Real-Time Plant Monitoring Installation Manual
Contents
1. Power and Hardware faulted Processor Hardware Cycle power Contact your local Allen FAULT LEDs Error Bradley representative if the error persists on Loose Wiring Verify connections to the controller solid Power LED Application fault Hardware Software For error codes and Status File information on and Major Fault Detected see MicroLogix 1200 and 1500 FAULT LED Programmable Controllers Instruction Set flashing Reference Manual Publication 1762 IRM001C EN P RUN FORCE Operating system Missing or Corrupt See Missing Corrupt OS LED Pattern on FAULT LEDs fault Operating System page D 2 all flashing Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 25 of 25 5 30 20082. Installation Manual Amtech Imaginera Page 11 of 25 5 30 2008 Photo Eye Sensors The Photo Eye sensor is used to determine the production piece count There is one Photo Eye sensor for each machine being monitored There is a dedicated counter in the PLC program for each Photo Eye sensor The counter is incremented each time a piece passes past the Photo Eye sensor Each Photo Eye sensor is provided with a label attached showing the sensor s unique network address MOUNTING The Photo Eye sensors offer a good degree of flexibility with regards to mounting location Almost any mounting location may be used as long as the product piece will interrupt the light beam during operation and mechanical mounting guidelines below are followed The mounting method used for each Photo Eye sensor must be determined on a machine by machine basis Use of the supplied mounting bracket is optional In some cases existing machine hardware and surfaces may be used It may be necessary to modify or custom fabricate a mounting bracket as needed to provide a suitably secure location The mounting location must meet the following criteria Mechanical Location must provide a firm rigid location to reduce excessive vibration Movement of the Photo Eye sensor during machine operation may produce false counts and may reduce the lifespan of the Photo Eye sensor Attachment Bolts and nuts must be secured using self locking nuts lock washers and or thread
3. Scanner 4 1 in Da cz Il LL Re I Programmable Logic Controller Terminal Strip Pon E ES RR va DeviceNet Power Supply T ADPUME Figure 2 Plant Controller Components Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 4 of 25 5 30 2008 Plant Controller Specifications Height 20 inches 51 cm Width 16 inches 41 cm Depth 10 inches 25 cm Weight 65 pounds 30 kg Enclosure Rating when installed properly NEMA 12 Oil Tight Dust Tight Power 120 Volts AC with Ground Phase 60 hertz 10 amps Ethernet Network Ethernet with RJA5 Connector Photo Eye sensor network Female DeviceNet Connector DeviceNet Network Cabling The DeviceNet Network cabling utilizes one Trunk Line that starts at the network connector of the Plant Controller cabinet The Trunk Line is run so that a there is a drop connection at each piece of equipment 1 drop for each Photo Eye sensor The cabling is supplied and installed by the client see the Installation section of this document Since the network cabling provides both power and communication no further connections are required at each sensor Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 5 of 25 5 30 2008 Photo eye Sensors The Photo Eye sensor is used to determine the production piece count by counting each piece of product as it passes past the Photo Eye sens
4. about the status of the module When the numeric Segment Address display is showing 0 to 63 it is indicating the 1769 SDN module s DeviceNet node Numeric and address When it shows 70 to 99 it indicates an Error Code for the displayed node Display Status address When it flashes alternating numbers one is the Error Code 70 to 99 and Display the other is the Node Number 0 to 63 that has generated the error See the list of Error Codes on page 17 for more information Some Common Error Codes on the LED display of the DeviceNet Scanner Error Code Description T There is a size mismatch and most likely the module is configured improperly Go back and check the module in question also verify the scan list entry 78 or 72 The module in question is not communicating properly A 72 means the connection is very intermittent and a 78 means the module is not responding at all Usually faulty wiring or power are the causes of these errors 91 A Bus Off condition exists This can mean several things 1 There is a short between one or both of the CAN lines Blue or White to either Ground Shield or Black or to 24v Red Verify wiring with an ohmmeter or the 1788 MCHKR media checker 2 It could mean there are devices on the network with the incorrect baud rate Removed devices and cycle power after each device is removed Check the SDN s baud rate refer the knowledge base and download the troubleshooting guide do
5. being rogrammed Solid Unrecoverable fault Verify module connectors are properly seated Red If they are verify that bus terminator end cap Is installed Cycle power If still faulted replace the module Network Off INo module power no network Verify module has power Check that the power or communications are not DeviceNet cable is securely connected and the occurring between the module and DeviceNet network is powered Verify that the DeviceNet network This may network power is adequate 11 to 25V dc be an acceptable condition Flashing Device is operational There are no If the module is supposed to be controlling Green connections established with any of DeviceNet slaves configure the module s scan the network devices list Amtech Imaginera Real Time Plant Monitoring Page 20 of 25 Installation Manual 5 30 2008 Solid Normal operation Scan list is INo action required Green configured Module is not in Idle mode Flashing One or more of the devices that the Monitor the status display or the module s Red scanner is communicating with is in status field to determine which slave device is a timed out state offline Solid Critical network failure Duplicate Reset module Change module s node address Red DeviceNet node address detected lor change conflicting device s node address If failure continues replace module 7 Node Indicates diagnostic information
6. lock as appropriate This is necessary to ensure the Photo Eye sensor does not vibrate loose during machine operation Cable Access The communication cable must be routed away from those parts of the machine that move during operation In addition the cable must be routed away from access doors machine guides and other similar machine components that may be moved occasionally during setup or maintenance activities Led Indicators Each Photo Eye sensor has three LED indicators to display status information The arrangement of the indicators is shown schematically in the following diagram viewed looking at the face of the Photo Eye sensor with the light beam out the bottom and the cable out the rear away from the viewer Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 12 of 25 5 30 2008 STATUS OUT MAR Light beam Indicators Indicator labels Photo Eye Sensor body Mounting plate Mounting nut Figure 10 Photo Eye LED Indicators During normal operation the STATUS indicator should be illuminated green in color at all times During normal operation with no product piece present to block the light beam the Photo Eye sensor indicators should all be illuminated When a product piece is present and blocks the beam the OUT indicator must be off the state of the MAR indicator may be On or Off used only for advanced diagnostics The following table provides details r
7. operation with no product piece present the input indicators will NOT be illuminated When a product piece is present and causes a signal the input indicator will illuminate CONFIGURATION INITIAL SYSTEM INSTALLATION No action is required All Adapter Hubs provided with a new Real Time Plant Monitoring system are pre configured labeled and pre tested for the particular installation Wiring input connections from individual production machines must be done in the correct sequence for the RPM system to properly identify each unit CONFIGURATION ADAPTER HUB REPLACEMENT Each Adapter Hub has a unique address in the DeviceNet system The address of each Adapter Hub is set with the two 2 rotary dials on the top of the unit Addresses for 00 to 99 are possible A replacement hub must be set to the same addresses as the hub it replaces Input connections similarly must be re connected in the same order to the replacement Adapter as the original The correct order is imperative for the RPM system to properly identify all production machines connected to each hub Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 17 of 25 5 30 2008 USE OF EXISTING MACHINE SIGNALS When using a DeviceNet Hub with an existing signal from a photo sensor PLC output etc it will usually be necessary to provide some method of signal isolation so that the signal strength is not diminished or adversely affected Typically the u
8. the Key parameter does not match the slave siflashing node address matches the Mismatch configuration in the module s scan desired electronic key vendor product list code product type 75 No Messages No network traffic received by the Verify the scan list is correctly Received scanner 10 seconds have elapsed configured to scan slave devices and no network traffic for the Verify DeviceNet network module or for any other device have connections been received by the module 76 No Message No direct network traffic for the None There are other active devices For scanner detected 10 seconds elapsedjon the network initiating messages Scanner and no DeviceNet input being but none of the messages are for the screened by the module has been module received 77 Slave Data The data being received from the Either reconfigure the slave device or Size slave device does not match the change the module s scan list to match Mismatch configuration in the scan list the slave device 78 No Such Slave device in scan list does not Either add the device to the DeviceNet Device exist network or delete the device s entry in the scan list 79 Transmit The module has failed to transmit a Make sure that the module is Failure message connected to a valid network Check for disconnected cables 80 n Idle Mode Module is in Idle mode Put the controller into Run mode and enable the scanner Run bit bit 0 of the Module Command Array
9. 1 See age 15 81 Scanner The Scanner has stopped producing Check the FAULT value in the module Faulted and consuming I O data This command array condition does not affect the scanner s system or messaging modes 82 FragmentationError detected in sequence of Check scan list table entry for slave Error fragmented I O messages from device to make sure that input and device output data lengths are correct Check slave device configuration 83 Slave Init Slave device is returning error Check slave device s configuration Error responses when the module attempts Reboot slave device to communicate with it 84 Not Yet Module has not completed its initial None This code clears itself once the nitialized attempt to establish communications module properly initializes all slave with its slaves devices on the network 85 Receive Data size returned is larger than Configure the slave device for a Buffer expected smaller data size Overflow Amtech Imaginera Real Time Plant Monitoring Installation Manual Page 22 of 25 5 30 2008 86 Device Went Device is producing Idle state Check the device configuration and Idle lave node status 90 Disabled DeviceNet Port is Disabled Check for the disable being set in the Network module command array 91 Bus Off Bus off condition detected on Check the DeviceNet connections and integral DeviceNet port physical media integrity Check system for failed slave device
10. AMTECH ix Real Time Plant Monitoring Installation Manual WARNINGS aeaaaee aa Caa o EE AAEE AA C EENS ESENE ALAE EANET 2 OVERVIEW naisissa sissa AESSR ESSES ASSESS KANES ASENNE AaS E AEA EES EASD ESSE SSS KESAS 3 MAIN COMPONENT S cccccccccscscccscccccccccscssccnccsccccccscscassccscccesccnscccsccssccesccsccsscccanscaceccccsesscanccaceccccecssassns 4 Plant Conttollet 5 nece R teases aaa nese a ew eee escent des NL TI IMS M 4 DeviceNet Network Cabling vaio acesssccasissshvnesnesisncissciodussosiaceseniaatenesisscastaumdssantaaccsamarusieauiacaseaaeamaasios 5 Photo eye SESS oo utes cxdla ep suME es sE EE EEEE EOE OEE ATE A SEEE EE TE E 6 DeviceNet H bSs ehe a TO AOA A AR 6 INSTALLATION iias aaO EANA as ns bse bs oii 7 Plant Comte Wer EE TTE T 7 DeviceNet Network Cabling 2seososcescsscerkexpuaqee ten un eren ete pair uF pna i rn ved neppure du un Pres np FERES anne ERIS 9 Pholo Eve SENSO S cq oscndzsenscnavit ibant n ie tab EE cia duse IE pes Nou assi CREE N ODER se au pP ed stas D bii MEN 12 DeyiceNet Hubs nran a A R AAA A TA AR 15 TROUBLESHOOTING ssssssssessssssscssccseccssscscccssccssscsccceeccscscscsesecesesescsccecesescsssccecessecsssccecessscssscscceesecssscsee 19 Genera oeenn T a E uct neces TA m E ones R TE AR 19 DeviceNet Scanner Error Codes ececeeeeeeeeeeesesessssssssssssssssssssssesssssssssssssssssssssssessssssssssssssssssssesssssesesesees 20 PLC Error Code ieescicsecescetsscetecesevecsetssecdocssece
11. Arrangement Each DeviceNet Hub Adapter is provided with a label attached inside the enclosure with a wiring chart showing which production machines must be connected and the position that each machine occupies at the adapter hub input connection The following chart shows a typical label diagram partial Wire Terminal Address Description Equip Id 00100 0 X0 125 Stock A Labeler 1 00101 1 X1 166 Koppers 1c Rdc 2 5 00102 2 X2 164 Bobst Spo 1575 3 x ES 00103 3 x3 163 Bobst Spo 1600 4 o v 00104 4 X4 161 BOBST SP 1600 5 E 9 00105 5 X5 gt E E 00106 6 X6 A X 00107 7 X7 00108 10 X10 00109 11 X11 00110 12 X12 Chart of Wiring Connections partial Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 16 of 25 5 30 2008 LED INDICATORS Each DeviceNet Hub has two 2 primary LED indicators one to indicate module status and the second to indicate network status There are also LED indicators for each input connection up to 16 for the 16 point hub Adapter MODULE NETWORK LED Indicators LED Indicator Status Description Solid RED Unrecoverable Fault in Adapter Flashing RED Unrecoverable Fault in Adapter Module Status Solid GREEN Normal Operation OFF Loss of Power Solid RED Unrecoverable Communication Fault Flashing RED Recoverable Communication Fault Network Status Solid GREEN Communications Normal Flashing GREEN Communication Path Error During normal
12. cument ID number G15098 3 3 It could mean that there is a large amount of noise on your network This could be due to High Voltage power cables being too close Improper or lack of termination Improper grounding again refer Knowledge base document ID G15098 or to the DeviceNet Media installation guide publication DN 6 7 2 92 There is no network power 24V Verify cabling or use an isolated regulated power supply rated for DeviceNet usage A detailed procedure is contained in the User Manual for the DeviceNet Scanner available from Allen Bradley Allen Bradley document number 1769 SDN Document title Compact I O 1769 SDN DeviceNet Scanner Module Code Name Description Recommended Action decimal 70 Duplicate Controller has Failed Duplicate Change the module s or conflicting Node INode Address Check The node device s network address node address selected is already in use number to an available one Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 21 of 25 5 30 2008 71 Illegal Scan Ilegal data in Scan List Reconfigure the scan list table and List Data remove any illegal data 72 Slave One of the module s slave devices Inspect the module s slave devices and Timeout lhas stopped communicating verify the DeviceNet connections 73 Electronic The slave device Vendor ID key Make sure that the device at
13. ects to the appropriate port on the client s Ethernet hub or switch The Ethernet hubs switches cabling and connectors are supplied and installed by the client Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 8 of 25 5 30 2008 DeviceNet Network Cabling The Plant Controller communicates to the DeviceNet Photo Eye sensor cabling using the bulkhead connector located on top ofthe enclosure Using a male DeviceNet connector provided connect one end of the trunk line to the Plant Controller cabinet at that bulkhead connector For details see Cable Connection Instructions later in this document DEVICENET NETWORK CABLING The Network cabling utilizes one trunk line that starts at the network connector of the Plant Controller and is run in daisy chain fashion so that a there is a drop at each piece of equipment for the Photo Eye sensor Since the network cabling provides both power and communication no further connections are required at each sensor DeviceNet round thick cable is used as a trunk line to communicate from the Plant Controller to each of the Photo Eye sensors The cabling are supplied and installed by the client The Male and Female connectors for the Trunk cable as well as the Tee connector and drop cable are included in each Photo Eye sensor set The total length of cable used must not exceed 1640 feet 500 meters in length DeviceNet Round Thick Cable Specification Allen B
14. egarding the meaning of each indicator In the table Margin corresponds to the MAR indicator and Output corresponds to the OUT indicator on the Photo Eye sensor Photo Eye LED Indicators Label Color State Status Output OUT Yellow On Target Detected Margin MAR Orange Off Margin 2 0 On Margin gt 2 0 Status Red Green Off Sensor not Powered Green On Steady Sensor Active and Allocated by Master Green Flashing Sensor Active but not Allocated by Master Red Flashing Minor Correctable Fault Baud Rate Red On Steady Major Fault Possible Duplicate Address Amtech Imaginera Page 13 of 25 Real Time Plant Monitoring Installation Manual 5 30 2008 CONFIGURATION INITIAL SYSTEM INSTALLATION No action is required All Photo Eye sensors provided with a new Real Time Plant Monitoring system are pre configured labeled and pre tested for the particular installation Re configuration or re addressing should be required only when a Photo Eye sensor is replaced see next section CONFIGURATION PHOTO EYE SENSOR REPLACEMENT Each Photo Eye sensor must have a unique address in the DeviceNet system Each Photo Eye sensor is shipped from the factory with an address of 63 When replacing a faulty Photo Eye sensor the sensor must be re configured to set its DeviceNet network address A detailed procedure for re configuring a Photo Eye sensor is outside the
15. he braided shield and the foil shields surrounding the power and signal conductors 4 Trim the conductors to the same length SS Terminator L 3 Photo Eye Sensor Male Trunk Line Connector T Port Tap Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 10 of 25 5 30 2008 5 Slide the connector hardware onto the cable in the order shown rubber washer grommet enclosure ys rmm od slide hardware CT EN I ri 9 mm bevelled side 0 374 in Do not nick the conductor strands Figure 8 Installing Connector Hardware 6 Strip 9 mm 0 374 1n of insulation from the ends of all conductors except the bare drain wire Important Do not twist or pull the cable while tightening the gland nut 7 Attach wires to the connector using screw terminals as seen in the following diagram Male Connector Female Connector power conductors toa dus power conductors signal bare bare blue signal Tbare conductors l conductors Rear Vi Rear View ear View Figure 9 Attaching Wires to the Connector 8 Screw the enclosure body to the connector 9 Screw the rear nut into the connector enclosure Important Do not twist or pull the cable while tightening the rear nut TERMINATING RESISTOR The terminating resistor provided must be attached to the last tee in the network farthest along the Trunk Cable from the Plant Controller cabinet Real Time Plant Monitoring
16. iecvaseetdecstvessetubeeteceseectectascaddsastuecsatubeetecssvectsctas eveeacedsesdeeses 24 core Technology Inc Warnings Warning Before beginning the installation make sure all the following precautions are taken e 120 VAC power supply to the Plant Controller cabinet is turned off e The DeviceNet cable system is inactive All devices attached to the DeviceNet cabling are turned off All auxiliary power supplies attached to the DeviceNet are turned off e Manufacturer s instructions for stripping crimping and or tightening are followed as outlined in the following sections of this document e All equipment must be installed in compliance with any applicable National and or Local regulations or codes Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 2 of 25 5 30 2008 Overview The Real Time Plant Monitoring System will collect data from a network of Photo Eye sensors and or DeviceNet Adapters located on equipment throughout the plant floor Hardware and software components located in the Plant Controller will collect signals from those sensor inputs A Programmable Logic Controller PLC located in the Plant Controller will increment and reset the piece counts from each Photo Eye sensor and determine the operating mode and rate of each piece of equipment Imaginera will obtain data from the industrial computer located in the Plant Controller via the plant s Ethernet netw
17. n Executing the user program in run mode green flashing Memory module transfer occurring FAULT off No fault detected red flashing Application fault detected red Controller hardware faulted FORCE off INo forces installed amber Forces installed BATTERY LOW off battery OK amber battery needs replacement COMM 0 off Not transmitting via RS 232 port green Transmitting via RS 232 port COMM 1 off flashes when communications are active 1764 LRP only ereen DCOMM off Configured communications ereen Default communications INPUTS off Input is not energized amber Input is energized terminal status OUTPUTS off Output is not energized amber Output is energized logic status When Operating Normally The POWER and RUN LEDs are on If a force condition is active the FORCE LED turns on and remains on until all forces are removed When an Error Exists Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 24 of 25 5 30 2008 If an error exists within the controller the controller LEDs operate as described in the following tables If the LEDS The Following Probable Cause Recommended Action indicate Error Exists All LEDs off power supply error INo input power or INo line Power Verify proper line voltage and connections to the controller Power Supply Overloaded This problem can occur intermittently if power supply is overloaded when output loading and temperature varies
18. or It is critical to install the Photo Eye sensor properly to ensure pieces are not missed and to prevent false counts see the Installation section of this document Each Photo Eye sensor set contains e Photo Eye sensor with its network address label and bracket 32 foot 10 meter Drop Cable Network Tee Male Connector for the Network Trunk Cable Female Connector for the Network Trunk Cable Mounting and cabling requirements are included in the Installation section of this document DeviceNet Hubs A DeviceNet Hub Adapter is used as an alternative to a Photo Eye to measure piece counts on a production machine DeviceNet adapters are multi point devices usually 16 input points per adapter which can receive signals from existing sensors or from new photo sensors that are not DeviceNet compatible allows more flexibility in sensor selection Each DeviceNet adapter set contains e 16 point adapter with selectable address switch Fiberglass enclosure 9 X 11 with screw on cover 16 foot 5 meter Drop Cable Network Tee Male Connector for the Network Trunk Cable Female Connector for the Network Trunk Cable Mounting and wiring requirements are included in the Installation section of this document Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 6 of 25 5 30 2008 Installation Plant Controller MOUNTING The Plant Controller should be centrally located to minimize the length of Network cabling req
19. ork DeviceNet Photo Eye Sensor DeviceNet Network Cabling Ethernet DeviceNet Photo Eye Sensor i Amtech Imaginera Server DeviceNet VO if required Additional Plant Controller DeviceNet Photo Eye Hub Or L Ld Imaginera Users Figure 1 Real Time Plant Monitoring System Overview Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 3 of 25 5 30 2008 Main Components Plant Controller The Plant Controller collects data from Photo Eye sensor network DeviceNet and communicates to and from the Imaginera server The Plant Controller cabinet contains the following major components The main connection to the Photo Eye sensor network DeviceNet The DeviceNet Power Supply for the Photo Eye sensor network The DeviceNet Scanner that manages communication to the Photo Eye sensor network The Programmable Logic Controller PLC The program inside the PLC increments and resets the piece counts from each Photo Eye sensor and determines the operating mode and rate of each piece of equipment The Industrial Computer that collects data and provides it to the Imaginera server The enclosure itself is oil tight and dust tight NEMA 12 when installed properly Mounting and Electrical requirements are included in the Installation section of this document DeviceNet
20. p cable must be routed away from obstructions that could damage the cable In addition the cable must be routed away from access doors machine guides and other similar machine components that may be moved occasionally during installation or maintenance activities 4 1 4 Mounting Holes 10 5 8 REF 11 REF 6 REF 9 3 8 REF Figure 11 DeviceNet Hub Dimensions Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 15 of 25 5 30 2008 WIRING PHOTO EYES OR CONTACTS Standard hook up wire is required to carry the input signal from each machine to the DeviceNet Hub Typically 18 Ga multi strand 3 conductor shielded and jacketed cable should be used The arrangement of the input wiring for a typical unit is shown schematically in the following diagram PLC Input Module PLC Input Module Check Wiring Chart for PLC Check Wiring Chart for PLC a Terminal Inpu Terminal Inpu a 2 2 ojojojojojojojojo I o o lol olojo o o o o o I Ld o o Z Z o o e VDC VDC e 2 2 oO O o olojololo oO e e OJO OJO O O O O O OJOIO ar g Q um Photo Eye Solid State Relay Figure 12 DeviceNet Hub Wiring
21. radley 1485C P1 A300 Belden 3082A DeviceNet Cable blue white gt data pair it red black dc power pair ri tinned copper twisted braid shield drain wire jacket polypropylene fillers Figure 5 Device Net Cable Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 9 of 25 5 30 2008 CABLE ROUTING The cable must be routed so that there will be a drop to each Photo Eye or Adapter Hub while keeping the total length of trunk cable to a minimum Each segment of trunk cable should be long enough so that it can be connected to the 32 foot 10 meter drop cable and tee provided for each Photo Eye or Adapter Refer to the following diagram for typical cabling arrangement Actual arrangement will vary depending on the layout and quantity of machines in the facility 1 Drop y Dro Cable Cable Female Trunk Line Connector Connector to Drop Cable Figure 6 Typical Photo Eye Sensor Installation CABLE CONNECTION INSTRUCTIONS D Le 1 Prepare the cable jacket by cleaning loose particles from the jacket 70mm jacket 2 75 in J p 29 mm clean jacket 1 165 in Figure 7 Preparing the Cable Jacket 2 Strip 29 mm 1 165 in of the cable jacket from the end of the cable 3 Cutt
22. s from all machines is incorrect check the entire length of the DeviceNet Trunk Cable for breaks or damage Also check the 24 VDC Power Supply and the DeviceNet Power Tap in the Plant Controller cabinet Be sure there 1s power to the Tap from the Supply 24 VDC Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 19 of 25 5 30 2008 DeviceNet Scanner Error Codes The DeviceNet Scanner is connected to the PLC and is located inside the Plant Controller If DeviceNet is powered up and the indicators on all Photo Eye sensors are properly illuminated it may be necessary to resolve error codes shown on the DeviceNet Scanner The following table summarizes the meanings of the LEDs and numeric codes Module LED MODULE NETWORK Network LED DewiceNet Node Address and Status Display ADDRESS ERROR Ba Indicator Color Indicates Recommended Action Status Module Off INo power applied to module Apply power Flashing INo Bus Master MicroLogix or Verify module connectors are properly seated Green CompactLogix controller present If they are cycle power to the controller If this does not correct the problem replace the controller If replacing the controller does not correct the problem replace the 1769 SDN Solid Normal operation INo action required Green Flashing Recoverable Fault Memory has Complete flash update or start a new update Red been erased or is
23. s or other possible sources of network interference Check the Baud Rate 92 No DeviceNet No network power detected on Provide network power Make sure the Power DeviceNet port module drop cable is providing the roper power to the DeviceNet port 95 IFLASH Flash Update In Progress None DO NOT disconnect the Update module from the network while a flash update 1s in progress 98 Firmware Firmware is corrupted Reflash module firmware DO NOT Corrupted power cycle the module Doing so will cause the module to become inoperable If the problem persists contact Rockwell Automation Technical Support 99 Hard Fault Cycle Power Reflash module firmware Contact Rockwell Automation Technical Support Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 23 of 25 5 30 2008 PLC Error Codes In the unlikely event the PLC is suspected of improper operation the following information may be useful This information was obtained from the Allen Bradley PLC documentation and is included here for convenience Understanding Controller LEDs The controller status LEDs provide a mechanism to determine the current status of the controller if a programming device is not present or available 0000000 Color Indicates POWER off No input power or power error condition green Power on RUN off Not executing the user program gree
24. scope of this Installation Manual A detailed procedure 1s contained in the User Manual for the DeviceNet Scanner available from Allen Bradley Allen Bradley document number 1769 SDN Document title Compact I O 1769 SDN DeviceNet Scanner Module Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 14 of 25 5 30 2008 DeviceNet Hubs The DeviceNet Hub is used instead of a Photo Eye on some machines to determine the production piece count There must be either a Photo Eye or an input to a DeviceNet Hub for each machine being monitored on the RPM system The DeviceNet input may come from an isolated signal from an existing photo sensor a PLC input output a micro switch or another source There is a dedicated counter in the PLC program for each Photo Eye sensor and for each individual input of the multi point adapter The counter is incremented each time a piece passes past the Photo Eye sensor or a signal is received at the DeviceNet Hub MOUNTING The DeviceNet Hubs are supplied mounted in a fiberglass reinforced plastic enclosure The enclosure must be securely mounted in a suitable location The preferred location for an adapter is centrally located to all of the production machines that connect to that adapter The mounting location must provide a firm rigid location to reduce excessive vibration Mounting hardware should include self locking nuts lock washers and or thread lock as appropriate The DeviceNet dro
25. se of a general purpose relay will suffice for this purpose however a standard mechanical relay should be avoided as it may have limited response capability or exhibit contact bounce and flutter It is therefore recommended that a solid state relay be used or at least a magnetic reed type isolation relay with high input impedance Typical Solid State Relays Input Control Voltage Rated Resistive Load Manufacturer Part Number Omron G3NA D210B DC5 24 auos e 10A at 5 to 200 VDC Allen Bradley 700SH5FZ24 x Omron G3NA D210B AC100 240 100 to 240 VAC Allen Bradley Typical Hook Up Cables Manufacturer Part Number Belden Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 18 of 25 5 30 2008 Troubleshooting General Whenever piece counts for an individual machine are incorrect the machine s Photo Eye sensor should be inspected to be sure it is still installed and operating properly After a Photo Eye sensor has been in service for a while its mounting hardware may vibrate loose The lens may be dirty or it may become permanently blocked by some unexpected obstruction The cable may be disconnected or damaged With no product piece present in the light beam check the indicators on the Photo Eye sensor All three indicators should be illuminated Refer to the preceding section for details regarding the LED Indicators Whenever the piece count
26. uired to reach all machines The Plant Controller is intended to be surface mounted using the four mounting holes located on the enclosure Please allow ample room to open the enclosure door fully and to service components inside of the enclosure 7 4 7 164 MOUNTING HOLES T a A I ee Figure 3 Plant Controller Dimensions Power The Plant Controller requires 120 Volt Alternating Current see Table for operation and to power the Photo Eye sensor network The line black neutral white and ground green wires should be connected to the L1 N and GND green terminals respectively of the terminal block Please refer to the following diagram Figure 4 Real Time Plant Monitoring Installation Manual Amtech Imaginera Page 7 of 25 5 30 2008 Customer Power Supply DeviceNet 115 Volts AC Sensor Network Customer ertz Single Phase Ethernet lt E E LJ __ Li Figure 4 Plant Controller Connections ETHERNET NETWORK The Plant Controller communicates to the Imaginera server via the client s plant wide Ethernet network One end of the Ethernet cable connects to the LAN connector type RJ45 on the industrial computer The other end of the Ethernet cable conn
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