Allen Bradley 1756 L55 ControlLogix 5555 PLC with 1756 ENBT A EtherNet adapter CLX e NetGear EtherNet hub e EtherNet IP Interface order code AB7007 EIP e Patch Cables e Cable for configuring the EIP from the PC HMS part number 017620 e 24V DC Power Supply e Home made serial interface cable ABC EIP lt gt MC controllers See Connect the EIP to the MCs and check communications on page 10 Configuring the ABC EIP EIP configuring is described in the AnyBus Communicator User Manual ABCUM The ABC Configurator and ABCUM can be downloaded from the HMS web site http www anybus com We are trying to keep specific links updated on the Merrick connectivity web site http merrick inc com mct You can also download the actual ABC configuration file we used from that site hms mc3 pdf Page 3 09 23 04 Lars Mennick Conne
29. need to change a variable only at certain instances Note 4 The Word Order Bit when set reverses the order of the two words that contains value information To correctly transfer floating point values to and from PLC s these bits may have to be set Note 5 The Integer Fraction bits are used when the device using the data does not support floating point numbers With the corresponding Word Order bit cleared the first word will carry the Integer part and the second the fractional part multiplied with 10000 4 implied decimal places Note that for a negative value both the integer and fractional clx_hms_mc3 pdf Page 15 09 23 04 Lars Mennick Copyright 2004 Merrick Industries Inc All rights reserved parts are negative This scheme will not work for values outside the interval 32767 32767 since those are the extreme values for an INT Connecting to the MC from EtherNet IP via ABC EIP Note 6 Bits 0 3 are used to signal problems with Tag Register Numbers as follows Bit 0 Attempt to write to a conditionally write protected MC register while the Extended Access logical input is OFF Bit 1 Attempt to write to a write protected register Bit 2 Attempt to write to a non existing register Bit 3 Attempt to read from a non existing register Zero returned Note7 Rack 1 input 1 in bit 0 Rack 1 input 2 in bit 1 etc Rack 2 input 1 in bit 4 Note8 Rack 1 output 1 in 42 bit Rack 1 output 8 in 42 bit 7 Rack 2 outpu
30. rning No valid RTU telegram has been received for 5 seconds Load Simulator Warning Don t run the feeder for real with the Load Simulator turned on Bit Drive Ovrld Warning Signal from the belt motor drive connected to an MC input LER OL The qualifiers are set up in the Digital Inputs O amp M Page 55 and Ser Comm Last Digital Outputs O amp M Page 59 screens With the settings above Sum Acar the Warnings and Faults screens look like this The state of the checkmark is transferred to the Warnings 18 and ELE gu ES Faults 19 word in the CIT The bit order is the same as the displayed order of the screen It is important to note that the bits in the Warnings and Faults registers reflect the state of the PUR checkmark not the dot In this warning screen both are on for the logical input Load Simulator Bit 3 of the Warnings register is on If the Load Simulator input is turned off then the dot goes away but the checkmark stays until the warning is ACK d either on this um xcu Screen or by the Clear Warnings Command bit in the Control 44 register Note that the order of display is not configurable It is derived from the order of logical outputs and logical inputs in the Digital Inputs and Digital Outputs screens If you add or remove a warning or fault qualifier to a logical input or output the order may change Configuring External Inputs and Outputs Logical inputs and outputs can
31. ro to a variable used in a divide operation The only remedy in this case is to Ram Reset the MC You will then have to enter all the MC parameters again If you have WinMerik which can be used to upload and download all MC parameters with a PC it is a good idea to upload before you start writing to internal MC variables Words 60 to 67 are also accessible in the MC Comm Numeric Params screen See Setting the MC communications parameters on page 8 If you write to them from the ABC PDP the values set in that screen will be overwritten Words 60 to 67 are sticky and will survive power cycling Word formatting and write protection properties are set in words 60 62 It is a good idea to have all tagged registers write protected 4095 OxFFF in word 60 until the floating point transfer method has been checked out It is possible to transfer an invalid floating point number into a variable that is used in actual calculations which will also crash the MC The following table lists all transitions from the MC CIT table to the data structures in the PLC in this example Note that this is example specific hms mc3 pdf Page 12 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved table CIT Contains Data Word format Bit Note 2 Element o jPhyscal O Compatibility 8 8 ogcalUO Backwards Compatibili
32. ster database and the MC CIT Some of this mapping is fixed and some is configurable You set this up in the MC in the Comm 1 Numeric screen e Between the MC CIT and the Read and Write Tables in the EIP This is entirely configured in the EIP using the ABC Configuration Utility e Between the EIP tables exposed to EtherNet IP and the adapter data structure in the PLC This is done in the PLC I O configuration or by using Message instructions hms mc3 pdf Page 1 09 23 04 Lars MennicKk Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved e Between the adapter data structure in the PLC and the final data structures in the PLC This is done with PLC programming methods For performance reasons all network transfers encompasses entire tables For this reason all elements in a table transfer must be of the same data type Modbus RTU transfers handles 16 bit INT s by design EnterNet IP transfers handles 32 bit DINT s in this example In the CIT and eventually in the PLC different data types are used for control status bits integer numbers and floating point numbers Control Status bits and integer numbers are organized in INTs 16 bit words Parameters are organized as REALs IEEE 32 bit floating point numbers located in two consecutive 16 bit words In order to have usable data in the PLC a user defined data structure is used which closely resembles the MC CIT
33. t 1 42 bit 8 Rack 2 output 2 in 42 bit 15 Rack 3 output 1 in 43 bit O etc CONFIGURING CONTROLLOGIX PLC The RSLogix5000 V10 00 00 file for this example can be downloaded from the Merrick connectivity web site Controller HMS 4MC3 ig Controller Tags Controller Fault Handler 29 Power Up Handler 5 89 Tasks E MainTask EB c amp MainProgram A Program Tags MainRoutine 2 99 MC3_SCH 51 88 A Program Tags Eh MAIN B MC3_1_Comm Bi 2 Comm Bi MC3 3 Comm Bj MC3 4 Comm Unscheduled Programs 21 39 Motion Groups 3 Ungrouped Axes 29 Trends E 3 Data Types Strings FH oe Predefined FH Cg Module Defined Ei 3 Configuration amp BJ 1 1756 ENBT A To verify CLX to MC communication integrity a test set up was arranged A user defined data type MC was defined A four element array of that data type was allocated with tag name MC3 The MC data type resembles the CIT The EIP was configured as an EtherNet IP adapter Some logic was added to convert the raw data in the CLX adapter I O tables into MC3 and to monitor the communications integrity The communications related logic is running as a scheduled task with 500 ms interval There is no reason to run this task more often since the turn around time on the Modbus side is around 800 ms The priority has to be at least higher lower number than the Main Task 10 MC3 MAIN calls the four MC3 n Comm ro
34. t field disagrees with length field in Preset Multiple Registers command 8 Telegram length disagrees with length field in Preset Multiple Registers command 9 Trying to write to read only registers 10 Unknown Modbus command 11 MC Reciever buffer overrun more than 255 bytes in telegram 12 Linefeed not following Carriage Return in Modbus ASCII telegram 13 Bytes received after complete telegram before telegram interpretation too fast 14 Should never happen Unknown receiver state 15 Should never happen Transmitter buffer overrun Increase Message Delimiter to see every telegram The telegram exchange rate typically exceeds the display update rate in the MC Modbus Statistics screen If you want to see each telegram received and transmitted you can increase the Message Delimiter time in the Sub Network parameters list the EIP configuration to 20 corresponding to 200 ms This allows you to see all telegrams received and transmitted Use the ABC PDP Node Monitor Lipi xi File Node Command Columns View Berl ws Read Coil Status Query Slave Address Function Starting Address Hi Lo Number of points Checksum Value Value Value Value Eror check type Error check start byte w Read Coil Status Response Slave Address Function Byte count Data Checksum In rea 228 bytes 512 Out Area 68 bytes 512 General Area 0 bytes 728 0000 0 F0 C 0 020078B BT 180 0 1 0 a
35. t incoming RTU telegram lalen Length in bytes of the last outgoing RTU telegram cCRC CRC16 value calculated out of the incoming telegram Hex hms mc3 pdf Page 20 09 23 04 Lars mm ICK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved Label Meaning tCRC CRC16 value received in the incoming telegram Hex Should be the same as cCRC mxtim Communications timeout in 100 ms ticks Comm Timeout in the Com Num menu unita Slave address for this controller number Controller Number in Com Num menu ints Comm events counter Counts all incoming and outgoing bytes rxchs Received bytes counter txchs Transmitted bytes counter rtgms Received complete telegrams to this slave counter ttgms Transmitted telegrams from this slave counter rENQs Not used for Modbus tENQs Not used for Modbus rNAKs Not used for Modbus tNAKs Transmitted counter Telegrams to this node with badly formatted data requesting non existing registers or writing to write protected registers rACKs Not used in Modbus tACKs Not used in Modbus NotMe Counter for Received telegrams intended for other slaves Received telegrams in error counter Latest See note 2 rxuae Received bytes with UART errors counter rxlua Last encountered UART error See note 1 rxcse Received tel
36. to do triggered updates Performance is good mode enough with cyclical update Minimum 10 Broadcasts are not used This setting has no meaning time between Broadcasts Reconnect 25 Trying to re connect too often will degrade performance 250 ms is time a reasonable value Retries 3 It appears that retries are not done consecutively The performance penalty for a retry is minimal Timeout 25 The MC normally responds within 10 ms but if a heavy screen time such as the line graph screen is displayed on the controller the response time can be as long as 200 ms Update time 1 Set to 10 ms to maximize throughput Trigger OxO5FF Not used This is the default Address Use the following tables to set the parameters in all transactions hms mc3 pdf Page 6 09 23 04 Lars Mennick Copyright 2004 Merrick Industries Inc All rights reserved Read Holding Registers Query Connecting to the MC from EtherNet IP via ABC EIP Parameter MC 1 MC 2 MC 3 MC 4 Slave Address 0x01 0x02 0x03 0x04 Function 0x03 0x03 0x03 0x03 Starting Address Hex Word 0x0010 0x0010 0x0010 0x0010 Number of points Hex Words 0x001C 0x001C 0x001C 0x001C Checksum type Start Byte CRC 0x0000 CRC 0x0000 CRC 0x0000 CRC 0x0000 Read Holding Registers Response Parameter MC 1 MC 2 MC 3 MC 4 Slave Address 0x01 0x
37. ty CIT Comment je 1 Status 1 below for bit info External Outputs R 1 Bit 0 Ex Out 1 Bit 1 Ex Out 2 etc Warnings R2 Js they appear in the Warnings screen fa raus R3 they appear in the MC Faults screen 20 2 1 R Value 0 0001 IR4 5 Register pointed to by Tag 1 RegNo Tag 2 R Value 1 0002 IR67 Register pointed to by Tag 2 RegNo Tag 3 R Value 2 0004 IR8 9 Register pointed to by Tag 3 RegNo 26 2 j Tag4RValue 3 0008 R 10 11 Register pointed to by Tag 4 RegNo 28 2 Tag5RValue 4 0010 R 12 13 Register pointed to by Tag 5 RegNo 30 2 Feedrate 5 0020 R 14 15 As seen in the main screen 32 2 Weight Load 6 0040 R 16 17 As seen in the main screen Speed Info 7 0080 R 18 19 Speed if available or Drive CV Subtotal 8 0100 R21 22 Asseenin the main screen 38 12 Total 9 0200 R23 24 As seen in the main screen 40 1 App Ver R24 Ver ASCII in low Phys Inputs R25 Note 7 Phys Outputs R2627 Note 8 aa fi Control See Note 1 below for bit info External Inputs ow 1 Bit 0 Ex In 1 Bit 1 Ex In 2 etc Primary Setpoint 10 0400 W2 3 Typically Feedrate Setpoint 0800 eo Structure member in MC3 n in CLX n 1 4 dc P MC3 n CVars 1 48 2 Sec Setpoint 11 50 2 Tag 1 W Value 0 0001 Tag 2W Value t 0002 09 23 04 Lars clx_hms_mc3 pdf Page
38. uchpad Demand Disables all touch buttons on the MC Done A Ser Comm Lost will re enable them Reserved Reserved Planned for Register Download Pacing flag Low Feedrate Deviation Used for pacing functions whereby other feeders in the system will follow a starving feeder Not Serial Setpoint MC will ignore sent setpoint Set when the Setpoint Method is something else than Serial MC in menu Used for tampering monitoring This bit is on whenever the MC menu system is entered MC recalibrated Recalibration ACK In place for historical reasons Set when any calibration procedure is accepted or any parameter is changed Reset with a Low to high transition of Recalibration ACK Note 2 This column defines the bit weight for the corresponding variable in the format words 60 61 and 62 Example Tag 2 Read and Write values both are governed by bit one with bit weight 0002 Hex in the format words 60 61 and 62 In this way Write Protection Word Order and Integer Fraction representation is individually settable for every numerical variable in the data map Note 3 The write protection property should be set when an MC register is tagged for monitoring only When writing to words that are write protected the corresponding Tag n W value changes accordingly but the corresponding MC register which you see in Tag n R Value is unaffected This is useful for testing data transfers to the MC before they are implemented or when you
39. utines one for each MC controller It is possible to use only one such routine and call it four times with parameters This saves controller memory but makes it harder to debug the system g ETHERNET MODULE AnyBus_4MC3 Several versions of the test logic used can be found in the Merrick communications website It is possible to copy and paste between different RSLogix5000 projects To incorporate the definitions and logic from the test file into your project you must first convert our project to your version The easiest way to do this is to import the L5K file into a new project and then cut and paste objects from the new project into your existing project Proceed in the following order 1 l O configure the EIP using the name AnyBus_4MC3 in I O configuration If you use another name you have to edit all ladder files You can rename the adapter later Copy and paste the user defined data type MC Copy and paste the tag MC3 in Controller Tags Copy and paste MC3 SCH in Tasks Copy and paste MC3 TOP in MC3 SCH This will take Program Tags MC3 MAIN and all four MC3 n COMM routines with it amp oN hms mc3 pdf Page 16 09 23 04 Lars MennicK Connecting to the MC from EtherNet IP via ABC EIP Copyright 2004 Merrick Industries Inc All rights reserved MC User Defined Data type lolx ioi xd Warning This structure is being referenced Modifications will result in loss of data General
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