PLC Gateway Planning, Installation, and Service
Contents
1. e Figure 3 5 CLCN A BI O Address Pinning PLCG Planning Installation and Service 3 5 7 95 3 2 5 3 2 5 PLCI Pinning Refer to Figure 3 6 to locate the pinning headers and jumpers in the following steps If you are installing a redundant PLCG pair both PLCI boards must be pinned the same way 3 2 5 1 Ram Clear J1 Locate J1 and insure that a jumper is installed 3 2 5 2 Board Revision TS1 Do not alter TS1 the Board Revision header 3 2 5 3 Baud Rate and Parity TS2 The baud rate of the two serial interfaces serving Ports 1 and 2 are set up with the jumpers on TS2 near right center in Figure 3 6 See Table 3 1 or the table on the PLCI board for the pinning information Be sure the baud rate for a given port matches the PLC s it is communicating with The baud rates of the ports may be set at different speeds Notice Port 1 uses the higher numbered pins The transmit and receive data parity for Ports 1 and 2 are set by jumpers 5 and 1 respectively To send and receive odd parity on a port its respective jumper must be shorted Conversely even parity is obtained by the jumper being open Make sure the parity of a port agrees with the parity sent and expected by the PLC s to which it is connected Table 3 1 Baud Rate Pinning on PLCI Board PORT 2 PORT 1 PIN 2 PIN 3 PIN 4 PIN 6 PIN 7 PIN2. 51304421 100 CG O LG Honeywell Cables to Programmable Logic Controllers NVA Each port may be configured to either the Modbus or Allen Bradley A B protocol That is in the nonredundant configuration you may have Port 1 connected to a Modbus and Port 2 connected to A B equipment or both ports configured to the same bus type Figure 2 1 PLCG in a Nonredundant Configuration In all nonredundant configurations the pinning header on the PLCG Relay Panel must be plugged into the OTHERS socket on the relay panel See subsection 3 2 4 and Figure 3 3 for a more detailed illustration of the pinning sockets and header 2 4 2 Redundant Configurations Figure 2 2 shows two PLCG 5 slot modules connected in a redundant configuration This configuration also supports up to a total of 16 PLCs Notice only one PLCG Relay Panel is used In this configuration the PLCG electronics within the modules are redundant with the relay panel the only nonredundant part of the system Again connections for a dual node module configuration are the same the single relay panel being mounted horizontally To reduce the possibility of failure of the relay panel the relay used is a special high reliability device See subsection 2 5 3 for examples of redundant port cabling configurations PLCG Planning Installation and Service 2 3 7 95 2 4 2
3. PLCI I O Primary PLCG I Je Let er e LON B g LCN vO PE PORT1 PORT2 C E C E PLCG MELAY PANEL Secondary PLCG 51304421 100 P CG O LG Honeywell C_NOTUSED Fe vo J LCN A LCNB LCN VO eee EEEa Wee Q s newe Cables to Programmable Logic Controllers Figure 2 2 PLCG Modules in a Redundant Configuration If you use Modbus protocol in this redundant configuration both ports Port 1 and Port 2 must be connected to Modbus compatible equipment The configuration is again capable of serving up to 16 PLCs on both ports The pinning header on the PLCG Relay Card must be plugged into the OTHERS socket See subsection 3 2 4 and Figure 3 3 for a more detailed illustration of the pinning sockets and header If you use A B protocol in a redundant configuration only Port 1 may be used You must plug the pinning header on the PLCG Relay Card into the REDUNDANT A B socket and be sure no cable is connected to Port 2 This configuration is capable of serving up to 16 PLCs on Port 1 through an Allen Bradley communications controller See subsection 3 2 4 and Figure 3 3 for a more detailed illustration of the pinning sockets and header NOTE Ports 1 and 2 are independent ports in either nonredundant or redundant configurations and
4. fe Figure 3 2 LCN I O Board Address Jumpers 1 Remove the LCN I O paddleboard from rear slot 2 in the PLCG module Refer to Figure 3 1 for instructions and the location of the pinning header on the LCN I O board Pin the node address as shown Be sure to adjust the parity jumper as required 2 Reinstall the LCN I O paddleboard PLCG Planning Installation and Service 3 3 7 95 3 2 4 3 2 4 EC Equipment Installation The I O board interfaces both LCN cable A and Cable B to the KxLCN board or LLCN ina Five Slot Module and Ten Slot Module New I O boards and inteface cabling are developed to support the EC community standards The following illustrations show the new hardware TERM 1 TERM 2 Q Lona O Figure 3 3 CLCN A B Faceplate ASSY NO 51305072 100 REV A BAR CODE J1 J2 na 2 Lone O Figure 3 4 CLCN A B I O Board PLCG Planning Installation and Service 3 4 7 95 3 2 4 ASSY NO 51305072 100 BAR CODE 0 Ji LCN LCN A je e Address
5. PORT 1 kd D PLCG RELAY PANEL 51304421 100 O Oc Honeywell Figure 3 7 PLCG Relay Panel PLCG Planning Installation and Service 3 8 7 95 3 2 7 3 2 7 PLCG Cabling 1 Connect a 1 meter 3 ft cable 30731611 001 from J2A on the relay panel to J2 on the PLCI I O board in same PLCG module If necessary refer to Figure 2 1 2 If this is a redundant PLCG installation connect a 2 meter 6 ft cable 3073161 1 002 from J2B on the relay panel to J2 on the PLCI I O board in the secondary PLCG module If necessary refer to Figure 2 2 3 Be sure the two latches which secure each cable end to its connector are fastened on all of the cables 3 2 8 Port Cabling and Pinning for Modems Using Modbus Protocol NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs 3 2 8 1 Modem Cable For connection to a Modicon J478 modem or other short haul modem serving a Modbus port as illustrated in Figure 2 3 C or 2 4 C install a connector on the free end of cable 51304514 100 using Figure 3 8 as a guide Use a standard 25 pin male D Sub connector SHL TXD RXD PLCG Port 1or2 RIS CTS 25 Pin 25 Pin
6. as such cannot support the same tag names on different ports For this reason PLCG redundancy applies to the electronics modules within the TDC 3000X equipment and cannot be configured to provide PLC Network Cable redundancy PLCG Planning Installation and Service 2 4 7 95 2 4 3 2 4 3 Limitations There are certain limitations and several options which must be considered in planning your installation 2 4 3 1 Physical Limitations In a redundant application the primary and secondary PLCG modules generally mount in the same rack or in the same dual node module They are normally installed close to each other because the interconnect cable between primary and secondary PLCGs is only 2 meters long If you have a specific reason for separating the PLCG modules further thereby substituting a longer interconnect cable you must reduce the cable length of each cable connected to Port 1 and Port 2 by the same amount that you have increased the length of the interconnect cable Obviously the length of a substitute interconnect cable must be less than 15 meters 2 4 3 2 Single vs Multidrop Cabling There must be only a single cable from a port to the PLC modem or communications controller that port is to service If you want to use a Modbus protocol multidrop arrangement you must place a local modem at the PLCG with remote modems connected to each of the PLCs in the network Allen Bradley A B protocol multidrop arrangements
7. The I O File has been modified to make electrical contact with face plates attached to the I O boards This provides low impedance ground path for the cable shields The face plates and the wire mesh covering the fan openings also provides EMI shielding around the module The module is similar in all other respects EPLCI I O CLCNB Figure 1 2 CE Compliant PLCG Nonredundant Dual Node Module 1 3 HONEYWELL SUPPORT SERVICES Optional Installation Support Field Services and Technical Support are available during the on site installation and checkout of TDC 3000 System equipment Honeywell representatives are available to assist in interpreting this manual and to help resolve problems or situations not covered by this manual A toll free number 800 822 7673 in Arizona 602 863 5558 is available for technical assistance PLCG Planning Installation and Service 1 2 7 95 1 4 RELATED PUBLICATIONS 1 4 Honeywell s standard documentation is included with the system The following publications apply to the TDC 3000 System and should be referred to as required and available Title LCN Site Planning LCN System Installation LCN System Checkout Hiway Gateway Specification and Technical Data Five Ten Slot Module Service Dual Node Module Service Test System Executive Hardware Verification Test System Core Module Test System Maintenance Test Operations P
8. The Programmable Logic Controller Gateway provides a method of economically connecting various Programmable Logic Controllers to your Honeywell TDC 3000 System This manual guides you through the planning and installation considerations unique to the PLCG equipment However this manual is not intended to be a substitute for the LCN Site Planning manual and LCN System Installation manual listed in the standard LCN publications referenced in subsection 1 3 of this manual The PLCG runs under an unmodified HG Hiway Gateway software personality The hardware is similar to HG hardware contained in a standard TDC 3000 five slot equipment module that supports the Local Control Network LCN In the PLCG the Data Hiway Interface DHIF board and its I O board are replaced with the Programmable Logic Controller Interface PLCI board and its I O board A PLCG Relay Panel is installed on the rear of the module A redundant PLCG pair is composed of two PLCG modules equipped as above but sharing one relay panel Indicators AC Power Switch Figure 1 1 PLCG Nonredundant Five Slot Module PLCG Planning Installation and Service 1 1 7 95 1 3 1 2 PLCG MODULE FOR EC The CE compliant PLCG and PLCI I O cage supports the three styles of modules It supports the non redundant PLCG the redundant PLCG and the communications redundant PLCG The CE compliant modules are capable of holding both the older and newer types of I O board designs
9. communication interface module In all nonredundant configurations one port may Note Both ports of a PLCG support a total of 16 PLCs support ModBus while the other port uses A B protocol provided the cables are wired to match the equipment Figure 2 3 Typical Nonredundant PLCG Port Connections PLCG Planning Installation and Service 2 7 7 95 2 5 2 Allen Bradley includes their CIM Communications Interface Module inside some PLC models allowing the direct connection shown in B See Section 3 for detailed wiring of this cable Figure 2 3 C and D illustrate examples of modem usage from a nonredundant PLCG The modems used in illustration C are the short haul modems previously discussed The single PLC connected via two modems to Port 1 illustrate a maximum length configuration which will service a PLC at the greatest distance from the PLCG The multidrop PLCs connected to Port 2 in illustration C show a typical network of PLCs using the Modbus protocol These drops are connected half duplex with the local modem connected to the PLCG and remote modems connected to the PLCs The local is a master which commands each remote to respond at a specific time Additional loading caused by several modems on the network may reduce the overall length of the network twisted pair cable consult the manuals for your modem for particulars Specific details for wiring and pinning these modems are contain
10. indicates BATT FAIL when a slot 16 failure has been posted from a emulated DHP This does not indicate a battery failure instead it has been used to show the REDUNDANT PARTNER IS NOT ON LINE This indication is only valid when the corresponding emulated DHP is enabled on scan The status of the redundant partner is also indicated by the 10 segment display see subsection 5 4 1 If you get this BATT FAIL indication when using a nonredundant PLCG recheck the PLCI pinning in subsection 3 2 3 5 4 3 2 Device Failure The Device Failure codes listed in Table 5 2 are posted in the Box Status Display at the US when the Hiway Status display indicates DEV FAIL The error code presented at the US is in the form 11DC where D Device Number PLC index and C Error Code in Table 5 2 NOTE Table 5 2 indicates Modbus protocol errors presented by Modicon controllers Other brands of controllers may not present the same errors as Modicon under the same circumstances or may not present any error at all Check the instruction manuals with your controller to verify the similarities and differences in error codes NOTE PLCI Communications Retry Guidelines Retries on transient communication errors will be performed for all messages but timeouts are given special processing The PLCI will perform retries until three consecutive timeouts have accumulated against a PLC Data collection from the PLC is suppressed for the remainder of the current sc
11. 2 9 Port Cabling for Direct Connection to Modbus Equipment PLCG Planning Installation and Service i 7 95 Table of Contents 3 2 10 Port Cabling for Equipment Using Allen Bradley Protocol 3 2 10 1 Direct Connection to Allen Bradley Controllers 3 2 10 2 Allen Bradley CIM Pinning 3 3 Installation Wrap Up 4 CHECKOUT 4 1 Power On Tests 4 1 1 Electronics Checks 4 2 Startup 4 3 Communications and Performance Statistics 4 3 1 PLC Error and Retry Counters 4 3 2 Port Statistics 4 3 2 1 Subslots Processed Per Second 4 3 2 2 Number of Messages Transmitted Second 4 3 2 3 Number of Messages Received Second 4 3 2 4 Number of Bytes Transmitted Second 4 3 2 5 Number of Bytes Received Second 4 3 2 6 Number of Scan Buffer Misses Second 4 3 2 7 Number of Keepalive Buffer Misses Second 4 3 2 8 Number of Output Buffer Misses Second 4 3 2 9 Firmware Freetime Second Counters 4 3 2 10 Number of Processing Buffer Misses Second 5 SERVICE 5 1 Overview 5 2 Field Adjustment 5 3 General Troubleshooting 5 4 PLCI Troubleshooting 5 4 1 PLCI Hardware Indicators 5 4 2 PLCI Hardware Indicator Troubleshooting Chart 5 4 3 PLCI System Software Indications 5 4 3 1 Battery Failure 5 4 3 2 Device Failure 5 4 3 3 Data Hiway Port Error Codes 5 5 Spare Parts PLCG Planning Installation and Service ji 7 95 INTRODUCTION Section 1 This section provides an overview of the PLCG equipment and lists reference documents available from Honeywell 1 1 GENERAL DESCRIPTION
12. 8 OPEN SHORT OPEN SHORT SHORT OPEN SHORT OPEN SHORT SHORT SHORT SHORT OPEN OPEN OPEN OPEN OPEN SHORT OPEN SHORT SHORT OPEN SHORT OPEN SHORT SHORT SHORT SHORT OPEN OPEN OPEN OPEN Honeywell factory setting is 9600 baud PLCG Planning Installation and Service 3 6 7 95 3 2 5 Board Revision Socket Do not change TS1 TS3 Program TS3 as follows DESCRIPTION Program TS2 according to chart in lower Always Shorted right corner of board All pins Always Shorted SHORTED both ports at 9600 baud Short Enable User Outputs with odd transmit receive parity Open Disable User Outputs Always Shorted Always Open TS2 JUMPERS Short Max Data Acquision Open Reduced Bandwidth Short Allow PLCG Output to track changes to PLC Ladder Open Don t track changes to PLC Ladder Short Redundant operation must be set in both PLCGs Open Nonredundant operation RAM CLEAR Jumper Do not change JI 51400997 100 f ip PLCI gi Figure 3 6 PLCI Pinning Honeywell factory setting 3 2 5 4 Program Options TS3 Pin 1 If you are installing a redundant PLCG leave pin 1 shorted it must be shorted on the PLCI board in both PLCGs If you are installing a nonredundant PLCG open pin 1 Pin2 This pin is only recognized in applications involving Modbus protocol If you want the PLCG to track chang
13. LN 9 Y A gt w A 4AuUupOs nynkBwWnNA RAANOO PLCG Planning Installation and Service Index 3 7 95 PLCG Planning Installation and Service Index 4 7 95 READER COMMENTS Honeywell IAC Automation College welcomes your comments and suggestions to improve future editions of this and other publications You can communicate your thoughts to us by fax mail or toll free telephone call We would like to acknowledge your comments please include your complet name and address BY FAX Use this form and fax to us at 602 313 4108 BY TELEPHONE In the U S A use our toll free number 1 800 822 7673 available in the 48 contiguous states except Arizona in Arizona dial 1 602 313 5558 BY MAIL Use this form detach fold tape closed and mail to us Title of Publication PLC Gateway Planning Installation and Servicelssue Date 7 95 Publication Number PLO2 400 Writer D Downey R Ball COMMENTS RECOMMENDATIONS NAME DATE TITLE COMPANY ADDRESS CITY STATE ZIP TELEPHONE FAX If returning by mail please tape closed Postal regulations prohibit use of staples Communications concerning technical publications should be directed to Automation College Industrial Automation and Control Honeywell Inc 2820 West Kelton Lane Phoenix Arizona 85023 3028 BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4332 PHOENIX ARIZONA POSTAGE WILL BE P
14. Male D Sub Male D Sub DSR GND DCD DTR Ney Figure 3 8 Cable for a Modem Serving Modbus Protocol PLCG Planning Installation and Service 3 9 7 95 3 2 8 3 2 8 2 Modem Wiring Use the instruction manual provided with your modems to install modem wiring between all of the modems Be sure the wiring meets the following criteria The multidrop modem telephone lines must be 4 wire full duplex with the line driver of the local modem PLCG end in parallel with the line receivers of all remote modems PLC ends Likewise the line drivers of all remote modems are in parallel with the line receiver of the local modem A single pair of modems point to point must also be 4 wire full duplex with the line driver of each modem in parallel with the line receiver of the other modem 3 2 8 3 Modem Pinning Use the instruction manual provided with your modems to properly pin your modems Be sure they meet the following criteria The local PLCG end modem must be pinned to hold its transmitter enabled at all times normally by putting RTS CTS in the ON position The local modem must also be pinned to hold RXD in the marking state in the absence of a valid carrier Each remote PLC end multidrop modem must be pinned to enable its transmitter only when the PLC raises RTS All remote modems must also be pinned for an RTS CTS delay of approximately 5 to 1
15. Number of Output Buffer Misses Second Number of Processing Buffer Misses Second Number of Scan Buffer Misses Second Overview Physical Limitations PLC Error and Retry Counters PLCG Cabling PLCG Relay Panel Pinning PLCG to PLC Connections Modem Usage and Selection Nonredundant PLCG Port Connections Redundant PLCG Port Connections PLCI Hardware Indicator Troubleshooting Chart PLCI Hardware Indicators PLCI Pinning PLCI System Software Indications PLCI Troubleshooting PLCI Hardware Indicator Troubleshooting Chart PLCI Hardware Indicators PLCI System Software Indications Battery Failure Device Failure Port Cabling and Pinning for Modems Using Modbus Protocol KR NO ww ANND oO Www AK AQAARDAR IWIN VYAR WI WWWWWWNYNWYNYNYNNw Ni c VOWARATANARATAUNNNWHOUN IL YNYNYYNNTANDTBXODANWAMAWNTNNYA WWW N o o VPP MH W ANAWHNANWNAUOANHAAADOADNWNAUNHA ANH AWAWNWWWANONRWN ANW PLCG Planning Installation and Service Index 2 7 95 Index Topic Section Heading Port Cabling for Direct Connection to Modbus Equipment Port Cabling for Equipment Using Allen Bradley Protocol Port Statistics Power On Tests Electronics Checks Program Options TS3 Ram Clear J1 Redundant Configurations Redundant PLCG Port Connections Related Publications Single vs Multidrop Cabling Site Requirements Dimensions and Weight Spare Parts StartUp Storage Conditions Subslots Processed per Second Unpacking ao NNN Rs Png wow ONNAGTNNOAHAMA gt RO
16. On The Desired Target And Press HELP 1 Each emulated DHP hiway box address has its own Data Display 2 Each memory word is 16 bits displayed as 6 digit octal 3 4 Error Counters of Bytes of of Output Rec d Sec Keepalive Buffer B Misses Firmware Minimum PLCI Firmware Firmware Maximum Number of Freetime 1 Second Current Freetime Freetime 1 Second Processing on Record Last Second on ana Buffer Misses Reserved for Firmware Hiway Unused Bavicion Unused Security Word Numbers Figure 4 3 Hiway Box Memory Data Display PLCG Planning Installation and Service 4 4 7 95 4 3 1 4 3 1 PLC Error and Retry Counters The PLCG maintains eight communications error counters Memory addresses 1700 1707 PC Index 1 8 and eight communications retry counters 1710 1717 PC Index 1 8 for each configured physical PLC When a communications error is detected between the PLCG and the physical PLC the error counter is incremented If a retry is permitted the retry counter is incremented before the retry is performed Once a second the counters results are transferred to the enabled DHP s database Since the counters are kept by physical PLC all logical PLCs PC index values referencing the same physical PLC will show the same counter value This is true even if the logical PLCs PC index values are in different emulated DHPs The counters are allowed to rollover after reaching ma
17. Refer to Figure 2 2 for an illustration of a redundant PLCG installation Note the PLCG relay panel is only mounted on the primary PLCG NOTE Some assembly and cabling of this equipment may have been done at the factory If so please check your equipment and verify its installation is similar to that described 3 2 1 Module Installation If you are installing a redundant PLCG pair you have two PLCG modules Install the primary PLCG module first 1 Remove the primary PLCG module with relay panel from its shipping carton 2 Securely fasten the PLCG module to its rack mount with the hardware provided 3 Connect ground straps or leads from the base of the cabinet or a nearby module to the appropriate chassis ground and logic ground connections on the rear of the PLCG module Refer to the LCN System Installation manual in the LCN Installation binder for further grounding information 4 Insure the power switch on the front of the PLCG module is off Install the module power cord supplied Refer to LCN System Installation manual in the LCN Installation binder for power wiring information If this is a redundant installation repeat steps 1 through 4 on the secondary PLCG module PLCG Planning Installation and Service 3 1 7 95 3 2 2 3 2 2 LCN Node Pinning By convention the node address for a nonredundant PLCG is even The node addresses for a redundant pair is even for the primary PLCG and numerically one higher odd for t
18. always connect through an Allen Bradley communications controller a CIM for Communications Interface Module Since this communications controller supplies the multidrop connections only a single cable is needed from the PLCG port to the A B controller 2 4 3 3 Cable Lengths The cables from the PLCG ports cannot be longer than 15 cable meters 50 cable feet If the distance to a PLC or communications controller exceeds this limit you must use short haul modems See subsection 2 5 for modem considerations Subsection 3 2 6 shows how to wire the RS 232 cable supplied by Honeywell so that it will interface a modem 2 4 3 4 Direct Connection If you are connecting a single PLC or an A B communications controller to one of the ports and the cable length from the PLCG to the PLC is less than 15 cable meters you may use an RS 232 direct connection no modems In this arrangement the RS 232 cable supplied by Honeywell must be specifically wired to a connector which mates your PLC Subsections 3 2 7 and 3 2 8 show cable wiring schemes for several types of PLCs and interface devices PLCG Planning Installation and Service 2 5 7 95 2 5 2 5 PLCG TO PLC CONNECTIONS 2 5 1 Modem Usage and Selection Either direct connection or short haul modems sometimes called line drivers can be used with the PLCG As mentioned earlier direct connection is limited to a maximum of 15 cable meters A short haul modem presents an RS 232 hardware interf
19. are not followed Ground connection to building safety ground Ground stake for building safety ground Electrical Shock Hazard can be lethal Electrical Shock Hazard can be lethal Rotating Fan can cause personal injury 7 95 Table of Contents 1 INTRODUCTION 1 1 General Description 1 2 PLCG Module for EC 1 3 Honeywell Support Services 1 4 Related Publications 2 SITE PREPARATION Storage Conditions Site Requirements Dimensions and Weight Electrical Requirements AC Voltage Options Frequency Current in Amperes at 120 Vac Configurations Nonredundant Configurations Redundant Configurations Limitations Physical Limitations Single vs Multidrop Cabling Cable Lengths Direct Connection PLCG to PLC Connections uN w w 9 tw tw n NANANINSANANININININININININININIS N N ANAKHARARRARRARWWOWOND AON 1 Modem Usage and Selection 2 Nonredundant PLCG Port Connections 3 Redundant PLCG Port Connections 3 INSTALLATION 3 1 Unpacking 3 2 Assembly and Cabling 3 2 1 Module Installation 3 2 2 LCN Node Pinning 3 2 3 CLCN Node Pinning 3 2 4 EC Equipment Installation 3 2 5 PLCI Pinning 3 2 5 1 Ram Clear J1 3 2 5 2 Board Revision TS1 3 2 5 3 Baud Rate and Parity TS2 3 2 5 4 Program Options TS3 3 2 6 PLCG Relay Panel Pinning 3 2 7 PLCG Cabling 3 2 8 Port Cabling and Pinning for Modems Using Modbus Protocol 3 2 8 1 Modem Cable 3 2 8 2 Modem Wiring 3 2 8 3 Modem Pinning 3
20. 5 meters Do not use port 2 On some A B equipment each PLC supports RS 232 by including the CIM within the PLC The DF 1 Protocol must be used Note When wired direct connect each port serves a single PLC C Modem Usage Modbus Standard RS 232 Full duplex twisted pair or other cables lt 15 meters Single PLC Three multidrop PLCs shown D Modem Usage Allen Bradley RS 232 cables wired for A B equipment RS 232 cables wired for A B equipment A B Data Hiways Do not Three multidrop use port 2 PLCs shown RS 232 cables wired for Maximum 16 A B equipment CIM Allen Bradley communication interface module Figure 2 4 Typical Redundant PLCG Port Connections PLCG Planning Installation and Service 2 9 7 95 PLCG Planning Installation and Service 2 10 7 95 INSTALLATION Section 3 This section provides information for unpacking and assembling the PLCG 3 1 UNPACKING When the equipment arrives at the system site open each shipping box remove the protective wrapping and carefully inspect each piece for any physical damage If damaged immediately notify the carrier and your Honeywell sales representative as to the extent and type of damage Also check each piece of equipment against the invoice list for any missing items 3 2 ASSEMBLY AND CABLING Refer to Figure 2 1 for an illustration of a nonredundant PLCG installation Note the PLCG relay panel located on the rear of the module
21. 5 milliseconds This delay can be determined empirically by the user based upon the hardware he has chosen We have found the LD485A Black Box modems Table 2 1 operate satisfactorily using the 5 millisecond delay RTS CTS delay need not be pinned in the local modem of a multidrop network and is also immaterial in a point to point arrangement PLCG Planning Installation and Service 3 10 7 95 3 2 9 3 2 9 Port Cabling for Direct Connection to Modbus Equipment NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs If wiring information is not given here for your equipment check with Honeywell s Multivendor Interface Program If an MVI Program Test Report is available for that equipment cable wiring information will be given in that report For direct connection to Modbus protocol PLCs as illustrated in Figure 2 3 A or 2 4 A use Table 3 2 to find the model number of the equipment you are using From the table locate the Figure which will aid you in obtaining the proper connector then install it on the free end of cable 51304514 100 Table 3 2 Modbus Protocol Cable Wiring Locator PROGRAMMABLE CONTROLLER FIGURE MAKE AND MODEL NUMBER Honeywell 620 with 620 0043 CIM Figure 3 9 Modicon 184 with J347 interfac
22. 6 Two modules required MP PLCGN3 68020 based typical 0 939 1 27 Nonredundant Module maximum 1 45 1 94 MP PLCGR3 68020 based typical 1 878 2 54 2 Redundant Modules maximum 2 90 3 88 Two modules required 2 4 CONFIGURATIONS Peak 8 86 13 14 17 72 26 28 6 99 10 35 13 98 20 70 Wattage 217 8 283 1 435 6 566 2 152 5 198 3 305 0 396 6 BTUs hr 742 7 965 4 1485 4 1930 8 520 0 676 2 1040 0 1352 4 Various nonredundant and redundant configurations of the PLCG connected to PLCs of different manufacture are available Depending upon certain limitations the PLCG may communicate to the PLCs either through short haul modems or by a direct connection PLCG Planning Installation and Service 2 2 7 95 2 4 1 2 4 1 Nonredundant Configurations Figure 2 1 shows a PLCG connected in a nonredundant 5 slot module configuration Connections for a dual node module configuration are the same but the PLCG Relay Boards are mounted horizontally on the rear of the module Each PLC port PORT 1 and PORT 2 in the figure may service any number of individual Programmable Logic Controllers up to a Honeywell supported total of 16 PLCs per PLCG See subsection 2 5 2 for examples of nonredundant port cabling configurations _NOTUSED PLCI I O a REDUNDANT NO s A B CONNECTION LCN A LCN B LCN VO a a PORT D RELAY PANEL
23. AID BY Honeywell Industrial Automation and Control 2820 West Kelton Lane Phoenix Arizona 85023 3028 Attention Manager Quality NO POSTAGE NECESSARY IF MAILED IN THE USA SJUDUMUUOD eUODIPpY Cut Along Line Honeywell Industrial Automation and Control Helping You Control Your World Honeywell Inc 16404 North Black Canyon Highway Phoenix Arizona 85023 3099
24. EMBEDDED RESPONSES ON DUPLICATE MESSAGE DETECT PLCG Planning Installation and Service 3 15 7 95 3 3 3 3 INSTALLATION WRAP UP Dress all cables neatly and out of the way to protect them from accidental damage Plug all modems and PLCG modules into their proper receptacles PLCG Planning Installation and Service 3 16 7 95 CHECKOUT Section 4 This section tells you how to check the PLCG after it has been installed plugged in and is ready to go 4 1 POWER ON TESTS You do not need to have the PLC equipment installed or connected to perform the checks in this section Do not however perform any of these tests until all other parts of the PLCG have been installed according to Section 3 4 1 1 Electronics Checks Perform these electronics checks on the PLCG electronics module If this is a redundant PLCG installation perform these checks on both PLCG modules 1 Remove the front cover of the PLCG module Before turning power on ensure the LO NOM HI jumper or switch on the front of the power supply is in the center or NOM position 2 Set the POWER switch to ON while observing the LEDs on the power supply fan assembly and on the individual cards in the unit Note that the red LEDs on the boards light for a few seconds it takes less than 30 seconds to complete the power up tests then they turn off and the green LEDs turn on If any red LEDs on the boards remain on some portion of the power up tests have failed trecor
25. F KG and 1785 KE SHL TXD TXD RXD RXD PLCG Port RTS RTS 1or2 CTS sop Gis 25 Pin n DSR Female D Sub Male D Sup PSR GND GND DCD 8 DCDg DTR DTR 20 Ne J x Sf Transmit and receive data are cross wired in a direct connection Figure 3 12 Cable for Allen Bradley 1770 KF2 and 1775 KA PLCG Planning Installation and Service 3 14 7 95 3 2 10 SHL TXD RXD PLCG Port RTS 1or2 als 25 Pin 25 Pin Female D Sub Male D Sub DSR GND DCD 8 DTR 20 eae Na Transmit and receive data are cross wired in a direct connection Figure 3 13 Cable for Allen Bradley 1779 KFL KFLR and Triconex 4101 EICM 3 2 10 2 Allen Bradley CIM Pinning Methods for pinning CIMs vary between models The parameters listed in Table 3 4 are common to all PLCG A B configurations use them as a guide Table 3 4 Allen Bradley Communications Interface Module Settings PARAMETER SETTING BAUD RATE Set the same as the PLCG field port Do not set above 9600 baud on the KF2 The KE KF may be set to 19 2 kbaud see A B manual PARITY EVEN BCC CRC BCC Block Check Character HANDSHAKING OFF DH DH As required by A B devices RS 232 422 RS 232 DIAGNOSTICS Execute diagnostics locally
26. Honeywell PLC Gateway Planning Installation and Service PL02 400 Honeywell Implementation PLC Gateway PLC Gateway Planning Installation and Service PL02 400 Release 430 CE Compliant 7 95 Copyright Trademarks and Notices Printed in U S A Copyright 1992 1995 by Honeywell Inc Revision 02 July 15 1995 While this information is presented in good faith and believed to be accurate Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer In no event is Honeywell liable to anyone for any indirect special or consequential damages The information and specifications in this document are subject to change without notice ACKNOWLEDGEMENTS AND CREDITS Allen Bradley and A B are trademarks of the Allen Bradley Company Inc Black Box is a trademark of the Black Box Corporation Modicon and Modbus are trademarks of AEG Modicon About This Publication This publication is provided to guide the user in planning installing and servicing the Programmable Logic Controller Gateway PLCG Only those components unique to the PLCG are covered in detail It is not intended to be a substitute for standard LCN Site Planning System Installation and Service manuals which are referenced for further detail This manual describes PLCI bo
27. abase of each on scan emulated DHP making it available at the Universal Station via the System Maintenance Control Center SMCC To prevent interference with off line operations statistical information is not transferred to the database of an emulated DHP which is not enabled on scan See Figure 4 1 DD MMM YY 08 45 30 SMCC MAIN MENU MODULE MEMORY HIWAY BOX MEMORY PROBE FAILED MODULE SYSTEM MAINT JOURNAL ACTIVE MAINT JOURNAL MODULE ERROR REV CONFIG STATUS SECTOR INIT REASSIGN MAIN MENU For Information On Funtions And Options Displayed On this Menu Position The Cursor On the Desired Target And Press HELP Figure 4 1 System Maintenance Control Center Main Menu Display General information on use of the SMCC is in Maintenance Test Operations section of the LCN Service 1 binder PLCG Planning Installation and Service 4 2 7 95 4 3 Selection of the HIWAY BOX MEMORY target of the SMCC s Main Menu brings up a screen requiring specific data to be filled in See Figure 4 2 04 Jun 91 08 51 16 BOX MEMORY PARAMETERS Hiway Number Decimal 1 To 20 Decimal 1 To 63 Hiway Box Address 0 to 60 Seconds Or Of ON OFF First Memory Address Octal Cyclic Update Interval Change Detect For Information On Funtions And Options Displayed On this Menu Position The Curs
28. ace to the PLCG or PLC similar to that presented by conventional telephone modems The short haul modem however uses separate lines not telephone lines and may take some liberties with interface protocol that would not be acceptable in conventional telephone modem communications Conventional telephone modems are not used with the PLCG because they severely limit bandwidth and their necessary low speeds baud rate might degrade performance Where the text that follows reads modem substitute short haul modem because of these limitations Use short haul modems over moderate distances a maximum range of 2 to 4 kilometers Honeywell has given limited exposure to a couple of these modems and have found they performed adequately with the PLCG see Table 2 1 for their specifications Table 2 1 Short Haul Modem Examples MODEL MANUFACTURER PA DESCRIPTION Black Box Co LD485A 64 Drops maximum 4 wire 26 AWG Twisted Pair Box 12800 Estimated maximum distance versus speed Pittsburgh PA 15241 2 0 km 1 2 Miles 19 2 k baud 412 746 5500 2 7 km 1 7 Miles 9600 baud 3 7 km 2 3 Miles 4800 baud AEG Modicon Inc 32 Drops maximum 4 wire 22 AWG Shielded twisted pair see Local Modicon recommends Belden 8777 or equivalent Representative Maximum distance 4 5 km 2 8 Miles Maximum speed 19 2 k baud Honeywell supports a maximum of 16 drops on both ports of the PLCG There are also some fiber optic modem
29. an On the next scan it will attempt to collect the suspect PLC s data but with Timeout Retries still suppressed If any response is received even with an error Timeout Retries are enabled and normal data collection attempts are resumed Infrequent transient errors will allow communications to be restored before three consecutive timeouts occur and will cause minimal impact on scan times If communication cannot be re established the PLCI will wait for the next scan to try again Retries are not allowed on certain errors where they are deemed unlikely to succeed Each error code explanation in Table 5 2 indicates whether retries are allowed or not PLCG Planning Installation and Service 5 6 7 95 5 4 3 Table 5 2 PLCI Software Indication Troubleshooting Chart FAILURE POSSIBLE PROBLEM Link Failure Communications protocol violation detected by PLCI Possible errors are Receive Buffer Overflow Parity Error Framing Error etc Retries allowed A B Posted on receipt of local error code 03 or 04 Communications Verify by monitoring RX DATA and RTS indicators on indicated Timeout PLCG field port see subsection 5 4 1 Timeout indicated by RTS blinking while RX DATA is dark Retries allowed Possible causes are PLC cable disconnected or connected to wrong field port PLCI pinning of baud rate parity does not match PLC pinning DHP definition of PLC address does not match that at PLC PLCI I O paddleboard not cabled to relay pa
30. and shipping requirements are for one year duration only provided the equipment is properly packaged and contains an adequate amount of desiccant moisture removing agent 2 2 SITE REQUIREMENTS The PLCG is designed for a Class A General Industrial environment It must be operated in a temperature environment of 0 50 C 32 122 F While operating components of this system are not designed to withstand greater vibration than 1g This equipment is intended for use in a controlled environment Although TDC 3000X equipment will operate at 0 50 C Honeywell recommends a normal environment of 25 C 77 F with a relative humidity of 40 50 to realize maximum life and enhanced reliability 2 2 1 Dimensions and Weight The approximate dimensions and weight for each PLCG 5 slot module are Height 17cm 7 Weight 21 5 kg 46 Ib Width 48cm 19 Depth 61cm 24 PLCG Planning Installation and Service 2 1 7 95 2 3 ELECTRICAL REQUIREMENTS The customer selected ac power option is installed in the PLCG before shipment 2 3 The inrush current to each electronics module is limited to 15 A 120 V 30 A 240 V 2 3 1 AC Voltage Options 120 220 240 Vac 10 15 2 3 2 Frequency 47 Hz to 63 Hz 2 3 3 Current in Amperes at 120 Vac Avg True RMS MP PLCGN1 68000 based typical 1 34 1 82 Nonredundant Module maximum 2 06 2 78 MP PLCGR1 68000 based typical 2 68 3 64 2 Redundant Modules maximum 4 12 5 5
31. ard 51400997 100 with Firmware Revision J and PLCG relay panel 51304421 100 Early production relay panel 51304154 100 may be used in all applications except Allen Bradley protocol using redundant PLCGs This publication supports TDC 3000X software release 430 and CE Compliant hardware Any equipment designated as CE Compliant complies with the European Union EMC and Health and Safety Directives All equipment shipping into European Union countries after January 1 1996 requires this type of compliance denoted by the CE Mark Change bars are used to indicate paragraphs tables or illustrations containing changes that have been made to this manual effective with Release 430 and CE Compliancy Pages revised only to correct minor typographical errors contain no change bars PLCG Planning Installation and Service 7 95 Scope ATTENTION CAUTION on 53893 53894 1 DANGER SHOCK HAZARD W 9 DANGER HIGH VOLTAGE 53895 53896 j 53897 PLCG Planning Installation and Service Standard Symbols The following defines standard symbols used in this publication Notes inform the reader about information that is required but not immediately evident Cautions tell the user that damage may occur to equipment if proper care is not exercised Warnings tell the reader that potential personal harm or serious economic loss may happen if instructions
32. ard correspond with the counterpart it is replacing Do not alter pinning on a board revision socket the revision number might have changed on the newer board 5 3 GENERAL TROUBLESHOOTING Before investigating deeply into a problem make some preliminary checks e Is power applied to the module Check switches fuses and circuit breakers on all equipment to insure they are functioning WARNING DO NOT REMOVE OR REPLACE CIRCUIT BOARDS WITH THE POWER ON Do not remove handle or transport circuit boards without observing proper Electrostatic Discharge ESD procedures To review ESD procedures see the LCN Site Planning manual in the LCN Site Planning amp Installation binder e Note that the functional boards can be accessed through the front of each module by removing the front cover Inspect the confidence indicators on each processor EMPU HPK2 or K2LCN board and the PLCI board Check power supply and fan confidence indicators Double check the pinning on the PLCI board shown in subsection 3 2 3 e The small I O or paddleboards are accessed from the rear of the module To isolate a failed board power supply fan assembly or other Optimum Replaceable Unit ORU follow the service procedures provided in the Five Ten Slot Module Service manual or the Dual Node Module Service manual in the LCN Service 1 binder PLCG Planning Installation and Service 5 2 7 95 5 4 5 4 PLCI TROUBLESHOOTING The PLCI board has unique ind
33. count TAGs TIME overall SUBSLOT count TIME 4 3 2 2 Number of Messages Transmitted Second This location 1721 1731 contains the number of complete messages transmitted through this port in the previous 1 second period 4 3 2 3 Number of Messages Received Second This location 1722 1732 contains the number of complete messages received through this port in the previous 1 second period PLCG Planning Installation and Service 4 5 7 95 4 3 2 4 3 2 4 Number of Bytes Transmitted Second This location 1723 1733 contains the number of bytes transmitted through this port in the previous l second period It includes all control header trailer and BCC CRC bytes Multiplying this parameter by 11 1 start bit 8 data bits 1 parity bit 1 stop bit 11 and dividing by the port s baud rate will yield an approximate indication of port utilization on transmit as a fraction of the baud rate selected for this port bandwidth used 4 3 2 5 Number of Bytes Received Second This location 1724 1734 contains the number of bytes received through this port in the previous 1 period It includes all control header trailer and BCC CRC bytes Multiplying this parameter by 11 1 start bit 8 data bits 1 parity bit 1 stop bit 11 and dividing by the port s baud rate will yield an approximate indication of port utilization on receive bandwidth used 4 3 2 6 Number of Scan Buffer Misses Second This location 1725 1735 contain
34. d CO through FO PLCG Planning Installation and Service 5 9 7 95 5 4 3 5 4 3 3 Data Hiway Port Error Codes The Device Failure codes listed in Table 5 2 does not show all error codes that may appear on the journals Table 5 3 provides a list of the Data Hiway Port DHP error codes Table 5 3 Data Hiway Port Error Codes CODE MNEMONIC 1105 DHP FAIL Link Card Initialization Link Card Initialization failure Error 1106 DHP FAIL Unknown Failure Unknown Failure to L L ay 110F DHP FAIL Unknown Failure Unknown Failure 1191 BAT FAIL Battery Failure Memory Battery failure This is a nonfatal failure device status remains OK 1192 OVERLOAD Processor Overload Processor Overload 1193 SAVED In Hard Save Primary IPC HIM failure 1194 RC FAIL RC Failure Backup IPC HIM failure 1195 F Incorrect CPU IPC HIM firmware not at proper revision Configuration 1196 UNDEFINE Undefined Error Probable cause is failure of box I F card Continuous Notification Writes from the box and no response to the HG callup 1198 ALM FAIL Box Reporting Failure Box reporting failure detected Detected 1199 ALM FAIL Box Reporting Failure Alarm reporting device changed Detected 11A0 F NULL Slot failures 01 16 11B0 F NULL Slot failures 01 16 11BC DEV FAIL Device failure Device failure See Table 5 2 1 Device Link Failure 2 Device Box or Communications Failure 3 Device Configuration Error 4 to F Unknown Device Failure Box N
35. d the alphanumeric status display code and proceed to Five Ten Slot Module Service manual in the Service binder If the power up test is successfully completed for all nodes all green LEDs on all boards are on there may also be some yellow LEDs on or flashing and the alphanumeric status display indicates the node address you set in Section 3 2 2 of this manual 3 Check the power supply status LEDs POWER OK and ERROR and the FAN ALARM LED Note that the FAN ALARM and ERROR LEDs are off and the POWER OK LED is on it is a fault condition if both the ERROR and POWER OK LEDs are ON 4 Press the momentary RESET switch Note the power up tests are initiated similar to step 2 and the results are satisfactory 5 Replace the front cover PLCG Planning Installation and Service 4 1 7 95 4 2 4 2 STARTUP The PLCG software performs exactly like an HG Hiway Gateway and looks exactly like an HG to the operator To continue further load the PLCG with the HG personality use PLCG configuration rules and later use HG operations Configuration information is in the remaining publications in this binder Loading and operating procedures are in the Process Operations binder 4 3 COMMUNICATIONS AND PERFORMANCE STATISTICS To assist installation and on going performance monitoring the PLC Gateway provides information about PLC communications and certain PLCG performance statistics Once per second the information is transferred to the dat
36. e Figure 3 9 Honeywell Modicon 384 with J347 interface Figure 3 9 Modicon 584 Figure 3 10 Modicon 884 Figure 3 9 Modicon 984 Figure 3 9 Triconex 4101 EICM Figure 3 13 This device employs the Modbus protocol but uses a cable identical to one used for Allen Bradley devices PLCG Planning Installation and Service 3 11 7 95 3 2 9 SHL 25 Pin TXD Male D Sub 25 Pin EPLCG Port PXD Male D Sub 1or2 RTS CTS DSR Transmit and receive GND data are cross wired DCD in a direct connection DTR Figure 3 9 Cable for Direct Connection to Modicon 884 984 and Others TXD RXD RTS Male 24 Pin Round CTS Connector DSR EPLCG Port 1or2 RTS CTS 25 Pin Male D Sub DSR ITT Cannon GND KPTO6F 20 24P GND WHT or DCD oe Bendix DTR ORN DTR m PTO6E 20 24P SR Ne So Z ol njola a o Nj pe oO Transmit and receive data are cross wired in a direct connection Figure 3 10 Cable for Direct Connection to Modicon 584 PLCG Planning Installation and Service 3 12 7 95 3 2 10 3 2 10 Port Cabling for Equipment Using Allen Bradley Protocol NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the pr
37. econd period 4 3 2 10 Number of Processing Buffer Misses Second This location 1746 contains the number of times in the previous second that the PLCG was ready to process a requested PLC reply or unsolicited write exception reporting from the PLC but none was pending When this location is nonzero the PLCG is running faster than the connected I O subsystem network is transferring data PLCG Planning Installation and Service 4 6 7 95 SERVICE Section 5 This section presents service instructions unique to the PLCG 5 1 OVERVIEW The Programmable Logic Controller Gateway PLCG is housed in a standard TDC 3000 five slot module or in a newer also standard Dual Node Module A PLCG Relay Panel a unique functional circuit board PLCI an input output card PLCI I O and special cabling have been added to this standard module This manual provides instructions to test troubleshoot and repair those components unique to the PLCG Troubleshooting disassembly and assembly procedures for the remaining five slot module and its components are contained in the Five Ten Slot Module Service or Dual Node Module Service manual in the LCN Service 1 binder The PLCG Relay Panel contains special high quality high reliability components and is relatively expensive It is an ORU Optimum Replaceable Unit item and must be replaced if found faulty however attempt to prove the relay panel has truly failed before replacing it indiscriminate
38. ed in subsection 3 2 6 Illustration D shows Allen Bradley equipment connected in similar arrangements to illustration C Allen Bradley protocol is full duplex that is any PLC or the PLCG may talk at any time Allen Bradley requires use of their own CIMs which interface their own Data Hiway Refer to subsection 3 2 8 and your Allen Bradley manuals for specifics PLCG Planning Installation and Service 2 8 7 95 2 5 3 2 5 3 Redundant PLCG Port Connections Figure 2 4 A and B illustrate examples of direct connection to PLCs from a redundant PLCG Note there can be only two PLCs connected in this manner if you are using Modbus protocol or only one PLC if you are using the Allen Bradley protocol Port 2 cannot be used with Allen Bradley protocol because the protocol is full duplex and messages may be sent and received simultaneously The redundant PLCG firmware uses that port to listen to outgoing messages while Port 1 is receiving messages Modbus protocol is half duplex and messages are not sent and received simultaneously Notice Figure 2 4 C and D are very similar to those illustrations in Figure 2 3 Allen Bradley full duplex operation prevents Port 2 from being used but there is little loss of capability since up to 16 PLCs may be connected to the same network A Direct Connect Usage Modbus B Direct Connect Usage Allen Bradley RS 232 cables wired for A B equipment Cross wired RS 232 Cables lt 1
39. es to the digital outputs made by the PLC ladder logic leave pin 2 shorted The PLCG will include the digital outputs in its periodic scan If you do not want changes in the ladder logic tracked open this pin Note that in this mode the Modbus digital outputs are scanned immediately after the emulated DHP Enable Processing command Thereafter digital outputs are updated using PLC write echo data PLCG Planning Installation and Service 3 7 7 95 3 2 6 Pin 3 If you want the PLCG to acquire data at the maximum rate leave pin 3 shorted If you want the acquisition rate reduced open this pin Note that with this pin shorted data is double buffered when the pin is opened one data buffer is disabled Pin4 Always leave this pin open Pin5 Always leave this pin shorted Pin 6 If you want the PLC to receive user outputs via Analog outputs Digital outputs and Timer Counters leave Pin 6 shorted If you want to suppress user outputs to the PLC open Pin 6 Pins 7 amp 8 Always leave these pins shorted 3 2 6 PLCG Relay Panel Pinning Refer to Figure 3 7 If you are installing a nonredundant PLCG or if you are assembling a redundant Modbus installation check that the header on the relay panel is in the OTHERS socket If you are assembling a redundant Allen Bradley installation be sure the relay panel header is in the REDUNDANT A B socket OTHERS REDUNDANT A B J2
40. eshooting Chart Use Table 5 1 to aid you in determining the cause of a failure detected by the two fault indicators on the PLCI Table 5 1 PLCI Hardware Indicator Troubleshooting Chart INDICATION POSSIBLE CAUSE SOLUTION SELF TEST ON Missing PLCI I O Paddleboard Install PLCI I O Paddleboard in the after power up or correct slot behind PLCI board reset sequence Failed PLCI or PLCI I O Board Substitute known good boards SELF TEST goes Incorrect Software Release Check that Software Release 200 or OFF then ON after later is being used the HG personality has been loaded Incorrect Configuration Check that emulated Data Hiway ports used are addresses 8 through 15 Check that PLCGs are configured for Hiway addresses 2 and 3 Check that PLCG is configured to perform the HTD functions Check for hardware configuration errors re read Sections 2 4 2 5 and 3 2 of this manual TRANSACTION Memory Board Error Substitute known good memory ERROR ON board s If memory board s are OK suspect the PLCI itself PLCG Planning Installation and Service 5 5 7 95 5 4 3 5 4 3 PLCI System Software Indications System software indications that indicate hardware failures are presented in the Hiway Status display on the Universal Station US The Hiway Status display lists those brief error statements and codes and describes where they came from 5 4 3 1 Battery Failure The Hiway Status display at the US Universal Station
41. f Output Buffer Misses Second Number of Processing Buffer Misses Second Number of Scan Buffer Misses Second Subslots Processed per Second Configurations Limitations Cable Lengths Direct Connection Physical Limitations Single vs Multidrop Cabling Nonredundant Configurations Redundant Configurations Current in Amperes at 120 Vac Device Failure Dimensions and Weight Direct Connection to Allen Bradley Controllers Direct Connection Electrical Requirements A RAGAADARAR MMP PP RUNANNNARRARND BWV WHHHWHHHAR RNNALUYONNNYNNNNWWWHO NVWONWWARWWWHWANNNY L NYYUNYNYNYNWWATATNWOO NADONAUMATUANYNYNYNYNWOw UA NUON NH HWWAHI DOANWANATON WWNWOH HH NODOONW AWA ANWAOAONHNNDYD o Oia O PLCG Planning Installation and Service Index 1 7 95 Index Topic Section Heading AC Voltage Options Current in Amperes at 120 Vac Frequency Electronics Checks European Compliance EC for PLCG CLCN Node Pinning EC Equipment Installation Field Adjustment Firmware Freetime Second Counters Frequency General Description General Troubleshooting Honeywell Support Services Installation Wrap Up LCN Node Pinning Limitations Modem Cable Modem Pinning Modem Usage and Selection Modem Wiring Module Installation Non Redundant Configurations Non Redundant PLCG Port Connections Number of Bytes Received Second Number of Bytes Transmitted Second Number of Keepalive Buffer Misses Second Number of Messages Received Second Number of Messages Transmitted Second
42. g conditions e Module bus data parity error e Bus error occurred during DMA access to module RAM This LED is extinguished under the following conditions e Self test is completed successfully e Module power coming on e Module or PLCI reset completed e PLCI Abort Command in process PRIMARY PLCI Green This LED is lighted when the PLCI is on line and functioning as the primary HG 10 SEGMENT DISPLAY Yellow Also on the front edge of the PLCI board there is a 10 Segment display composed of yellow LEDs see Figure 5 1 The function of each LED in this display numbered 1 to 10 from left to right are Segments 1 2 and 3 monitor Field Port 1 Their functions are 1 TX RTS Illuminates when the transmit Request To Send is asserted 2 RX DATA Illuminates when Receive Data goes to a spacing condition 3 DSR CD lIlluminates when Data Set Ready and Carrier Detect are asserted Segments 4 5 and 6 monitor Field Port 2 Their functions are 4 TX RTS Illuminates when the transmit Request To Send is asserted 5 RX DATA Illuminates when Receive Data goes to a spacing condition 6 DSR CD lIlluminates when Data Set Ready and Carrier Detect are asserted Segments 7 8 and 9 are used at the factory They have no use in field troubleshooting 10 REDUNDANT PARTNER Illuminates when the redundant partner is on line PLCG Planning Installation and Service 5 4 7 95 5 4 2 5 4 2 PLCI Hardware Indicator Troubl
43. he secondary PLCG If you are installing a nonredundant PLCG perform the following steps on the PLCG module If this is a redundant PLCG installation perform these steps twice using a node address on the secondary PLCG one higher from that of the primary PLCG LCN I O BOARD FROM REAR SLOT 2 LCN ADDRESS 51107403 100 Binary Weight Jumper Removed 1 Parity Overall number of jumpers 64 cut including the parity jumper must be an odd number This example indicates node address 03 NOTE THE SOFTWARE WILL ALLOW ONLY NODE ADDRESSES 1 64 AT THIS TIME Figure 3 1 LCN I O Board Address Jumpers PLCG Planning Installation and Service 3 2 7 95 3 2 3 3 2 3 CLCN Node Pinning By convention the node address for a nonredundant PLCG is even The node addresses for a redundant pair is even for the primary PLCG and numerically one higher odd for the secondary PLCG If you are installing a nonredundant PLCG perform the following steps on the PLCG module If this is a redundant PLCG installation perform these steps twice using a node address on the secondary PLCG one higher from that of the primary PLCG ASSY NO 51305072 100 0 J1 J2 LCN LCNA o o LCN B K Address
44. he Implementation PLC Gateway binder for hints on avoiding configuration errors A B Posted on receipt of remote error code 50 or 80 Illegal Data Value Modbus Presented when the PLC returns the ILLEGAL DATA VALUE exception code 03 No retry A B Not used Device Fault Modbus Presented when the PLC returns the FAILURE IN ASSOCIATED DEVICE exception code 04 No retry A B Posted on receipt of remote error code 40 Entered Program Modbus Presented when the PLC returns the PROGRAM Mode ACKNOWLEDGE exception code 05 The PLCG considers this response an error because the PLCG cannot issue the PROGRAM command No retry A B Posted on receipt of remote error code 70 or 80 Busy Insufficient Modbus Presented when the PLC returns the BUSY Buffers REJECTED MESSAGE exception code 06 Retries allowed A B Posted on receipt of local error code 01 or remote error code 90 NAK Negative Modbus Presented when the PLC returns the NAK Acknowledge NEGATIVE ACKNOWLEDGE exception code 07 No retry A B Not used Continued PLCG Planning Installation and Service 5 8 7 95 5 4 3 Table 5 2 PLCI Software Indication Troubleshooting Chart Continued FAILURE POSSIBLE PROBLEM Access Blocked Modbus Not used A B Posted on receipt of remote error code 60 Not used by either Modbus or A B protocol Unspecified Error Modbus Not used A B Posted on receipt of local errors 05 through OF and remote errors AO an
45. icators on its front edge to offer confidence that the board is working and to provide assistance in case of a failure The board also communicates with the Universal Station to report software indications of hardware failures This section explains the function of these hardware software indicators and will guide you in finding a failure 5 4 1 PLCI Hardware Indicators GRN Pass GRN MOD PRI TEST MARY YELLOW 10 SEGMENT DISPLAY 51400997 100 RED RED SELF BUS TEST TRANS ERROR ERROR Figure 5 1 PLCI Test and Status Indicators There are four LEDs located on the front left edge of the PLCI board see Figure 5 1 Each LED s definition and a brief description of its use follows They are listed as shown in the figure from left to right SELF TEST or BOARD FAILURE Red This LED lights under the following conditions e Module power coming on Module or PLCI reset sequence working PLCI self test in progress Self test failed Local parity errors This LED is extinguished under the following conditions e Self test is completed successfully e Module or PLCI reset sequence completed successfully e PLCI Abort Command sequence completed PASSED MODULE TEST Green This LED is lighted after the PLCI successfully completes the CPU tests PLCG Planning Installation and Service 5 3 7 95 5 4 1 TRANSACTION ERROR Red This LED lights under the followin
46. ly Although cables are not considered ORU items their part numbers are listed in subsection 5 5 for reference The following is the board complement for the 68000 based PLCG Slot Front P N Rear P N 5 PLCI 51400997 100 PLCIIO 51195096 100 4 EMEM 51400910 100 3 EMEM 51400910 100 2 LCN 51400667 100 LCN I O 51107403 100 1 EMPU 51400901 100 The following is the board complement for the 68020 based PLCG Slot Front P N Rear P N 5 PLCI 51400997 100 PLCIIO 51195096 100 4 3 2 LLCN 51401291 100 LCNI O 51107403 100 1 HPK2 2 51401288 100 The following is the board complement for an 2 slot node Dual Node Module based PLCG Slot Front P N Rear P N 2 PLCI 51400997 100 PLCIIO 51195096 100 1 K2LCN 51401288 100 KLCNA 51304542 100 PLCG Planning Installation and Service 5 1 7 95 5 2 The following is the board complement for a 3 slot node Dual Node Module based PLCG Slot Front P N Rear P N 3 PLCI 51400997 100 PLCIIO 51195096 100 2 1 K2LCN 51401288 100 KLCNB 51304544 100 One of the following PLCG Relay Panels is mounted on the rear of the PLCG module PLCG RELAY PANEL 51304154 100 Early custom production can t use A B protocol in redundant configuration PLCG RELAY PANEL 51304421 100 Current Production required for the Dual Node Module based unit 5 2 FIELD ADJUSTMENT There are no field adjustments for the PLCG When replacing a board you may have to change some pins or jumpers on the board to make the bo
47. nel e Relay panel failure see pinning in subsection 3 2 3 A B May also be local error code 02 or remote error codes 20 and 30 Also check DHP definition of PLC address may not match that selected at the PLC Configuration Failure The definition of a PLC unacceptable to the PLCI No retry Possible causes are Assigned protocol Modbus or A B conflicts with PLC The model code for a physical PLC conflicts with the model code already assigned to that physical PLC Any of the currently defined DHP configuration errors see subsection 2 5 in the PLC Gateway Control Functions manual in the mplementation PLC Gateway binder for hints on avoiding configuration errors CRC Error The Cyclic Redundancy Check for a reply was incorrect Retries allowed A B Not used Message Error The received reply was incorrect for the query sent Retries allowed Possible causes are e Wrong PLC answered e Reply size incorrect for number of parameters requested e Message length inconsistent with message count byte A B Posted on receipt of remote error code 10 Continued PLCG Planning Installation and Service 5 7 7 95 5 4 3 Illegal Function Modbus Presented when the PLC returns the ILLEGAL FUNCTION exception code 01 No retry A B Not used Illegal Data Address Modbus Presented when the PLC returns the ILLEGAL DATA ADDRESS exception code 02 No retry See subsection 2 5 in the PLC Gateway Control Functions manual in t
48. oper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs If wiring information is not given here for your equipment check with Honeywell s Multivendor Interface Program If an MVI Program Test Report is available for that equipment cable wiring information will be given in that report 3 2 10 1 Direct Connection to Allen Bradley Controllers For connection to Allen Bradley protocol PLCs as illustrated in Figure 2 3 B or D and 2 4 B or D use Table 3 3 to find the model number of the equipment you are using From the table locate the figure which will aid you in obtaining the proper connector then install it on the free end of cable 51304514 100 Table 3 3 Allen Bradley Protocol Cable Wiring Locator PROGRAMMABLE CONTROLLER FIGURE MAKE amp MODEL NUMBER Allen Bradley 1770 KF2 Allen Bradley 1771 KE Allen Bradley 1771 KF Allen Bradley 1771 KG Allen Bradley 1775 KA Allen Bradley 1779 KFL Allen Bradley 1779 KFLR Allen Bradley 1785 KE PLCG Planning Installation and Service 3 13 7 95 3 2 10 TXD RXD PLCG Port RTS 1or2 CTS 25 Pin DSR 15 Pin Male D Sub Male D Sub GND DCD e o DTR 11 GND 13 Transmit and receive data are cross wired in a direct connection Figure 3 11 Cable for Allen Bradley 1771 KE K
49. or On the Desired Target And Press HELP Figure 4 2 Hiway Box Memory Selection Display Enter the correct Data Hiway number in the first port Add 32 decimal to the DHP box number and enter the result in the next port Enter 1700 for the First Memory Address Also enable Cyclic Update Interval and Change Detect if desired Press the Enter key to display the data See Figure 4 3 PLCG Planning Installation and Service 4 3 7 95 4 3 04 Jun 91 08 55 00 HIWAY BOX MEMORY DATA CHANGE DETECT RESET PRINT DATA SPI 64 CONSECUTIVE WORDS ARE DISPLAYED STARTING WITH FIRST ADDR PRESS MENU KEY TO RETURN TO MAIN MENU PRESS PAGE FWD PAGE BACK KEY TO ADVANCE OR BACKUP DATA PRESS ENTER KEY TO RE DISPLAY SAME AREA DEMAND UPDATE HIWAY NUMBER 05 HIWAY BOX ADDRESS 4 0 L 2 3 4 5 6 000000 000000 000000 000000 000000 000000 000000 000000 Error Counters 000000 000000 000000 000000 000000 000000 000000 000000 Retry Counters 000000 000000 000000 000144 000000 011621 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 Port 1 Statistics 000000 000000 000000 012131 000000 021316 011621 000000 000000 000000 000000 000000 000000 000000 000000 000000 Port 2 Statistics 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 153450 000000 020203 000000 Unused For Information On Functions And Options Displayed On This Menu Unused Position The Cursor
50. rocess Operations Manual Programmable Logic Controller Gateway Specification and Technical Data Programmable Logic Controller Gateway Control Functions Programmable Logic Controller Gateway Parameter Reference Dictionary Programmable Logic Controller Gateway Forms Programmable Logic Controller Gateway Implementation Guidelines PLCG Planning Installation and Service 1 3 Binder System Site Planning LCN Installation LCN Installation Implementation Hiway Gateway 1 LCN Service 2 LCN Service 2 LCN Service 3 LCN Service 3 LCN Service 3 LCN Service 1 Operation Process Operations Implementation PLC Gateway Implementation PLC Gateway Implementation PLC Gateway Implementation PLC Gateway Implementation PLC Gateway 7 95 PLCG Planning Installation and Service 1 4 7 95 SITE PREPARATION Section 2 This section provides the following information for the PLCG Storage conditions site requirements electrical requirements and configuration information 2 1 STORAGE CONDITIONS If the PLCG is to be placed in storage follow these environmental constraints Temperature 35 70 C Humidity RH 10 80 max wet bulb 20 30 C Shock 3 0 g for 10 milliseconds When enclosed in the original shipping container Note that the temperature relative humidity cannot be cycled such that moisture or condensation occurs on the equipment keep the rate of change less than 6 per hour These storage
51. s on the market that may be used where the maximum distances above are insufficient Please check with your Honeywell representative before utilizing this type of equipment in your application PLCG Planning Installation and Service 2 6 7 95 2 5 2 2 5 2 Nonredundant PLCG Port Connections Figure 2 3 A and B illustrate examples of directly connecting PLCs to a nonredundant PLCG A maximum of only two PLCs may be connected in this manner Notice the cables can be no longer than 15 meters Also note the cables must be wired so that both the PLCG and the PLCs think they are connected to a modem Details of this cross wiring will be covered in subsections 3 2 7 and 3 2 8 A Direct Connect Usage Modbus B Direct Connect Usage Allen Bradley Cross wired RS 232 RS 232 cables wired Cables lt 15 meters for A B equipment On some A B equipment each PLC supports Note When wired direct connect each port serves a single PLC RS 232 by including the CIM within the PLC The DF 1 Protocol must be used C Modem Usage Modbus Standard RS 232 Full duplex twisted pair or other cables lt 15 meters Single PLC cable suitable for modem use MODEM Standard RS 232 cables lt 15 meters Three multidrop PLCs shown D Modem Usage Allen Bradley RS 232 cables wired for A B equipment Single PLC A B Data Hiways Port 2 RS 232 cables wired for A B equipment Three multidrop PLCs shown CIM Allen Bradley
52. s the number of times in the previous second that the PLCG was ready to build a Data Request to a PLC on this port but did not have a Scan Buffer available This value is typically nonzero indicating that PLCG data acquisition is running faster than the connected I O subsystem network 4 3 2 7 Number of Keepalive Buffer Misses Second This location 1726 1736 contains the number of times in the previous second that the PLCG was ready to build a Keep Alive refresh message for this port but did not have a buffer available This value is typically nonzero indicating that PLCG Keep Alive writes are running faster than the connected I O subsystem network 4 3 2 8 Number of Output Buffer Misses Second This location 1727 1737 contains the number of times in the previous second that the PLCG was ready to build a User Output message for this port but did not have an Output buffer available This value is typically nonzero indicating that PLCG output writes are running faster than the connected I O subsystem network 4 3 2 9 Firmware Freetime Second Counters These three counters 1740 1741 1742 1743 1744 1745 display approximations of PLCI processor free time The MINIMUM value indicates the least free time per second on record which equates to the heaviest loading The MAXIMUM value indicates the most free time per second on record which equates to the lightest loading The CURRENT value indicates the free time during the previous 1 s
53. umber Not applicable to Honeywell 620 HIM PLCG Planning Installation and Service 5 10 7 95 5 5 5 5 SPARE PARTS Spare parts for the Five Slot Module or the Dual Node Module and its components fan power supply boards etc are listed in the Five Ten Slot Module Service manual or in the Dual Node Module Service manual in the LCN Service 1 binder Spare parts unique to the PLCG are listed in Table 5 4 Table 5 4 Parts List PART NUMBER DESCRIPTION 51201420 001 CABLE ASSY PLCI I O Board to Relay Panel 1 meter 51201420 002 CABLE ASSY Secondary PLCG I O to Relay Panel 2 meter 51107403 100 LCN I O LCN Adapter Board Assembly 51190516 100 RELAY SOLID STATE Optically lsolated Relay 51190526 100 RELAY DC GEN PUR High Reliability Relay 51195096 100 PLCI I O ADAPTER PLCI Paddleboard 51304421 100 PLCI RELAY PANEL Relay Panel on rear of Primary PLCG Module 51401596 200 MOUNTING BRACKET Bracket for Relay Panel on dual node chassis 51304514 100 RS232 DATA CABLE PLCG Field Port Cable 51400667 100 LCNI Local Control Network Board 51400901 100 EMPU Enhanced Microprocessor Board 51400910 100 EMEM Enhanced Memory Board 1 M Word 51400997 100 PLCI Programmable Logic Controller Interface Board 51401288 100 HPK2 2 High Performance Kernel Processor 2MW Mem 51401291 100 LLCN Low Power Local Control Network Board 51401551 200 K2LCN Dual Node Processor LCN Board 2MW Mem 51304542 100 KLCNA LCN A Cable Interface Con
54. verter Board 51305072 200 CLCN A CLCN A Cable Interface Converter Board EC 51304981 100 CLCN A CLCN A Faceplate EC 51304544 100 KLCNB LCN B Cable Interface Converter Board 51305072 300 CLCN B LCN B Cable Interface Converter Board EC 51304982 100 CLCN B CLCN B Faceplate EC ORU Level Replacement Item This item replaces 51304154 100 PLCG Planning Installation and Service 5 11 7 95 PLCG Planning Installation and Service 5 12 7 95 Index Topic Section Heading iY AC Voltage Options Allen Bradley CIM Pinning Assembly and Cabling LCN Node Pinning Module Installation PLCG Cabling PLCG Relay Panel Pinning PLCI Pinning Baud Rate and Parity TS2 Board Revision TS1 Program Options TS3 Ram Clear J1 Port Cabling and Pinning for Modems Using Modbus Protocol Modem Cable Modem Pinning Modem Wiring Port Cabling for Direct Connection to Modbus Equipment Port Cabling for Equipment Using Allen Bradley Protocol Allen Bradley CIM Pinning Direct Connection to Allen Bradley Controllers D wo oo NEWID COW w w w Battery Failure Baud Rate and Parity TS2 Board Revision TS1 Cable Lengths Communications and Performance Statistics PLC Error and Retry Counters Port Statistics Firmware Freetime Second Counters Number of Bytes Received Second Number of Bytes Transmitted Second Number of Keepalive Buffer Misses Second Number of Messages Received Second Number of Messages Transmitted Second Number o
55. ximum value 16 bit counters at maximum displayed as 6 octal digits 177777 8 65 535 10 and are only reset when all emulated DHPs that reference a given physical PLC are disabled off scan 4 3 2 Port Statistics Statistics for both ports are provided as an approximate measure of PLCG performance 4 3 2 1 Subslots Processed Per Second Each time the PLCG processes a subslot parameter assigned to a given port a 16 bit counter is incremented and once per second the results are transferred to the emulated DHP database The counter provides a measured versus calculated value of the number of subslots processed per second as seen by the PLCG The number of subslots processed during the last second before the transfer is then displayed in this location 1721 1731 for the respective port NOTE Although TDC 3000X system software treats a composite tag as a single data point its implementation requires the use of 2 3 or 4 subslots in the PLCG Since the PLCG must collect the data for each subslot in use PLCG performance must be measured and compared in subslots parameters per second If you wish to convert to TDC tags per second from subslots per second you must use a correction factor which expresses the number of subslots per TDC tag To calculate the correction factor use the equation below If the system being measured contains any composite TDC tags the correction factor will have a value less than one SUBSLOTS overall TAG
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