PACSystems RX3i CPUs, IC695CPU310-CC v2.90, GFK
Contents
1. 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 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 rack With the following combination of circumstances it is possible to render serial communications with the CPU impossible 1 User configuration disables the Run Stop switch 2 User configures the power up mode to Run or Last 3 Logic is stored in FLASH and user configures CPU to load from FLASH on power up 4 User application issues COMMREQs that set the protocol on both of the serial ports to something that does not permit communications to the ME programmer2. Address field of I O Fault Table for Universal Analog Module The I O Fault Table Ref Address field now always displays the correct value for the Universal Analog Input module and circuit faults This problem was reported in the IPI for the Universal Analog Module IC695ALG600 GFK 2348 Error with a Flash Write or Clear The CPU firmware no longer reports faults for large flash writes or clears Faults with Hot Swap and DO_IO Previously hot inserting a module that does not support DO_IO into a slot configured for DO_IO or vice versa caused the CPU to record faults This has now been fixed Hot insertion of Series 90 30 smart module to ETM slot If a Series 90 30 smart module is hot inserted into a slot that has been configured for an RX3i Ethernet module ETM001 the fault table does not list multiple Extra Module faults and the module is not repeatedly reset interrupt handling for the Universal Analog Module CPU goes to If an unsupported module is hot inserted into the RX3i system an Unsupported Module fault is STOP HALT with generated and the CPU goes to STOP HALT mode Unsupported Module Fault Lost or late This CPU pulls all interrupts from a Universal Analog Input module IC695ALG600 when the module sends many interrupts in a short period of time or interrupts that execute late It will not appear to have lost interrupts Unsupported Module fault for DSM module After a pow
3. differences are that the elapsed time 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 Service Requests 6 15 and 23 have slightly different parameters Refer to GFK 2222 PACSystems PLCs support Service Request 26 30 functionality via fault locating references Service Request 13 requires a valid value in the input parameter block Refer to GFK 2222 for details On the Series 90 30 and Series 90 70 the parameter block value was ignored 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 are not available The Series 90 30 Enhanced DO O instruction is converted to a standard DO 1 O instruction the ALT parameter is discarded and ignored The Series 90 30 END instruction is not supported Alternate programming techniques should be used Non nested JUMPs LABELs MCRs amp ENDMCRs are translated to the corresponding nested JUMPs LABELs MCRs amp ENDMCRs when converting from Series 90 30 to PACSystems RX3i Storing a hardware configuration with a new IP address to the RX3i while connected via Ethernet will succeed then immediately disconnect because the RX3i is now using a different IP address tha
4. December 22 2004 GFK 2329D IMPORTANT PRODUCT INFORMATION READ THIS INFORMATION FIRST Product PACSystems RX3i CPU IC695CPU310 CC with Firmware Version 2 90 Note 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 an update to the CPU firmware Support for the following modules has been added e The new RX3i PROFIBUS Master module IC695PBM300 e Genius Bus Controller Modules IC694BEM331 and IC693BEM331 e Serial IO Processor Modules IC694APU305 and IC693APU305C This update also resolves the problems described in Problems Resolved by this Version on page 3 Version Identification Hardware Identification Firmware Identification Catalog Number Circuit Board ID Firmware ID Version IC695CPU310 CC CP4A1 CPU Primary 2 90 Build 50A4 BOC Build 28A1 CPU Boot 2 50 Build 25A3 CPU Programmable Parts Part ID Revision BIOS f4_r05 MCU r07 6 04 FPGA X05 SDRAM CPLD C HW rev EPROM f4_r05 MAC EPROM f4_r05 Updates IC695CPU310 AA is field upgradeable to firmware version 2 90 by ordering the upgrade kit below or downloading from the services web site The hardware is not field upgradeable Upgrade Kit 44A752290 G03 2 Important Product Information GFK 2329D Product Documentation PACSystems CPU Reference Manual GFK 2222 PACSystems R
5. PU unit behind the battery door on the faceplate but it is not connected Do not connect the battery until the CPU is installed in the rack and the rack powered on The battery may then be attached to either of the two terminals in the battery compartment Once that is done the CPU may be powered down and normal battery back up operation will begin To save battery life do not connect the battery for the first time until the CPU is powered up Machine Edition LD PLC no longer supports a function that connects to the PLC downloads then disconnects from the PLC The connect and download functions are now separate To perform a download to the PLC you must first connect to the PLC Logic execution in PACSystems RX3i is performed in row major order similar to the Series 90 30 This is different from the Series 90 70 that executes in column major order This means that some complicated rungs may execute slightly differently on PACSystems RX3i and Series 90 70 For specific examples see the programming software on line help The PACSystems RX3i CPU may return slightly different values for Not A Number as compared to Series 90 30 CPUs In these exception cases e g 0 0 0 0 power flow out of the function block is identical to Series 90 30 operation and the computed value is still Not A Number The PID algorithm used in PACSystems has been improved and therefore PID will function slightly differently on PACSystems RX3i than on the Series 90 30 The
6. 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 setting is not high enough A large number of COMMREQs 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 COMMREQs issued to a given board should be spread across multiple sweeps so that only a limited number typically 8 or less of COMMREQs 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 COMMREQ 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 IO 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
7. X3i Hardware and Installation Manual GFK 2314 TCP IP Ethernet Communications for the PACSystems GFK 2224 C Toolkit for PACSystems User s Manual GFK 2259 Proficy Machine Edition Getting Started GFK 1868 Proficy Logic Developer PLC Programming Software Getting Started GFK 1918 Datasheet PACSystems RX3i CPU GFK 2316 IPI PACSystems RX3i CPU GFK 2329D this document CPU Functional Compatibility Programmer Machine Edition Logic Developer 5 0 or later must be used to configure and program the RX3i Version Service Pack 2 is required to support the new features in release 2 90 Requirements C Toolkit The C Toolkit for PACSystems is distributed with Machine Edition Logic Developer 5 0 or greater Compatibility Toolkit build 50A1 or later is required for use with the RX3i Please note The Series 90 Toolkit 1C641SWP709 719 is not compatible with PACSystems Series 90 30 The PACSystems RX3i supports the following Series 90 30 modules Module Discrete Input Modules IC693ACC300 Compatibility IC693MDL230 231 240 241 632 634 645 646 648 654 655 Discrete Output Modules IC693MDL310 330 340 390 730 731 732 733 734 740 741 742 748 752 753 760 930 93 1 940 Discrete Combinational IC693MAR590 IC693MDR390 Analog I O Modules IC693ALG220 221 222 223 390 39 1 392 442 High Speed Counter IC693APU300 FANUC 1 O Link IC693BEM320 IC693BEM321 Motion Control IC693DSM314 IC693DSM324 Genius Bus Controller Module C693BEM331 Serial IO P
8. ct Description 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 stores 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 o
9. edirection 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 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 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 2329D Important Installation Instructions for Battery LD PLC operations Logic Executed in Row Major Instead of Column Major NaN Handled Differently Than in 90 30 PID Algorithm Improved Some Service Requests different from Series 90 30 or no longer supported IL and SFC END Instruction Non nested JUMP LABEL MCR amp ENDMCR Instructions Changing IP Address of Ethernet Interface While Connected Duplicate Station Address for Modbus Will Conflict with Other Nodes DO I O Instruction A battery is shipped with the C
10. er cycle a DSM 314 or DSM324 module will not generate an Unsupported Module fault New CPU Features and Enhancements Subject Description Feature Description This version of the RX3i CPU supports The new RX3i PROFIBUS Master module IC695PBM300 Genius Bus Controller Modules IC694BEM331 and IC693BEM331 Serial IO Processor Modules IC694APU305 and IC693APU305C CPU Restrictions and Open Issues Subject Description Ethernet Disconnect During Word for Word Change If the Ethernet connection is broken during a word for word change the programmer may not allow a subsequent word for word change after reconnecting due to the fact that it thinks another programmer is currently attached If this occurs you should go offline and then back 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 Edit Power Cycle During Online 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 Important Product Information GFK 2329D Subje
11. hen installed in a rack It is referenced for configuration and by user logic applications reference by the leftmost slot that it occupies For example if the RX3i CPU has its physical connector inserted in to slot 4 which means it occupies slots 3 and 4 the CPU is referenced as being located in slot 3 The referenced location 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 3 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 4 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 5 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 lists the areas tha
12. n the Programmer You must enter a new IP address in the Target Properties in the Machine Edition Inspector window before reconnecting 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 Important Product Information GFK 2329D Timer Operation Constant Sweep Large Number of COMMREQs Sent to Module in One Sweep Causes Faults C Block Standard Math Functions Do Not Set errno Upgrading Firmware Hot Swap Single Power Supply Serial Port Configuration COMMREQs 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
13. operation of the scan set after entering RUN mode They do work properly for subsequent scans 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 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 Two loss of modul faults for Universal Analog mocule Occasionally the hot removal of the Universal Analog Input Module IC695ALG600 results in two Loss of I O Module faults instead of one CPU logs incorrect fault f
14. or Overtemp When the CPU detects an overtemp condition the overtemp fault causes the CPU to go to STOP HALT instead of STOP FAULT Important Product Information 5 GFK 2329D Subject Description Powerup of High speed Counter may take up to 20 seconds As power is applied to a Series 90 30 High Speed Counter module the module ready bit in the status bits returned each sweep may not be set for as long as 20 seconds after the first PLC sweep even though there is no loss of module indication I O data exchanged with the module is not meaningful until this bit is set by the module c f pages 4 3 to 4 5 of GFK 0293C Lost count at powerup for Serial IO Processor A Serial IO Processor module will lose the first count after every powerup or every time the module receives a configuration Info fault at power up Intermittently during powerup an Informational non critical CPU software fault may be generated with fault extra data of 01 91 01 D6 This fault will have no effect on the normal operation of the PLC But if the hardware watchdog timer expires after this fault and before power has been cycled again the outputs of I O modules may hold their last state rather than defaulting to zero Serial Port Lock up after Bad Modbus Message If a badly formed Modbus RTU message is sent ot the PLC the serial port will lock up Power must be cycled to recover proper port operation Faults possible when p
15. ower cycling or hot swapping smart modules in an RX3i When power is cycled on a rack in a system containing a Series 9030 smart option module or if the module is hot swapped in an RX3i rack the module may intermittently fail in one of three ways 1 There is a loss of module fault 2 There is a System Configuration Mismatch fault or 3 There is an Unsupported hardware fault In all three cases the module will not be scanned until power is cycled on the module In the latter two cases the PLC fault table must be cleared before the PLC can be placed into RUN mode These failures are much less likely if the module is in the main RX3i rack or if the module is in an expansion rack and only the expansion rack power is cycled If operation of the module is critical in the application then the user logic should monitor the fault locating reference for the module as described on pages 12 11 and 12 12 of GFK 2222 Lost Connection to Machine Edition On rare instances Machine Edition may disconnect from the PLC after a download Possible Machine Edition disconnect when multiple Genius Bus Controllers are present in expansion remote racks If a system contains multiple Genius Bus Controllers in expansion remote racks the Machine Edition software can time out its connection to the PLC on a clear operation or a store of configuration For each Bus Controller in an expansion remote rack there is a 3 second delay added to the time
16. required for a clear store of configuration The default connection timeout is 10 seconds and the default request timeout is 16 seconds These values should be increased by at least 3 seconds per Genius Bus Controller in an expansion remote rack This is true for both Ethernet and serial programmer connections Timed interrupt response time increased A Genius Bus Controller in the system may impact response time for timed interrupts The worst case interrupt response time for a PLC system with a Genius Bus Controller and no other Genius devices is 0 5 milliseconds The worst case interrupt response time for a PLC system with a Bus Controller and maximum amount of Genius data is 50 milliseconds Extended Memory Types for IO Triggers R W and M cannot be used as IO triggers for the Universal Analog Input module IC695ALG600 6 Important Product Information GFK 2329D CPU Operational Notes Slot 1 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 2 The RX3i CPU IC695CPU310 is a doublewide module whose connector is right justified as placement and viewed w
17. rocessor IC693APU305 All other Series 90 30 modules are not currently supported IC694 Module The PACSystems RX3i supports the following IC694 modules Compatibility IC694ACC300 IC694MDL230 231 240 24 1 632 634 645 646 654 655 Discrete Output Modules IC694MDL310 330 340 390 732 734 740 74 1 742 752 753 930 931 940 Analog I O Modules IC694ALG220 221 222 223 390 391 392 442 High Speed Counter IC694APU300 Fanuc I O Link Modules IC694BEM320 IC694BEM321 Motion Control C694DSM314 IC694DSM324 Genius Bus Controller Module C694BEM331 Serial IO Processor IC694APU305 Expansion Backplanes IC694CHS392 398 Expansion Power Supplies C694PWR321 330 331 IC695 PCI Ethernet Interface IC695ETMO001 Module Universal Analog Input Module IC695ALG600 Compatibility Profibus Master Module IC695PBM300 Series 90 30 The PACSystems RX3i supports local and remote Series 90 30 expansion racks Expansion Rack PACSystems RX3i CPUs do not operate in a Series 90 30 Rack Compatibility Important Product Information 3 GFK 2329D Series 90 30 Main Rack Compatibility Series 90 30 Main Racks cannot be used in a PACSystems RX3i system Series 90 30 CPUs do not operate in PACSystemsRX3i Racks Isolated 24V In applications that use the IC69xALG220 221 222 consult PACSystems RX3i Hardware and power Installation Manual GFK 2314 for details of wiring the 24V power Problems Resolved by this Version Subject Description Ref
18. t 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 location but will reflect the slot the CPU is located in Fault Table Entry User logic that decodes fault table entries retrieved Service Request 20 by these service requests may need updating Read Fault Tables Communications Commregs directed to the CPU e g those directed Request Commreq to the 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 The location of faults logged for the CPU in the fault CPU 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 In order 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 r
19. ut Number of Active Programs Returned as Zero The SNP request Return Controller Type and ID currently returns the number of active programs as zero 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 Incorrect Commreq Status For Invalid Program Name The program name for PACSystems is always LDPROG1 When another program name is used in a CommRegq accessing L memory an Invalid Block Name 05D5 error is generated SNP ID not always provided Unlike the Series 90 30 the RX3i CPU s SNP ID will not appear in the Machine Edition programmer Show Status display Service Request 11 will always return zeros Second programmer can change logic while in Test amp Edit mode While currently active in a Test and Edit session using Machine Edition on one PC Machine Edition running on another PC is not prevented from storing new logic to the PLC FANUC I O Master and Slave operation Scan sets on the master do not work properly for the first
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