PACSystems RX3i CPUs, IC695CPU310
Contents
1. Waiting for Target until the hyperterm session is closed Hot Swap of power supplies or CPUs is not supported in this release Use only one power supply in an RX3i main rack2. June 24 2004 GFK 2329 IMPORTANT PRODUCT INFORMATION READ THIS INFORMATION FIRST Product PACSystems RX3i CPU with Firmware Version 2 50 IC695CPU310 AA This document contains information that is not available in any other publication therefore we recommend that you read and save it for future reference This is the initial release of the RX3i CPU310 Version Identification Hardware Identification Firmware Identification Catalog Number Circuit Board ID Firmware ID Version CP4A1 CPU Primary 2 50 Build 26A4 IC695CPU310 AA BOC Build 24A1 CPU Boot 2 50 Build 25A3 CPU Programmable Parts Part ID Revision BIOS f4_r05 MCU f4_r05 FPGA X05 SDRAM CPLD C HW rev EPROM f4_r05 Product Documentation PACSystems CPU Reference Manual GFK 2222 PACSystems RX3i Hardware and Installation Manual GFK 2314 TCP IP Ethernet Communications for the PACSystems GFK 2224 C Toolkit for PACSystems User s Manual GFK 2259 CIMPLICITY Machine Edition Getting Started GFK 1868 Logic Developer PLC Programming Software Getting Started GFK 1918 Datasheet PACSystems RX3i CPU GFK 2316 IPI PACSystems RX3i CPU GFK 2329 this document Important Product Information GFK 2329 CPU Functional Compatibility Subject Programmer Version Requirements C Toolkit Compatibility Series 90 30 Module Compatibility IC694 blue Module Compatibility Ser
3. Logic execution in PACSystems RX3i is performed in row major order similar to the Series 90 30 Executed in This is different from the Series 90 70 that executes in column major order This means that some Row Major complicated rungs may execute slightly differently on PACSystems RX3i and Series 90 70 For Instead of specific examples see the programming software on line help Column Major NaN Handled The PACSystems RX3i CPU may return slightly different values for Not A Number as compared to Differently Series 90 30 CPUs In these exception cases e g 0 0 0 0 power flow out of the function block is Than in 90 30 identical to Series 90 30 operation and the computed value is still Not A Number PID The PID algorithm used in PACSystems has been improved and therefore PID will function slightly Algorithm differently on PACSystems RX3i than on the Series 90 30 The differences are that the elapsed time Improved is computed in 100 uS instead of 10 mS units This smooths the output characteristic eliminating periodic adjustments that occurred when the remainder accumulated to 10mS Also previous non linear behavior when the integral gain is changed from some value to 1 repeat second was eliminated Some Service Service Requests 6 15 and 23 have slightly different parameters Refer to GFK 2222 Requests PACSystems PLCs support Service Request 26 30 functionality via fault locating references different from The first word of a Servi
4. cal and remote Series 90 30 expansion racks PACSystems RX3i CPUs do not operate in a Series 90 30 Rack Series 90 30 Main Racks cannot be used in a PACSystems RX3i system Series 90 30 CPUs do not operate in PACSystemsRX3i Racks In applications that use the IC69xALG220 221 222 consult PACSystems RX3i Hardware and Installation Manual GFK 2314 for details of wiring the 24V power Important Product Information GFK 2329 New CPU Features and Enhancements Release 2 50 of the RX3i CPU provides the following new features and enhancements compared to the family of Series 90 30 CPUs Non volatile flash 10Mbyte and battery backed user memory up to 10 Mbytes A new register WORD reference table W that is configurable up to 4Mbytes Auto located Symbolic Variables that can use any amount of user memory Larger reference table sizes which include 32 Kbits for discrete l and Q and up to 32K words each for analog AI and AQ Support for new Rx3i modules as well as Series 90 30 discrete and analog I O and High Speed Counter Application compatibility with PACSystems RX7i applications Up to 512 program blocks Maximum size for a block is 128KB Online Edit and Test modes that allow editing and testing of logic changes that are permitted for a Run Mode Store Bit in word referencing that allows you to specify individual bits in a WORD reference in retentive memory as inputs and outputs of Boolean expressions function blocks and cal
5. ce Request command block is required to contain a zero On the Series 90 90 30 or no 30 this value was ignored Please note the parameter to the service request must be the address of longer the location containing the zero supported Service Requests 48 and 49 are no longer supported there is no auto restart because most faults can be configured to be not fatal IL and SFC IL and SFC are not available DO I O The Series 90 30 Enhanced DO I O instruction is converted to a standard DO O instruction the Instruction ALT parameter is discarded and ignored PE The Series 90 30 END instruction is not supported Alternate programming techniques should be used Non nested Non nested JUMPs LABELs MCRs amp ENDMCRs are translated to the corresponding nested JUMP JUMPs LABELs MCRs amp ENDMCRs when converting from Series 90 30 to PACSystems RX3i LABEL MCR amp ENDMCR Instructions Changing IP Storing a hardware configuration with a new IP address to the RX3i while connected via Ethernet will Address of succeed then immediately disconnect because the RX3i is now using a different IP address than Ethernet the Programmer You must enter a new IP address in the Target Properties in the CME Inspector Interface window before reconnecting While Connected Subject Duplicate Station Address for Modbus Will Conflict with Other Nodes Timer Operation Constant Sweep Large Number of COMM_REQs Sent to Module in One S
6. communication devices that interact with the CPU should be checked for compatibility with CPU slot locations other than slot 1 Problems may arise with but are not limited to initial connection sequences and fault reporting CIMPLICITY Machine Edition View customers should select GE SRTP as their communications driver it can communicate with a CPU in any slot Host Communications Toolkit HCT Applications that utilize the Host Communications Toolkit may require updated drivers Important Product Information 7 GFK 2329 Important A battery is shipped with the CPU unit behind the battery door on the faceplate but it is not Installation connected Do not connect the battery until the CPU is installed in the rack and the rack powered on Instructions The battery may then be attached to either of the two terminals in the battery compartment Once for Battery that is done the CPU may be powered down and normal battery back up operation will begin If the battery is installed before the CPU is powered up it will drain the battery 10 times faster until power is applied To save battery life do not connect the battery for the first time until the CPU is powered up LD PLC Machine Edition LD PLC does not allow a user to perform operations that change the PLC until operations explicitly connecting to the target device For example to perform a download to the PLC you must first connect to the PLC Logic
7. condition can cause the programmer to lose communications with the PLC The user must insure that when Constant Sweep mode is configured sufficient buffer is allowed for communications to occur with the programmer Serial I O Failure at 115K During Heavy Interrupt Load Rare data corruption errors have been seen on serial communications when running at 115K under heavy interrupt load on the PLC Under heavy load applications users should restrict serial communications to 57K or lower RAND_MAX and rand Function Incompatible In the C Toolkit the RAND_MAX system variable is defined as a 32 bit integer However the rand function returns a 16 bit integer By definition rand should return an integer between 0 and RAND_ MAX Firmware Update Attempt to Incorrect Module If an attempt to load Ethernet module firmware is inadvertently directed to a slot containing a different type of module for example an analog module WinLoader will fail with the error Target is unable to enter boot mode Serial communications error Request timed out After this error occurs the CPU will be in an invalid state and should be power cycled Incorrect Commreg Status For Invalid Program Name The program name for PACSystems is always LDPROG1 When another program name is used in a CommReq accessing L memory an Invalid Block Name 05D5 error is generated Important Product Information 5 GFK 2329 Subject De
8. et of I O Module fault appears in the PLC fault table For RX7i systems two faults appear Reset of I O Module and Loss of I O Module Configuration mismatch with unsupported module causes PLC sequence store failure If you attempt to store a hardware configuration to the CPU that has a module configured for a slot that physically contains an unsupported module the store will fail with a sequence store failure Overtemp thresholds are too low The CPU has two thresholds for operating temperature normal and critical These thresholds are intended to be set at 58 C and 63 C respectively but the current thresholds are 55 C and 60 C These thresholds are determined under worst case thermal operating conditions minimal air flow with hot modules on either side of the CPU When the operating temperature of the CPU exceeds the normal operating temperature the system variable OVR_TMP SA8 turns ON To turn it OFF clear the PLC fault table or reset the PLC This fault fault group 0x18 error code 0x0001 is configurable to be diagnostic or fatal default configuration is for diagnostic A second overtemp threshold will cause a fatal error fault group Ox0D error code 0x00A8 when the CPU has exceeded the critical temperature point just prior to hardware failure Conditions for Changing Sweep Mode In PACSystems users can change sweep mode parameters while the CPU is running only if they have previously stored logic
9. etting is not high enough A large number of COMM_REQs typically greater than 8 sent to a given board in the same sweep may cause Module Software faults to be logged in the PLC fault table The fault group is MOD_OTHR_SOFTWR 16t 10h and the error code is COMMREQ_MB_FULL_START 2 When this occurs the FT output of the function block will also be set To prevent this situation COMM_REQs issued to a given board should be spread across multiple sweeps so that only a limited number typically 8 or less of COMM_REQs are sent to a given board in each sweep In addition the FT output parameter should be checked for errors If the FT output is set meaning an error has been detected the COMM_REQ could be re issued by the application logic In C Blocks standard math functions e g sqrt pow asin acos do not set errno to the correct value and do not return the correct value if an invalid input is provided The process of upgrading the CPU firmware with the WinLoader utility may fail when multiple lO modules are in the main rack due to the time it takes to power cycle the rack system If the upgrade process fails move the CPU to a rack without IO modules and restart the upgrade process Winloader initial connect baud rate is fixed at 19200 baud Note that the firmware download will occur at 115 2K baud by default Note that if you have hyperterm open on a port and then try to use Winloader on the same port Winloader will often say
10. ies 90 30 Expansion Rack Compatibility Series 90 30 Main Rack Compatibility Isolated 24V power CIMPLICITY Machine Edition Logic Developer 5 0 or later must be used to configure and program the RX3i The C Toolkit for PACSystems is distributed with CIMPLICITY Machine Edition Logic Developer 5 0 or greater Toolkit build 50A1 or later is required for use with the RX3i Please note The Series 90 Toolkit IC641SWP709 719 is not compatible with PACSystems The PACSystems RX3i supports the following Series 90 30 modules Discrete Input Modules IC693ACC300 IC693MDL230 231 240 24 1 632 634 645 646 648 654 655 Discrete Output Modules IC693MDL310 330 340 390 730 731 732 733 734 740 741 742 748 752 753 760 930 931 940 Discrete Combinational IC693MAR590 IC693MDR390 Analog I O Modules IC693ALG220 221 222 223 390 391 392 442 High Speed Counter IC693APU300 FANUC 1 O Link IC693BEM320 IC693BEM321 Motion Control IC693DSM314 All other Series 90 30 modules are not currently supported The PACSystems RX3i supports the following IC694 modules IC694ACC300 IC694MDL230 23 1 240 24 1 632 634 645 646 654 655 Discrete Output Modules IC694MDL310 330 340 390 732 734 740 741 742 752 753 930 931 940 Analog I O Modules IC694ALG220 221 222 223 390 391 392 442 High Speed Counter IC694APU300 Motion Control IC694DSM314 Expansion Backplanes IC694CHS392 398 Expansion Power Supplies C694PWR321 330 331 The PACSystems RX3i supports lo
11. le entries retrieved by these service requests may need updating Service Request 20 Read Fault Tables Communications Request Commregs directed to the CPU e g those directed to the Commreq serial ports of the CPU will need to be updated with the correct CPU slot reference H W CPU Slot location Slot location of the CPU must be updated in the HW Configuration Configuration to reflect the CPU s true location Fault Tables Faults logged for the CPU The location of faults logged for the CPU in the fault table will not be the standard 0 1 rack slot location but will reflect the CPU s actual slot External Series 90 PLCs Devices Remote Series 90 PLCs that use SRTP Channels COMMREQs expect the CPU to be in slot 1 To support communications with Series 90 SRTP clients such as Series 90 PLCs using SRTP Channels the RX3i internally redirects incoming SRTP requests destined for rack 0 slot 1 to rack 0 slot 2 provided that the CPU is located in rack 0 slot 2 and the remote client has not issued an SRTP Destination service on the connection to discover the rack and slot of the CPU This special redirection permits Series 90 30 applications that expect the power supply to be located leftmost and the CPU to be located to the right of the power supply to function Attempts to establish channels with CPUs in slots other than 1 or 2 will fail if initiated from Series 90 PLCs HMI and External Communication Devices All external
12. ls that accept bit parameters CPU over temperature status bit Two serial ports one RS 485 serial port and one RS 232 serial port neither are isolated Important Product Information GFK 2329 CPU Restrictions and Open Issues Subject Description Ethernet If the Ethernet connection is broken during a word for word change the programmer may not Disconnect allow a subsequent word for word change after reconnecting due to the fact that it thinks During Word for another programmer is currently attached If this occurs you should go offline and then back Word Change online again Simultaneous Clears Loads and Stores Not Supported Currently PACSystems CPUs do not support multiple programmers changing CPU contents at the same time The programming software may generate an error during the operation Power Cycle During Online Edit If the user stores a folder to flash that is configured to power up from flash and then subsequently power is cycled in the middle of a Online Edit session the programmer will still indicate that the Online Edit session is in progress after the power cycle The user should cancel the Online Edit session to continue Power Cycle During Write to Flash If the CPU is power cycled during the process of writing to flash and is configured to power up from flash a fault will be generated on power up Hardware Configuration Not Equal After Changing Target Name If the user sto
13. n of the CPU is not determined by what slot the physical connector is located in but rather by the left most slot occupied by the entire module Due to item 2 above the RX3i CPU may be located in Slot 0 of a rack physical connector in Slot 1 In addition the CPU cannot be located in Slot 11 of a 12 slot rack nor Slot 15 of a 16 slot rack since doing so would require the physical connector to be located in the slot reserved for an expansion module When migrating a Series 90 30 CPU system to a PACSystems RX3i CPU be aware that to maintain the Slot 1 location of the CPU only a singlewide power supply may be used in Slot 0 Currently the only available singlewide power supply is a DC power supply IC695PSD040 Therefore if the application using an existing Series 90 30 system must maintain a Slot 1 CPU and uses an AC power supply the RX3i system must have the RX3i AC power supply located in a slot to the right of the RX3i CPU in Slot 1 In deciding to place the CPU in slots other than Slot 1 the user should be aware of the possible application migration issues that could arise The following table lists the areas that could be affected when migrating an application from one CPU slot to another Item Affected How Affected User Logic Service Request 15 Location of CPU faults will not be the standard 0 1 Read Last Logged Fault location but will reflect the slot the CPU is located in Table Entry User logic that decodes fault tab
14. res a hardware configuration to flash which indicates that Logic Config Power up Source is set to Always Flash or Conditional Flash and then subsequently changes the name of the target in the programming software the hardware configuration will go Not Equal and will not Verify as equal PLC and IO Fault Tables May Need to be Cleared Twice to Clear Faulted State Both PLC and IO fault tables may need to be cleared to take the CPU out of Stop Fault mode If one of the tables contains a recurring fault the order in which the tables is cleared may be significant If the CPU is still in Stop Fault mode after both tables are cleared try clearing the fault tables again Setting Force On Off by Storing Initial Value Once a force on or force off has been stored to the PLC the user cannot switch from force on to force off or vice versa directly by downloading initial values The user can turn off the force by doing a download and then change the force on or off by another download Storing Large Numbers of Blocks to Flash Currently storing logic with approximately 200 blocks or more to flash may fail due to the programmer timing out Number of Active Programs Returned as Zero The SNP request Return Controller Type and ID currently returns the number of active programs as zero Over Sweep Condition in Constant Sweep Mode When the PLC is configured for Constant Sweep mode a consistent over sweep
15. scription Second programmer can change logic while in Test amp While currently active in a Test and Edit session using CIMPLICITY Machine Edition on one PC CIMPLICITY Machine Edition running on another PC is not prevented from storing new logic to the PLC Edit mode FANUC I O Master Scan sets on the master do not work properly for the first operation of the scan set after and Slave entering RUN mode They do work properly for subsequent scans operation After downloading a new hardware configuration and logic a power cycle may be required to resume FANUC I O operation Use PLCs of similar performance in FANUC I O networks If a master or slave is located in an RX3i system the other PLCs should be RX3is or Series 90 30 CPU374s Must Have Logic If Powering Up From Flash If the application will configure the CPU to retrieve the contents of flash memory at power up be sure to include logic along with hardware configuration when saving to flash memory Avoid Ethernet module resets Resetting the Ethernet module either by Service Request 24 or by the restart pushbutton will cause some of the CPU s internal memory to be consumed if EGD is configured The problem becomes more pronounced with larger EGD configurations Power cycling the system will recover the internal memory Service Request 24 results in different fault messages When Service Request 24 is used to reset a module in the RX3i system a Res
16. stop mode Run Mode store or word for word change during the current connection Performing a Test Edit operation removes the ability to change sweep mode parameters until another store of logic stop mode RMS or WFW change is done Power Supply Firmware Version Reported Incorrectly The information presented for the power supply in CIMPLICITY Machine Edition s Device Information Details window will say N A not applicable rather than supply the version information for the firmware in the power supply 6 Important Product Information GFK 2329 CPU Operational Notes Slot The A C Power Supply IC695PSA040 for the RX3i is a doublewide module whose connector numbering is left justified as viewed when installed in a rack It cannot be located in Slot 11 of a 12 slot power supply rack nor Slot 15 of a 16 slot rack No latch mechanism is provided for the last right most slot in placement a rack therefore it is not possible to place the power supply in the second to last slot CPU The RX3i CPU IC695CPU310 is a doublewide module whose connector is right justified as placement viewed when installed in a rack It is referenced for configuration and by user logic applications and reference by the leftmost slot that it occupies For example if the RX3i CPU has its physical connector inserted into slot 4 which means it occupies slots 3 and 4 the CPU is referenced as being located in slot 3 The referenced locatio
17. weep Causes Faults C Block Standard Math Functions Do Not Set errno Upgrading Firmware Hot Swap Single Power Supply Important Product Information GFK 2329 Description The default serial protocol for the RX3i is Modbus RTU The default Station Address is 1 If the PLC is added to a multi drop network care must be taken that the PLC is configured with a unique Station Address Nodes with duplicate Station Addresses on the same network will not work correctly Care should be taken when timers ONDTR TMR and OFDTR are used in program blocks that are NOT called every sweep The timers accumulate time across calls to the sub block unless they are reset This means that they function like timers operating in a program with a much slower sweep than the timers in the main program block For program blocks that are inactive for large periods of time the timers should be programmed in such a manner as to account for this catch up feature Related to this are timers that are skipped because of the use of the JUMP instruction Timers that are skipped will NOT catch up and will therefore not accumulate time in the same manner as if they were executed every sweep Constant Sweep time when used should be set at least 10 milliseconds greater than the normal sweep time to avoid any over sweep conditions when monitoring or performing on line changes with the programmer Window completion faults will occur if the constant sweep s
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