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PLC033 Installation and Operation Manual

1. 6 7 033 Pin Descniptions 9 CHAPTER 2 BEFORE YOU BEGIN 2 2 0 11 Safety PreCautions iet etes tbe OU ne e 11 General iii aee cate na aaa ss EIN Ass nalen 11 Working with the PLCO3 sui a nome 11 12 Receipt of Equipment dee et er ee alas Dee Br nn 12 CHAPTER 3 PRINCIPLES OF OPERATION c cscessoossosssnonnnessnnnnnensnnsnnnssnnsnnessnnsnnensnnsnnensnnsnssnsnssnse 13 Installed in Specially designed 13 tede et ER RUE HP RE RUN 13 Typical Installation i ne ere eti HS een 13 Emulate Multiple DES RTUS 14 PEC Central P 7 14 SetPoint Variables O e deiecti d 14 22 15 Modbus Serial Master Slave 02 1 0010 eene 16 Supports Multiple Protocols cise e vr e tia ta 16 VO M EE 16 Programming Interface eer teo idein 17 Programmed with Ladder Logic enne enne 17 Monitor and Control via Custom en 18 Contr lled Sh tdown J 5 55 oes 18 Typical DFS RTU 033 19
2. 49 Eumished Parts 49 Optional Ps 49 APPENDIX E 51 APPENDIX SUPPORT SERVICE AND WARRANTY eeeeeeeeeee eo nete sonet etse 53 Support and Service rt f na Hahn el niet ERE Pepe 53 Technical Product Assistance 53 Return Authorization RA Procedure sss 53 Mich 55 Questions or Comments on This entente trennen en 55 57 PURPOSE OF THIS MANUAL This manual is a reference guide for installing programming and operating the PLC033 programmable logic controller DFS 00507 008 01 It contains information meant to guide and assist you through installation configuration and programming procedures This includes mounting and wiring instructions product features and specifications I O listings instructions for integrating with telemetry and information on configuring communication and I O properties programming the PLC using ladder logic and creating custom user interface screens DOCUMENT CONVENTI ONS The following conventions are used throughout this manual e Bulleted lists provide information not procedural steps e Numbered lists provide sequential steps or hierarchal information e Italic type is used for emphasis ORGANI ZATI ON e Chapter 1 Product Ove
3. N 5 S K S PLCO33 INSTALLATION amp OPERATION MANUAL PLC033 INSTALLATION AND OPERATION MANUAL Data Flow Systems Inc 605 N John Rodes Blvd Melbourne FL 32934 Phone 321 259 5009 Fax 321 259 4006 NOTICE Data Flow S ystems Inc assumes no responsibility for any errors that may appear in this document nor does 11 make any commitment to update the information contained herein However questions regarding the information contained in this document are welcomed Data Flow S ystems also reserves the right tom ake changes to the specifications of the PLC033 Programmable Logic Controller and to the information contained in this document at any time without notice DFS 00507 011 01 This document last revised August 24 2011 TABLE OF CONTENTS PREFACE 1 Purpose of this een eed RIS 1 Conventions elei Birnen 1 Organization 0 a et deae 1 Abbreviations Used this 7 2 CHAPTER 1 PRODUCT OVERVIEW 5 eee sooo See nenne no ron aane i ooo sea aoo ne 3 Ib euin 3 ESAS 0 4 Technical Specifications en e n Tete to i 5 PECOIS EA 6 Reserved Set Point Registers e e tee
4. 4 GETTING STARTED 21 CHAPTER 5 HARDWARE INSTALLATION eeeeeeeeeee ee eto eese setate sess eset essa sesto esses stesso ete 23 Installing the PLCO33 in the RU testet ete ee is eee eie teet 23 By Pass Gard ander UHR RH DRE BRE REESE 26 Network Interface a RT e tp A e 26 Modbus Serial Master Slave Interface 27 APPENDIX A TESTING AND 2 2 2 lt 29 No Communication to Function Modules seen en 29 No Communication to RS 232 485 Modbus 1 eene nennen 31 No Power to Function Modules 32 RIM Locked in Transmit Mode penetret tree rete tire eee sa nah 33 Connection Ref sed 1 2 iii 33 Broadcast die ana HT tem ara HEEL e eee 34 Reset 033 to Factory Default State 36 Shutdown Process Ladder 37 Advanced Troubleshooting Tools 39 APPENDIX B APPLICATION NOTES odio Sou aee 41 Using Remote DFS VO in a 1 41 Implement PLC Central Function 43 APPENDIX C UPDATE PLC FIRMWARE 2 0 47 APPENDIX D PARTS LIST an a
5. centralib File Edit Ladder Digital Analog Math Compare TimeDate Help Detect cam lass and switch to central mode Com Loss Timer Greater ar Equal Latch Ch 1 Central Made 1 48851 60 Ch1 Central Mode Time Delay 60 Do events while in cental mode Ch 1 Central Mode ST Process Status ST Process Control Figure B 1 PLC Central Backup Mode Ladder Code For RTU systems that require a centralized site for logic but aren t large enough to warrant a HyperTAC II central site the PLC033 can be forced to permanently stay in PLC Central mode by setting and keeping the Comm 2 DFS Central Mode register at a true value in the PLC033 s ladder logic program For example the first line in the PLC033 s ladder logic program could be written to set the Comm 2 DFS Central Mode register to true if power is detected continued on next page Installation and Operation Manual 6033 44 Appendix Application Notes The remote I O that the 033 is to poll during PLC Central mode operation must be configured under the Remote branch in I O Builder Remote Branch VO BUILDER 2 GIDFS PLC 2 Mode MODULE The process of adding DFS modules to the Remote branch is similar to the process used when adding modules under the Bus branch with the addition of one step the station number ofthe RTU where the module s to be polled are located must also be specified
6. 281828561 2 gt 810428HHHHHHHHHHHHHHHHHH1 8 888 8 gt 01 642 8 HHHHHHHHHHHHHHHHHHHHHHHR 7 nin ninm inim nin 8 B7 9 gt 01 0205018 000000 6 52 gt 818428HHHHHHH8 A problem communicating with 1 port hardware is indicated when intermittent responses are received from the module bus No POWER TO FUNCTION MODULES If you notice that the PSM RIM and PLC are powered but the function modules downstream ofthe PLC are not powered the problem is probably due to the module bus fuse on the PLC033 The PLC033 is equipped with two fuses that control power along the bus One fuse is for incoming power from the PSM side of the bus The second fuse is for power to the module side of the bus This is a factory repair See Appendix F Support Service and Warranty for information on the procedure for returning the PLC033 to DFS for repair If you have a spare PLCO33 on site you can replace the faulty PLC033 Before replacing the PLC033 download its configurations into the PMT software so they can be uploaded to the spare See Retrieve Information from an Existing PLC033 in the Process Management Toolkit User Manual for more information Before installing the spare PLC033 it is important to identify and correct the condition that caused the fuse to blow in the first PLC Possible causes of a blown fuse include a bad module or b
7. RIM board without the radio installed in the RTU and polling the PLC033 from the HyperTAC II central using the DFS NIM protocol There 15 no additional configuration required to implement either of these functions As a Modbus TCP slave the PLC033 can be polled by any Modbus compatible software that uses the Modbus TCP protocol Using the COMI serial port the PLC033 can function as Modbus RTU ASCII master or slave device As a Modbus master the PLC033 can poll a single Modbus compatible RS 232 device or multiple Modbus compatible RS 485 devices via its COMI serial port using either the Modbus RTU or ASCII protocol As a Modbus slave the PLC033 can be polled by any Modbus compatible software that uses the Modbus RTU or ASCII protocols Another important feature of the PLC033 is its ability to function as a PLC central The PLC Central feature enables the PLC033 to poll remote DFS RTUS in addition to local modules and local Modbus compatible I O PLC Central can be a secondary function of the PLC033 or its primary function The PLC033 s mode is determined by the value of Special Function Register 9951 Comm 2 DFS Central Mode When the register is true the PLC033 functions as a PLC central As a secondary function limp or backup mode the PLC033 can temporarily switch to PLC Central mode when it determines that communications with the HyperTAC II central have been lost This mode uses two timers that are inserted in the PLC03
8. Right click Remote and select New In the New Remote Module dialog box enter the station number assigned to the RTU In the Module Table select the module s type from the Module Type drop down menu Boc Similar to DFS local I O remote I O must also be mapped Enter valid unused register numbers in Start1 and Start2 where applicable To keep things organized you may want to set aside a group of registers in each Modbus register range that is only used for remote I O DFS 00507 011 01 45 Notes 46 Appendix C UPDATE PLC FIRMWARE From time to time we will make updates to the PLC s firmware the ROM based software that controls the device These updates may add new features to the operation of the PLC or may fix bugs in the previous release When updates are available they will be placed on our server and can be downloaded and installed on the PLC via the Update command in the Process Management Toolkit To update the PLC s firmware you must be on a computer that has access to the PLC you want to update An Internet connection is optional but preferable If you are connected to the Internet you are ensured of getting the latest firmware updates Without an Internet connection PMT will update the PLC with any applicable updates that have been stored locally from a previous download Files are stored locally in a folder in the main PMT directory When you initiate the update process PMT attempts to connect to
9. MODULES TRANSMIT DATA CFG GROUND JUMP PIN 27 TO 29 FOR DEBUG MODE RUN TRAP OFFFFH CONFIGURATION BIT 3 8 CONFIGURATION 2 4 CONFIGURATION BIT 1 2 CONFIGURATION BIT 0 1 CONFIGURATION BIT 5 32 CONFIGURATION BIT 4 16 RS 485 B RS 485 A RS 485 SHIELD HOST 232 CTS HOST 232 RTS HOST 232 GND HOST 232 TXD HOST 232 RXD RIM SYSTEM DC VOLTAGE RIM SYSTEM GROUND RIM POWER DOWN RIM REQUEST TO SEND RIM CLEAR TO SEND RIM RECEIVE DATA RIM TRANSMIT DATA Notes 10 Chapter 2 BEFORE YOU BEGIN SAFETY PRECAUTIONS Review the following statements before installing servicing or replacing the PLC033 Programmable Logic Control or any of its components GENERAL PRECAUTI ONS Only trained and qualified personnel should install service or replace this equipment Carefully read the installation and wiring instructions before connecting the PLC033 to its power source Do not work on the PLC033 or connect or disconnect any of its cables during periods of lightning activity To prevent overheating the PLC033 do not operate it in an area that exceeds the maximum recommended temperature range of 0 C 32 F to 70 C 1589F Ensure that the unit is connected to earth ground during normal use Precautionary measures must be observed when installing operating and servicing the PLC033 in order to prevent shock from voltage
10. a PLC033 using DFS radio link if the RIM doesn t meet the specifications outlined above no communications will take place between the PLC033 and the radio The RIM will appear to be locked in transmit mode when observing its transmit LED the LED will be constantly on Additionally abort messages will appear when radio traffic is monitored using HyperTAC II s Telemetry Traffic Tool Instructions for determining ROM level appear on the next page If you find that you re RIM is not at version 12 08 05 or later contact DFS Service Department for information on upgrading 23 Chapter 5 Hardware Installation CHECKING RADIO S ROM VERSION As discussed above the RIM used in a PLC033 RTU must be 006 and must a ROM version of 12 08 05 or later There are several ways to check the ROM s version CHECK THE ROM LABEL You can find the ROM version listed on a label attached to the radios ROM chip Simply remove the cover plate to verify the version number Refer to the illustration below for the location of the label Figure 5 1 ROM Label on Radio Interface Module RIM Installation and Operation Manual 6033 24 Chapter 5 Hardware Installation USE WINRTU TEST A RIM in the field or one that is set up on a test bench can be queried using WinRTU Test 1 Connect a laptop or desktop computer that has WinRTU Test installed to the RIM s service port using the cable provided with Win
11. are white in color and are preceded by a right pointing carat gt Telnet 192 168 10 175 0 Enter R for Radio B for Backplane or M for Modbus Monitoring dev tts 2 8082 8885 DHHHBHHHHHBBH1HHHHH3 gt 803 807FOBHHBHHHHHHH 2801 1 6 2 808 2 8885 660061 gt B83 807 FOBHHHHHHHHHRB 0801pi80800000000000000000000001000000000007 002k800086 CG66660068001 660061 gt 663 667 FG60000000000 001p18000000000000000000000001000000000008 A problem communicating with the module backplane hardware is indicated when intermittent or no responses are received from the module bus 30 No COMMUNICATION RS 232 485 MODBUS DEVICES If you are having problems communicating from the PLC033 to RS 232 or 485 Modbus compatible devices you can perform a data tap to determine ifthe problem is hardware related A data tap is performed using a standard Telnet connection It enables you to view outgoing and incoming messages from the PLC master to the Modbus compatible devices If messages are going out from the PLC033 to the devices but no messages are coming in the problem may lie with the configurations Were they uploaded to the PLC Are they correct the connection to the device Is it connected properly Is the cable damaged or with the device itself 1 Opena Telnet connection by selecting Run from the Windows Star
12. indicate the PLC033 is going through the reset process The LED will turn off for approximately 30 seconds and then will return to its normal blinking pattern slowly turns on and then off 5 Using crossover cable connect a laptop to the PLC033 You may need to change the network settings for your computer so that it is on the 192 168 1 network For example set the computer to 192 168 1 101 Issue a PING command to the factory default IP 192 168 1 10 to verify that the factory default reset was successful Installation and Operation Manual 6033 36 CONTROLLED SHUTDOWN OF PROCESS LADDER There are several ways to stop the PLC033 s ladder e Battery voltage drops below 11 2 volts e PLCO33 s Shutdown button is pressed for several seconds e Remote Process Stop Command register Special Function Register 9921 15 set to true via logic this could be a control on HyperTAC II that sets the register over the radio or a condition in the PLC033 s own ladder that prompts the ladder to set the register itself or a switch wired to the PLC033 s card edge In all cases the ladder is given 30 seconds to perform any actions necessary to put the station in a safe state and set the Remote Process Running register Special Function Register 9930 to false When the PLC033 sees that register 9930 is false it will stop running the ladder in preparation for a physical shut down e g power to the PLC033 is turned off If the 30
13. our server After successfully connecting to our server it compares the files on our server to those stored in the local PMT directory Any updates not found in the local folder are downloaded If no Internet connection is found only the locally stored files will be used to update the PLC After downloading the updates the PMT connects to the PLC compares the PLC s current firmware to the locally stored update files and then makes the necessary updates Firmware updates are typically 1 2Mb although the file size could be smaller or larger depending on the changes that have been made Firmware Update Procedure Note If you will be updating more than one RDP a connection to the Internet is only required for the first device Once the update files have been downloaded to the PMT folder you can update the remaining RDP s without being connected to the Internet they can be updated using the locally stored files 1 Start PMT and open the project file for the PLC you want to update 2 Select Update PLC RDP from the Network menu The dialog box will show the download progress to the PMT folder 3 When the updates have finished downloading a second dialog box will show the file upload progress to the PLC When the transfer is complete click Done 4 Reboot the PLC cycle power to finalize the updates 47 Notes 48 Appendix D PARTS LIST FURNISHED PARTS PLCO33 Part No DFS 00507 008 01 OPTIONAL P
14. second timer expires before the ladder sets register 9930 to false the PLC033 will set the register itself and stop running the ladder Low BATTERY VOLTAGE The PLC033 is designed to monitor the RTU s battery voltage If it senses that the voltage has dropped below 11 2 volts the PLC033 will set the Remote Process Stop Command register Special Function Register 9921 to true PLC033 will stop running the ladder when one of two conditions occurs it sees that the ladder has set the Remote Process Running register Special Function Register 9930 to false or 30 seconds has expired in this case the 033 itself sets register 9930 to false When the process stops due to low battery voltage you will have to restart the ladder by powering up the RTU since a loss in voltage is likely caused by loss of AC power 37 Appendix A Testing and Troubleshooting SHUTDOWN BUTTON PLC033 features a shutdown button that can be used to stop and start the ladder The button can be found on the edge of the card just below the service port Service Port Shutdown Button Holding the button down for several seconds sends a signal to the PLC033 to turn on the Remote Process Stop Command register Special Function Register 9921 The PLC033 will stop running the ladder when one of two conditions occurs it sees that the ladder has set the Remote Process Running register Special Function Register 9930 to false 30 seconds has expi
15. the Network menu This works similarly to the update RDP PLC function The PMT obtains the update from our FTP server but it prompts the user for the IP address of the target RNA110 before installing the update Fixes Ladders that had rungs of logic too large to fit on a single page would not print The printing method was overhauled to correct this and print ladders more efficiently Analog registers were not being removed and or recreated in the points list properly The PMT now performs a complete re build of the points list each time a ladder check or install is performed This process is reflected with a busy progress bar at the bottom left of the PMT status bar Q Points were not being properly added to the logic file This fix only applies to the PLC033 A scaling error was corrected for analog points on the screen builder A math error was corrected with the flow totalizer object A condition that caused the PLC RDP to intermittently crash when used as a Modbus TCP slave device with HyperTAC II was corrected 51 Notes 52 Appendix F SUPPORT SERVICE AND WARRANTY SUPPORT AND SERVICE Data Flow Systems Inc offers support services nationwide from its home office and through authorized Value Added Resellers VARs and System Integrators Contact your local Data Flow Systems Inc representative for e Sales and order support e Warranty support e Product technical training e Support service agre
16. the ladder Logic Builder Get remote data Stn 1 Tank Level 1 41001 Stn 1 Tank Level 1 41001 The examined input could be used in a ladder statement that evaluated the level at station 1 and turned on the pump at station 35 For example if the tank level at station 1 is less than 25 feet then turn on the pump at station 35 Note The Examine Analog object must be scaled to match the configuration in HyperTAC II I MPLEMENT PLC CENTRAL FUNCTI ON The PLC Central feature enables the PLC033 to poll remote DFS RTUS in addition to local modules and local Modbus compatible I O PLC Central can be a secondary function of the PLC033 or its primary function The PLC033 s mode is determined by the value of Special Function Register 9951 Comm 2 DFS Central Mode When register 9951 Comm 2 DFS Central Mode is true the PLC033 functions as a PLC Central and polls all of the I O configured under the DFS PLC driver s Remote branch When this register is false the PLCO33 will not poll remote modules it will only poll its local I O and respond to queries received over the DFS radio link As a secondary function backup mode the PLC033 can temporarily switch to PLC Central mode when it determines that communications with the HyperTAC II central have been lost This mode uses two timers that are inserted in the PLC033 s ladder logic program These timers instruct the PLC033 when it
17. type should be configured as a 004 The station number in HyperTAC II must match that configured for the remote device in PMT For more information refer to the section titled Adding a Remote Device Emulated DFS RTU in the Process Management Toolkit User Manual PLC CENTRAL Another important feature of PLC033 is its ability to function as a PLC central The PLC Central feature enables the PLC033 to poll remote DFS RTUs in addition to local modules and local Modbus compatible I O PLC Central can be a secondary function of the PLC033 or its primary function The PLC033 s mode is determined by the value of Special Function Register Comm 2 DFS Central Mode When the register is true PLC033 functions as a PLC central As a secondary function limp or backup mode the PLC033 can temporarily switch to PLC Central mode when it determines that communications with the HyperTAC II central have been lost This mode uses two timers that are inserted in the PLC033 s ladder logic program that instruct the PLCO33 when it should switch to PLC Central Mode Comm 2 DFS Central Mode is set to true and when it should return to normal operation Comm 2 DFS Central Mode is set to false to check if communications with the HyperTAC central have been restored For RTU systems that require a centralized site for logic but aren t large enough to warrant a HyperTAC II central site the PLC033 can be forced to perma
18. your ladder that would turn on the Remote Process Stop Command register when a certain condition occurred The ladder could be restarted by pressing the Shutdown button for several seconds or via telemetry through a control mapped to the Remote Process Start Command register ADVANCED TROUBLESHOOTI NG TOOLS PMT s Communication Tools choose Comm Tools from the Tools menu is a suite of advanced troubleshooting tools for use by DFS Service personnel 39 Notes 40 Appendix APPLICATION NOTES USING REMOTE DFS I O A LADDER When creating a ladder to control a station or run a process you may find it necessary to evaluate a condition at another site in order to make a decision For example a tank level at station 1 determines when a pump at station 35 goes on Getting the information into your ladder requires that you create a logical digital or analog input that will hold the value of the I O from the other station These objects are by definition inputs to the ladder from either a user or another I O point Any VO point that needs to be directly writeable from outside of the ladder must be assigned to the writeable register ranges As a result the logical input discussed above must be assigned to an unused register in either the 40001 49999 range analog or 1 9999 range digital The logical input created in the ladder must then be mapped to an analog digital module point in the DFS radio map A
19. 033 To prevent static damage put on an electrostatic discharge wrist strap before touching any of the PLC033 s electronic components In addition to the preceding precautions the following steps can be taken to prevent damage from electrostatic discharge ESD e When unpacking a static sensitive component from its shipping carton do not remove the component antistatic packing material until ready to install the component in the PLC033 Be sure to put on an electrostatic discharge wrist strap before unwrapping the antistatic packaging e When transporting a sensitive component first place it in an antistatic container or packaging e Handle all sensitive components in a static safe area Place the equipment on a grounded surface If possible use antistatic floor pads and workbench pads Note Contact DFS if electrostatic discharge packaging is needed for return shipments See Return Authorization RA Procedure p 53 for more information on returning equipment RECEIPT OF EQUIPMENT When equipment is received examine the outside of the carton for any damage incurred during shipment Remove the packing list and the equipment from the shipping carton Carefully inspect the equipment for damage Resolve any damage with the local carrier Report damages to Data Flow Systems 321 259 5009 Include the serial number of the unit and the extent of damage in your report 12 Chapter 3 PRINCIPLES OF OPERATION The PLC033 is a powerfu
20. 2 device or multiple RS 485 devices The PLCO33 can communicate with these devices using either Modbus ASCII or Modbus RTU protocol TYPICAL I NSTALLATI ON In a typical installation the PLC033 is installed between the RIM Radio Interface Module and up to 15 DFS function modules The PLC033 uses the Radio Bus to communicate with the RIM and the Module Bus to communicate with the DFS function modules Once installed in the RTU the PLC033 automatically communicates with the other DFS function modules over the Module Bus getting their status and updating their outputs according to the ladder logic program It communicates with the central site via the RIM interface relaying status and control information It can also simulate logical analog and digital modules to allow the PLC033 s program to interact with the SCADA system EMULATE MULTIPLE DFS RTUS The PLC033 can emulate up to two RTUs This allows developers to exceed the 15 module maximum for DFS RTUs This is accomplished in PMT s Mapper by right clicking the main branch of the Radio Map and selecting Add Remote Device This remote device can accommodate up to 15 DFS modules The Remote Device Number should be the next station number after the physical address of the station the PLC is installed in for example if the PLC is in RTU 17 then add remote device 18 in the Radio Map When configuring the remote device emulated station In HyperTAC the remote device s RIM
21. 3 s ladder logic program that instruct the PLCO33 when it should switch to PLC Central Mode Comm 2 DFS Central Mode is set to true and when it should return to normal operation Comm 2 DFS Central Mode is set to false to check if communications with the HyperTAC II central have been restored For RTU systems that require a centralized site for logic but aren t large enough to warrant a HyperTAC II central site the 033 can be forced to permanently stay in PLC Central mode by setting and keeping the Comm 2 DFS Central Mode register at a true value in the PLC033 s ladder logic program FEATURES e 33 MIP ARM processor with 8M of Flash ROM and 16M of RAM 1200 or 9600 baud communications with II devices e Up to 38 4 Kbps with external RS 232 RS 485 devices using Modbus RTU or ASCII protocol e PLC Central functionality Modbus TCP and DFS NIM RTU based communications via Ethernet interface e Real time clock for time of day functions e Monitors its own power source and saves accumulated data when a power failure is detected e Communicates with master or slave devices via serial port that can be used in RS 232 or 485 mode e Programmed using ladder logic Logic Builder Program stored in Non Volatile memory e Communication and I O parameters configured with user friendly interface I O Builder e Custom status and control screens can be created using supplied software Screen Builder e Shutdown button enables graceful shutdo
22. 999 31001 31999 41001 41999 System generated logical I O 2000 9799 12000 32000 42000 49799 Reserved set point registers 9800 9899 49800 49899 Special Function Registers 9900 49900 Add and configure the physical I O using I O Builder Discussed in the Process Management Toolkit User Manual Map the physical I O into the appropriate register ranges using the Register Map Discussed in the Process Management Toolkit User Manual Transfer the mapped I O to the PLC Discussed in the Process Management Toolkit User Manual Create a ladder logic program that can locally control the hardware monitor status make decisions perform calculations etc Install the ladder in temporary memory during testing When everything is working correctly flash it to permanent memory Discussed in the Process Management Toolkit User Manual Map logical I O into the DFS Radio Map and transfer it to the PLC Note that it isn t necessary to map all of the logical I O only the I O that will be sent over the radio link Discussed in the Process Management Toolkit User Manual Create custom screens that enable users to view the status of equipment or control set points Discussed in the Process Management Toolkit User Manual 21 Notes 22 Chapter 5 HARDWARE INSTALLATION INSTALLING THE PLCO33 n THE RTU The PLC033 must be installed in a specially designed DFS RTU In a PLC capable RTU the mo
23. ARTS 100Base T Network Surge Arrestor Part No 002 0279 49 Notes 50 Appendix E RELEASE NOTES March 7 2008 Release New Features 5 PLC033 can now emulate up to two DFS RTUS This allows developers to exceed the 15 module maximum for DFS RTUs This is accomplished in the Radio Map by right clicking the main branch and selecting Add Remote Device It is recommended that you choose the next station number after the physical address of the station the PLC is installed in and that you configure the second station s RIM type as 004 in HyperTAC II e g If the PLC is in 17 then add remote device 18 in the Radio Map The RTU will now respond as station 17 and 18 in HyperTAC II The PLC033 and RDP180 now have a configurable Modbus slave device address for serial slave function This is configured in the settings panel of PMT as the Slave Device Prior to this change the PLC RDP would respond to any serial messaging This feature allows the PLC RDP to operate as a serial slave device on 485 or radio networks where there is more than one slave device System variable addresses can now be obtained from logic builder This is accomplished by right clicking the desired object Previously there was no easy way of determining what address the builder had assigned un addressed objects in the ladder The PMT is now the tool used to update the RNA110 This is accomplished by selecting Updated RNA from
24. DFS Radio Mapping Register Bit Shifting Options in the Process Management Toolkit User Manual PROGRAMMING INTERFACE The PLC033 s Ethernet port is its interface to the Process Management Toolkit PMT a suite of applications used to configure program and test the PLC033 When interfacing with the PMT the PLC033 can be accessed using a closed network This 15 accomplished by directly connecting the PLC033 to a laptop or desktop computer using an Ethernet crossover cable With a closed network the PLC033 s network settings can be left at the default IP address of 192 168 1 10 Note that if the PLC033 is going to be configured programmed or polled over the network it requires its own unique network IP address More information on PLC IP addressing can be found in Chapter 5 Hardware Installation in the section titled PLC Network Settings beginning on page 27 as well as in the Process Management Toolkit User Manual PROGRAMMED WI TH LADDER LOGIC The PLC033 is programmed using Logic Builder a user friendly application that enables you to construct ladder logic style programs that manage complex control functions Ladder logic is a graphical symbols and text language that is used to plan maintain and control industrial systems Each rung of the ladder hence the name ladder logic is used to control a single output The results of these graphical programs are logical points and auto controls that are continuously sc
25. Local I O Fault R R 9950 Comm 1 DFS Central Mode RW R 9957 Comm 8 DFS Central Mode RW R 49900 Local Analog Input Power Supply R R Voltage 49901 OS Free Memory R R 49902 Maximum Ladder Loop Time R R DFS 00507 011 01 Chapter 1 Product Overview Address Function Ladder R W Remote R W 49903 Average Ladder Loop Time R R 49904 Minimum Ladder Loop Time R R 49905 Maximum I O Loop Time R R 49906 Average Loop Time R R 49907 Minimum V O Loop Time R R 49908 Hardware Model R R 49909 Hardware Revision R R 49910 Software Version Year R R 49911 Software Version Month R R 49912 Software Version Day R R 49913 OS Version Year R R 49914 OS Version Month R R 49915 OS Version Day R R 49916 Serial Number High R R 49917 Serial Number Low R R 49918 Network Address Octet 4 R R 49919 Ladder Process ID RW R 49920 Ladder Process Version Year RW R 49921 Ladder Process Version Month RW R 49922 Ladder Process Version Day RW R 49950 Comm 1 Time Since Last Comm secs RW R 49957 Comm 8 Time Since Last Comm RW R 49999 Remote Reset data must be 0xA5A5 R RW Installation and Operation Manual 6033 PLCO33 P n DESCRIPTIONS LOCAL MODULES SYSTEM DC VOLTAGE LOCAL MODULES SYSTEM GROUND LOCAL MODULES POWER DOWN LOCAL MODULES REQUEST TO SEND LOCAL MODULES CLEAR TO SEND LOCAL MODULES RECEIVE DATA LOCAL
26. RTU Test 2 Launch WinRTU Test 3 Set WinRTU s communication settings by selecting Comm from the Config menu Communication Settings EIER Settings Port Baud IP Address Stop 1200 7 f2 Repeat Time 1 Sec s Cancel OK For Port select the serial port on the computer to which the RIM is connected Select 1200 for baud rate Verify that data bits is set to 7 parity is set to Odd and stop bits is set to 2 Click OK 4 Select ROM Patch from the Form menu Click Query WinRTU Test Rz 00Rm8C80401 1 x Patch Station A gt Module 4 Reset Module Model RIMOO6 S N 123456789 Query Hardware Rev Erase Patch Current ROM 12 08 05 Patch Module Current PATCH Patch Station Latest PATCH Fateh System Messages will appear in the Tx and Rx fields as WinRTU Test begins communicating with the RIM After a few seconds the Model number serial number and Current ROM will appear in the form Verify that the model is RIM006 and the Current ROM is 12 08 05 or later USE HYPERTAC IT S TELEMETRY TRAFFIC TOOL If the is online and can be accessed via telemetry you can launch HyperTAC II s Telemetry Traffic tool and query the station for its version 1 Enter RTU s station number in the Station box and enter R in the module box 2 Click Start to begin communicating with the station 3 When you see that messages are being rec
27. ackplane A device connected to the 12VDC backplane bus could also be the source of a blown fuse Keep in mind when connecting devices to the backplane bus that it is fused at 10amp The fuse itself including its age an internal defect or heat build up due to bad connections should also be considered If you need assistance with this process contact DFS Service Department 32 RIM LOCKED IN TRANSMI T MODE The RIM used in a PLC033 RTU must be a RIMO06 model and have ROM code version 12 08 05 or newer installed If the RIM doesn t meet these specifications no communications will take place between the PLC033 and the radio The RIM will appear to be locked in transmit mode when observing its transmit LED the LED will be constantly on Additionally abort messages will appear when radio traffic is monitored using HyperTAC II s Radio Traffic Tool To verify that the RIM has the latest ROM code installed use HyperTAC 5 Radio Traffic Tool to query the RIM for its version The version must be 12 08 05 or later If you have an older version of ROM code contact DFS Service Department to arrange an upgrade CONNECTI ON REFUSED If you receive a connection refused error when trying to connect to a PLC033 from the Process Management Toolkit PMT first verify that the correct IP was entered in the Target File gt Target and Settings File gt Settings dialog boxes and that you can ping the IP If the IP address is corr
28. anned by the system The speed of the scanning process enables you to have the most up to date information which in turn allows you to react to situations quickly and efficiently In traditional ladder logic the values that flow along rungs and branches are strictly logical 0 or 1 DFS Logic Builder provides the extra flexibility of allowing rungs and branches to hold numeric values for example the results of math operations such as ADD and MAXIMUM and inputs from analog points After a ladder logic program has been built and installed its logical points and auto controls can be used in custom screens graphical representations of your process control system that can be used to remotely monitor and control your system MONITOR AND CONTROL VIA CUSTOM SCREENS Graphical representations of your process control system can be created using the Screen Builder application Building a screen using text images objects and animation and linking the screen s components to real or logical I O enable you to get a real time view of your operation as well as control processes from a remote location For example you can build a screen that shows the flow of a pump or the level in a well and then use the device s address register to link it to the real field hardware This linking lets you create a virtual picture of how the equipment is operating the screen mimics the activity of the equipment It also enables you to control devices
29. ctory the Target IP is 192 168 1 10 the factory default For a PLC that has been configured the Target IP will be the IP specified in the Settings dialog Note that if the PLC hasn t been used as a network device then the destination IP the address specified in the Settings dialog is the factory default 192 168 1 10 unless this was changed by someone configuring the PLC Normally the IP addresses specified in Target and Settings will be identical However when you are first setting up a network bound PLC the IP addresses will be different In the Settings dialog you will enter the IP that you network administrator assigned to the PLC its destination IP In the Target dialog you will enter the PLC s current IP the factory default 192 168 1 10 This allows you to tell the PLC what its IP address will be while communicating with the PLC using its current Target IP address Another scenario where the Target and Settings IP could be different is if you needed to move the PLC to another IP address on your network You would set the Target IP equal to the PLC s current address and then provide the PLC with its new destination IP address via the Settings dialog MODBUS SERIAL MASTER SLAVE INTERFACE PLC033 features three serial ports One of these COMI can be used in either RS 232 or RS 485 mode to communicate with external serial master or slave devices The PLC033 can communicate with these devices using either Modbus ASCII or M
30. der logic 7 programming interface 7 requirements 3 set points AKA points 14 shutdown controlled 18 39 support of multiple protocols 16 57 typical installation 13 parts furnished 51 optional 51 pins descriptions 9 PLC by pass card 26 PLC Central 4 14 implementing 45 47 PLC033 description 3 4 features 4 installing safety precautions 11 12 IP address determining 36 37 pin desciptions 9 reset to factory default state 38 PMT See Process Management Toolkit principles of operation See operations overview Process Management Toolkit 77 connection refused error 35 processor type 4 programming interface See Process Management Toolkit protocols availabe for communication 5 protocols supported 16 Q points See set points quick start guide 2 radio acceptable models 23 checking ROM version 24 26 on ROM chip label 24 using telemetry traffic tool 25 26 using WinRTU Test software 25 RAM 4 register special function 7 8 registers reserved set point 6 7 release notes 53 54 remote DFS I O using in ladder logic 43 45 RIM locked in transmit mode 35 ROM 4 RTU multiple emulating 3 14 RTU installation of PLC033 23 RTU requirements 3 safety protecting against electrostatic discharge 12 serial Modbus communication troubleshooting loss of 33 34 serial interface 27 28 serial interfaces 5 serial port 3 service obtaining 55 set poin
31. dicate the PLC033 has been started in reset mode continued on next page Installation and Operation Manual 6033 34 IMPORTANT Do not remove the jumper while the PLC033 is powered This will result in the PLC033 being reset to its factory default state All configurations will be deleted and the IP address will be reset to 192 168 1 10 6 The PLCO33 s IP address should be displayed on the terminal program s screen along with the message Reset to Factory Default on Jumper Removal 7 When the PLCO33 s IP address has been verified power down the PLC033 and then remove the jumper 35 Appendix A Testing and Troubleshooting RESET PLCO33 TO FACTORY DEFAULT STATE It is possible to reset the PLC033 to its factory default state When this is done all of the configurations including the ladder program are deleted and the PLC033 s IP is reset to the default IP address of 192 168 1 10 1 Power down the PLC033 by turning off the Power Supply Module PSM 2 Remove the module from the backplane and place a jumper on pin JP7 FACTORY PIN JP7 FACTORY Figure 5 5 Pin JP7 FACTORY 3 With the jumper in place power up the PLC033 Observe the status LED The blinking pattern will be 8 quick flashes followed by a pause to indicate the PLC033 has been started in reset mode 4 Remove the jumper with the PLC033 still powered Observe the status LED The blinking pattern will be 5 quick flashes followed by a pause to
32. dular backplane MBP has been modified to separate the signals that go between the 033 and the Radio Interface Module RIM referred to as the Radio Bus and the 033 and the local function modules including modules in a separate enclosure connected with 0015 referred to as the Module Bus The hardware installation of PLC module into an RTU is slightly different than that of a regular I O function module Any LOCAL modules including modules in a separate enclosure connected with 0015 that need to be monitored or controlled by the PLC must be connected to the communications bus of the PLC but separated from the communications bus of the Radio Interface Module RIM The PLC033 and all other modules installed in the RTU s modular backplane get their power from the RTU s power supply module via the bus The PLC033 is wired into an RTU typically between the Radio Interface Module RIM and up to 15 other local modules Normally the PLC033 is located in the slot just to the left of the RIM and only one PLCO33 may reside in each RTU Consult DFS Engineering personnel for proper integration information if variations to this standard installation are required I MPORTANT The RIM used in a PLC033 RTU must be a RIM006 model and have a ROM version of 12 08 05 or later unless the PLCO33 will be communicating solely over the network in which case an RS 232 RIM RIM without a radio installed is placed in the RIM slot For
33. dules but messages are coming in the problem may lie with the module bus or with the module itself 1 Opena Telnet connection by selecting Run from the Windows Start menu and typing telnet xxx xxx xxx xxx 504 Where xxx xxx xxx xxx 15 the PLC s IP address followed by 504 the network port for this Telnet application If you are using a closed network to connect to the PLC033 crossover cable between the PLC033 and the computer change the network settings for your computer so that it is on the same network as the PLC For example if the PLC was at the factory default IP 192 168 1 10 you could set your computer to 192 168 1 101 and telnet to 192 168 1 10 Type the name of a program folder document or Internet resource and Windows will open it for you Open telnet 192 168 10 175 504 OK Cancel Browse 2 Click OK to open a Telnet connection A Telnet window opens with instructions for testing the radio backplane the module backplane or Modbus port Telnet 192 168 10 175 Enter R for Radio B for Backplane or M for Modhus continued on next page 29 and press the Enter key You should begin seeing transmitted messages and responses Transmitted messages messages sent from the PLC to the module bus are green in color and are preceded by a left pointing carat lt Responses messages sent from the module bus to the PLC
34. e customer STEP 4 Address the box to RA Department the RA number you received here Data Flow Systems Inc 605 N John Rodes Blvd Melbourne FL 32934 9105 STEP 5 Ship the box to DFS using any typical shipping carrier for example UPS FedEx etc If circumstances permit have a DFS employee hand carry the package to the headquarters for you NOTE DFS employees are not permitted to hand carry unpacked modules Modules are typically repaired and shipped back to the customer within a 2 week period starting at the time the module reaches the RA Department If additional information is required during the repair of the module s the DFS service department will contact you To get information on the progress of any of your equipment in for repair contact the DFS RA Department at rma dataflowsys com or 321 259 5009 Replacement of equipment may be necessary in the event that the equipment and or parts are unrepairable Warranty equipment will be replaced with out prior notification as warranty replacement The customer will be notified by phone if equipment not under warranty cannot be repaired with information of available options DFS reserve the right to return any material received without an RA or not conforming to the requirements of this RA process 54 WARRANTY Data Flow Systems Inc DFS offers a one 1 year on site warranty covering defects in materials and workmanship All DFS plug in function mod
35. ect and the ping was successful the issue may be caused by personal firewall software installed on your computer If a firewall is present you must either add the PMT software to the firewall s list of approved programs or add the IP address of the PLC033 to the list of trusted networks Without these settings the firewall may not allow Java the language on which PMT is built to connect to the PLC033 s IP address 33 Appendix A Testing and Troubleshooting BROADCAST PLCO33 IP If you need to find out the IP address to which the PLC033 is set you can have it broadcast the IP and view the results in a terminal program such as Hyper Terminal This may be necessary if you ve forgotten the PLC033 s IP The only solution in that case is to either have the PLC033 broadcast its IP or reset the PLC033 to its factory default state see Reset PLC033 to Factory Default State on page 36 1 Power down the PLC033 by turning off the Power Supply Module PSM 2 Remove the module from the backplane and place a jumper on pin JP7 FACTORY PIN JP7 FACTORY 3 Using a service cable connect a laptop to the PLC033 s service port 4 Start aterminal program session e g Hyper Terminal Bits per second 38400 Databits 8 Parity None e Stop bits 1 e Flow control None 5 With the jumper in place power up the PLC033 Observe the status LED The blinking pattern will be 8 quick flashes followed by a pause to in
36. eived from the station green messages click the Version button You should see a blue message requesting version Message Requesting DFS 00507 011 01 25 version for X where X represents the station number Shortly thereafter you should see a response Reply 0XRr 006 12 08 05 where X represents the station number Priority Log Filter Inject Control Convert station and comm addresses Station Hex Convert Inject a telemetry message Inject Poll a DFS station and module for status or version Station Module Send 021100C 2 R Version Status Start Hdriver v Figure 5 2 Check Radio ROM Version from HyperTAC II PLC By Pass CARD The PLC By Pass Card may be used in order to test basic module polling and control status wiring of the modules in an RTU configured for use with a PLC The PLC By Pass Card is a static hardware device that allows the communications bus ofthe RIM to be reconnected to the module communication bus Once the By Pass Card is installed into the PLC card edge connector the RTU will function identical to that of a standard 1 with the I O modules connected directly to the RIM Refer to the WinRTU Test Manual for testing basic control and status signals wired into DFS function modules NETWORK INTERFACE The PLC033 features a 10 100base T network interface This Ethernet port is used when configuring and programming the PLC In additio
37. ements If you are unsure of whom to contact call DFS Melbourne headquarters at 321 259 5009 and ask for the Sales Department Alternatively send email to sales dataflowsys com TECHNICAL PRODUCT ASSISTANCE Please review the information in Appendix A Testing and Troubleshooting before contacting Data Flow Systems Inc If you need further assistance contact your local Data Flow Systems representative If you are unsure of whom to contact call DFS Melbourne headquarters at 321 259 5009 and ask for the Service Department Alternatively send email to service dataflowsys com RETURN AUTHORIZATI ON RA PROCEDURE Data Flow Systems function modules are designed to be robust and highly reliable We back this performance with a 3 year full warranty see our warranty statement for details In the event that a function module fails during or after the warranty period it may be returned to Data Flow Systems to be repaired or replaced RA s will be subject to standard shipping and handling charges Minimum handling charge will be assessed in most cases for work such as Radio Tuning Backplanes No Problem Found and other minor repairs Handling charges will be waved on warranty equipment Standard shipping and charges will be based on UPS ground please advise if other arrangements are needed UPS Red FedEx Pickup Freight Standard cost of repairs and shipping charges can be obtained by contacting our RA Department by phone o
38. es the Modbus RTU or ASCII protocols When configuring this port 1 e Modbus driver in PMT s Configuration Editor you must select either SERIAL MASTER or SERIAL SLAVE for the TYPE option Configuration Editor will only allow the addition of devices and I O under a Modbus driver when TYPE is set to SERIAL MASTER When this port has been configured as a serial slave it cannot be used as a serial master The functionality of this port is not switchable as is the PLC Central feature The port s function can only be modified by changing the TYPE setting SUPPORTS MULTI PLE PROTOCOLS At its core the PLC033 is a Modbus device Modbus is an industry standard protocol and as such enables the PLC033 to communicate with any third party Modbus devices including Open Control Solutions RIO128 and RIO032 rail mounted I O devices The PLC033 is able to support both DFS and Modbus protocols through a process called mapping In mapping each physical I O point is assigned to a unique register in the PLC033 s Logical Memory Map The Logical Memory Map is comprised of four register ranges Type Register Range Digital Outputs Coils 00001 09999 Digital Inputs Discrete Inputs 10001 19999 Analog Inputs Input Registers 30001 39999 Analog Outputs Holding Registers 40001 49999 MAPPING The physical I O of local DFS function modules as well as the I O of any external Modbus compatible devices must be mapped This en
39. essages sent from HyperTAC II Like other I O Q points can be used in ladders and in custom screens It is important to note that Q points are not designed to be used as status points In HyperTAC II they are not polled as often as normal I O doing so would negatively impact the polling loop However as a set point variable the control is acted on immediately To add Q points to an existing PLC project you must chang the project type to RDP and then change it back to PLC If you have I O in the Logical Memory Map that is mapped to the registers assigned to Q points they will not be overwritten The points will be placed around the taken registers and will always start at an even register number Like the reserved set point registers set aside for storing user set point values discussed on page 6 Point values are automatically saved to the PLC033 s flash memory every 30 seconds and also during a controlled shutdown These stored values are loaded when the process resumes NETWORK SLAVE DEVICE In addition to being a programming interface the PLC033 s Ethernet port enables it to function as a network slave device using either DFS NIM RTU protocol or Modbus TCP protocol As a DFS NIM RTU slave the PLC033 can be polled by a HyperTAC II central over the network This feature can be used simultaneously with radio polling so that one RTU can be polled from two different systems one on the network and one over the radio lin
40. et 033 38 features of PLC033 4 firmware updating 49 getting started 27 remote using in ladder logic 43 45 T O mapping 16 installation typical 13 installign the 033 network interface IP address 27 installing the PLC033 cables and connectors how to connect and disconnect 11 network interface 26 27 PLC by pass card 26 protecting against electrostatic discharge 12 radio acceptable models 23 RTU installation 23 safety precautions 11 12 serial interface 27 28 typical installation 3 interface description 6 IP address determining for PLC033 using broadcast function 36 37 ladder logic 17 remote DFS I O 43 45 shutdown 4 due to low battery voltage 39 using shutdown button 40 using special function registers in logic 1 LEDs 5 logical I O 13 mapping I O 16 Modbus serial master 3 Modbus serial master slave device 16 Modbus serial master slave interface 27 28 Modbus serial slave 3 Modbus TCP protocol 3 Modbus TCP slave 3 15 module communication troubleshooting loss of 32 module power troubleshooting loss of 34 multiple RTUs emulating 3 14 network interface 5 26 27 IP address 27 network slave device 3 15 NIM RTU protocol 3 RTU slave 3 15 operations overview 13 18 custom screens for monitor and control 18 I O mapping 16 logical I O 13 Modbus serial master slave device 16 network slave device 5 PLC Central 14 programmed with lad
41. from a remote location For example a screen with an On Off button that is linked to a pump motor can be used to start or stop a pump CONTROLLED SHUTDOWN The following events initiate a controlled shutdown e f voltage in the panel falls to 11 2 volts the PLC s operating system will initiate the shutdown without user intervention e Press the shutdown button on the PLC to manually stop the process e Use Special Function Registers Remote Process Start Command 9920 and Remote Process Stop Command 9921 to shutdown the process from a remote location For example you could map these registers to a DFS module point in the PLC s DFS Radio Map and configure the same point in HT3 The registers could then be controlled from a custom screen or a default screen 18 Chapter 3 Principles of Operation TYPICAL DFS RTU PLCO33 APPLICATION Screen Status Viewer Third Party Modbus HMI Modbus TCP Protocol no map required Modbus TCP Protocol no map required Network Config Config Editor Editor 00000 1 bit wide 09999 10001 DFS Radio Map DI DFS TAC II Modules Module A 1 bit wide 19999 Module Point 1 Point 1 Pot 2 30001 2 Point 3 Al Point 3 Module Module Pont 1 DFS TAC II Protocol 16 bit wide 39999 1 Point 2 Point 2 Point 3 40001 Point 3 H Module Module AO 49999 DFS TAC II Protocol 16 bi
42. ith the RIM and the Module Bus to communicate with the DFS function modules Once installed in the the PLC033 communicates with configured DFS function modules over the Module Bus getting their status and updating their outputs according to the ladder logic program It communicates with the central site via the RIM interface relaying status and control information It can also simulate logical analog and digital modules to allow PLC033 s program to interact with the SCADA system The PLC033 can emulate up to two RTUs This allows developers to exceed the 15 module maximum for DFS RTUs This is accomplished by adding a remote device to PMT s Radio Map and configuring the remote device station in HyperTAC II Refer to the Process Management Toolkit User Manual The PLC033 features an Ethernet port and a serial port either RS 232 or RS 485 that can be used to expand the PLC033 s functionality In addition to being the PLC033 s programming interface the Ethernet port enables the PLC033 to function as a network slave device using either DFS NIM RTU protocol or Modbus TCP protocol As a DFS NIM RTU slave the PLC033 can be polled by a HyperTAC II central over the network This feature can be used simultaneously with radio polling so that one RTU can be polled from two different systems one on the network and one over the radio link Alternatively the PLC033 can function solely as a network device by placing an RS 232 RIM
43. k Alternatively the PLC033 can function solely as a network device by placing an RS 232 RIM RIM board without the radio installed in the RTU and polling the PLC033 from the HyperTAC II central using the DFS NIM protocol There is no additional configuration required to implement either of these functions The PLC033 will automatically respond to network queries as well as radio requests if the DFS Radio Map is configured explained in more detail in I O Mapping on page 16 Note that the DFS NIM RTU interface uses the radio map there is not a separate map for using network communications Modbus TCP slave the PLC033 can be polled by any Modbus compatible software that uses the Modbus TCP protocol The PLC033 requires its own unique network IP address in order for it to be polled over the network Refer to the section titled PLC Network Settings in Chapter 5 Hardware Installation beginning on page 27 as well as the Process Management Toolkit User Manual for more information on PLC033 IP addressing MODBUS SERIAL MASTER SLAVE DEVICE The PLC033 can function as a Modbus RTU ASCII serial master or slave device via its COMI serial port As a Modbus serial master the PLC033 can poll a single Modbus compatible RS 232 device or multiple Modbus compatible RS 485 devices via its COMI serial port using either the Modbus RTU or ASCII protocol As a Modbus serial slave the PLC033 can be polled by any Modbus compatible software that us
44. l programmable logic controller that can be installed in a DFS Remote Terminal Unit RTU This microprocessor controlled unit is designed for implementing local logical control at the RTU via an installed ladder logic program Users configure the PLC033 s I O and communication settings and create the ladder logic program using the applications included in the supplied Process Management Toolkit PMT software I NSTALLED IN SPECIALLY DESIGNED RTU The PLC033 must be installed in a specially designed RTU one with a modular backplane MBP that has been modified to split the communications bus into two entities the Radio Bus and the Module Bus The MBP is a printed circuit board composed of card edge connectors for the modules module bus circuitry and a connection for the back up battery The PLC033 and all other DFS plug in function modules used in the system are plugged into card edge connectors mounted on the RTU s MBP LOGICAL 1 The PLC033 itself doesn t any physical I O it is strictly a programmable device that polls external and responds to polls from a central site and then performs logic on this data using an installed ladder logic program The PLC033 polls the I O on the Module Bus 1 up to 15 local DFS function modules as well as the VO of any Modbus compatible devices connected to the PLC033 s COMI port The COMI port can be used in either RS 232 or RS 485 mode which enables it to support a single RS 23
45. n analog digital output will then be configured in HyperTAC as an auto control that is controlled by the real I O at the other station In our example a logical analog input would be created in the ladder This logical input would represent the tank level at station 1 It would be assigned to a register in the 40000 range for example 41001 F Logic Builder File Edit Ladder Digital Analog Math Compare Time Date Help Get remote data 5 Stn 1 Tank Level 1 41001 DFS RADIO MAPPING UTILITY lt lt TRANSFER C3 DFS RTU 1 GjAnalog Outputs Ga 001 9 41001 Stn 1 Tank Level 1 1 41001 1 49900 Local Analog Input P S Voltage 1 1 49900 35 2 1 32 49901 OS Free Memory 1 1 49901 1 2 i 1 32 49902 Maximum Ladder Loop Time 1 1 49902 X 4A0 1 32 49903 Average Ladder Loop Time 1 1 49903 B NONE 3 49904 Minimum Ladder Loop Time 1 1 49904 3 NONE 3 49905 Maximum I O Loop Time 1 1 49905 D NONE a 3 49906 Average VO Loop Time 1 1 49906 NONE 5 49907 Minimum NO Loop Time 1 1 49907 NONE 2 32 49909 Hardware Revision 1 1 49909 32 G NONE 32 49910 Software Version Year 1 1 49910 A i 49911 Sofware Version Mnnth 1 1 4991114 Mode DFS RADIO MAPPING UTILITY 41 Appendix Application Notes On the HyperTAC side you would crea
46. n to being the PLC033 s programming interface the Ethernet port enables the PLC033 to function as a network slave device using either DFS NIM RTU protocol or Modbus TCP protocol standard network crossover cable with RJ 45 connectors is all that is needed in most cases to connect the PLC to a computer However if the PLC is going to stay on the network permanently we recommend that you install a 100Base T Network Surge Arrestor which can be ordered from Data Flow Systems DFS Part No 002 0279 26 PLC NETWORK SETTINGS The PLC must be on a network either a local area network LAN or a closed network to be configured and programmed When a PLC leaves the factory it is set to a default IP address of 192 168 1 10 PLCs that will be using a radio link to communicate can be left at this default setting However if a PLC is going to be a network device your network administrator must assign it a unique network IP address The PLC is configured with this assigned destination IP address via the Settings dialog box in the Process Management Toolkit select File from the Settings menu If the PLC isn t going to be a network device leave the destination IP at the factory default setting A second IP setting the Target IP select File from the Process Management Toolkit s Target menu is only used when installing and retrieving configurations The Target IP is the PLC s current IP For a PLC that has just arrived from the fa
47. nently stay in PLC Central mode by setting and keeping the Comm 2 DFS Central Mode register at a true value in the PLC033 s ladder logic program This function is discussed in more detail in Appendix B Application Notes in the section titled Implement PLC Central Function beginning on page 43 SET POINT VARIABLES Q POINTS points named as such because they always reside at module address Q HyperTAC II s Configuration Editor are used to create user set point variables beyond the PLC s 15 module limit Q points allow you to access and use the PLC s 168 free unused memory locations Q points are non scaled 32 bit floating point values that are readable and writable over telemetry via DFS radio or network NIM protocol The Q point registers reside in the 49000 range beginning at register 49464 and ending at register 49798 Because Q points are 32 bit floating point values each point 14 requires two registers each point begins on an even register e g point number 50 resides at registers 49562 and 49563 points do not have to be configured in I O Builder 168 points are automatically added to the Logical Memory Map when a PLC project is created Each point is given a label that begins with the letter Q e g Q1 Q2 Q3 etc Additionally they do not have to be mapped from the Logical Memory Map into the DFS Radio Map Q points are mapped internally and respond to specially formatted m
48. odbus RTU protocol When used as a Modbus serial master PLC033 can support a single RS 232 slave device or multiple RS 485 slave devices For RS 232 mode use pins 1 3 5 7 and 9 For RS 485 mode use Pins 11 13 and 15 Review the drawings below and on the next page before connecting a device to the COMI part I MPORTANT Do not use the PLC s RS 232 service port when connecting to a serial master or slave device The service port is for use by DFS personnel only 27 RS 232 NOTES 1 RTS request to send and CTS clear to send connections are required to enable hardware flow control 2 If a 3 wire interface is required jumper RTS to CTS on both ends of the cable Figure 5 3 Wiring RS 232 Interface 1 The cable shield wire must only be grounded at one end as close as possible to the selected end 2 Requires 150 200 ohm resistor resistors should only be placed at the extreme ends of the RS 485 network Figure 5 4 Wiring RS 485 Interface 28 Appendix A TESTING AND TROUBLESHOOTING No COMMUNICATION TO FUNCTION MODULES If you are having problems communicating from the PLC033 down the bus to the function modules you can perform a data tap to determine if the problem is hardware related A data tap is performed using a standard Telnet connection It enables you to view outgoing and incoming messages from the PLC master to the modules If messages are going out from the PLC033 to the function mo
49. r e mail STEP 1 Replace the failed module with a spare module of the same type if one is available STEP 2 Contact Data Flow Systems Inc in one of the following ways to receive an RAF E mail An RA can be obtained by e mailing DFS at rma dataflowsys com and must include the following information e Customer Utility Name and Ship to Address e Contact Name and Phone Number 53 e Products to be returned and Serial Numbers Detailed description of failure e Phone RA will be issued over the phone by calling DFS at 321 259 5009 during normal operating hours The following information will be needed Customer Utility Name and Ship to Address Contact Name and Phone Number Products to be returned and Serial Numbers Detailed description of failure PO Note The lack of Detailed description of failure could result in the return of equipment due to the inability to properly determine the nature of the failure or testing resulting in No Problem Found STEP 3 Place the function module s individually in an electrostatic discharge bag and then wrap with foam or bubble wrap Pack the wrapped module s in a sturdy box filled with popcorn type or bubble wrap packing material Include a packing slip with the following information Module s model serial number probable cause of failure and the RA number e Shipping address e Shipping instructions shipping costs greater than UPS ground are charged to th
50. red in this case the PLC033 itself sets register 9930 to false To restart the ladder simply hold down the shutdown button again This sends a signal to the PLC033 to turn on both the Remote Process Start Command register Special Function Register 9920 and the Remote Process Running register Special Function Register 9930 The PLC033 then starts running the ladder again Loci 6 The PLC033 s ladder can be stopped and started using logic via the Remote Process Special Function Registers e Remote Process Start Command register 9920 e Remote Process Stop Command register 9921 e Remote Process Running register 9930 For example you could create controls on HyperTAC II that were mapped to registers 9920 and 9921 This would allow you to turn a ladder off and on from a remote location over the radio telemetry link When the ladder sensed that the Remote Process Stop Command register was true it could initiate Installation and Operation Manual 6033 38 actions to put the station in a safe state for shutdown The ladder would then be programmed to turn off the Remote Process Running register which lets the 033 know that it is safe to shutdown the ladder However if PLC033 doesn t see that the Remote Process Running register has been turned off within 30 seconds of the Remote Process Stop Command coming on it will turn off the register and stop the process on its own You could also have a section in
51. rt Shutdown Power Up Button LED 0 DS12 Programmable LED 1 DS11 SI LEDs LED 2 DS10 ER LED 3 059 Radio Receive Data RRX B Radio Transmit Data RTX Status STAT EN Card Edge Connector CPU Failure FLT Defined Module Receive Data MRX LEDs I Module Transmit Data MTX Hs Power PWR a L Network Status LINK TI Ethernet Port Figure 1 1 PLC033 Interface RESERVED SET POINT REGISTERS Blocks of registers in the DO and AO ranges are reserved for storing user set point values Values stored in these registers are automatically written saved to the PLC s flash memory every 30 seconds They are also saved during a controlled shutdown e During a controlled shutdown see next section user set point values are written to the PLC033 s flash memory These stored values are loaded when the process resumes e n the event of an abrupt loss of power the process will use the values written to the PLC033 s flash memory during the last automated save The following registers are reserved for set point values e Registers 9800 9899 are reserved the DO range e Registers 49800 49899 are reserved in the AO range Installation and Operation Manual 6033 Chapter 1 Product Overview CONTROLLED SHUTDOWN The following events initiate a controlled shutdown e If voltage in the panel falls to 11 2 volts the PLC033 s operating
52. rview Provides a brief description of the PLC033 along with a list of features specifications and pin descriptions e Chapter 2 Before You Begin Discusses safety measures that should be taken when working with the PLC033 e Chapter 3 Principles of Operation Presents information on how the PLC033 operates including discussion of serial and network interfaces I O mapping ladder logic and customized user interfaces e Chapter 4 Getting Started Outlines the steps required when setting up a system e Chapter 5 Hardware Installation Provides information on installing the PLC033 in RTU and wiring RS 232 485 and network devices Also discusses the use of a PLC By Pass card e Appendix A Testing and Troubleshooting Discusses how to test and troubleshoot radio and network communication problems e Appendix B Application Notes Describes how the PLC033 can be used to solve specific problems e Appendix C Update PLC Firmware Gives instructions on updating the PLC s firmware the ROM based software that controls the device e Appendix D Parts List Provides a list of products available for use with the PLC033 e Appendix F Support Service and Warranty Gives information on how to obtain support and service from Data Flow Systems Inc The warranty statement is also provided here ABBREVI ATI ONS USED IN THIS MANUAL ACM Analog Control Module AMM Analog Monitor Module I O Inpu
53. s present If the PLC033 is to be installed into an existing control panel make sure that all breakers are shut off before starting the installation wiring should conform to federal state and local electrical codes When using the PLC033 observe the following safety guidelines e help prevent electric shock wire the PLC033 and peripheral power cables into properly grounded power sources e Be sure nothing rests on the PLC033 s cables and that the cables not located where they can be stepped on or tripped over WORKING WI TH THE PLCO33 Before working with the PLC033 where the removal of components is necessary perform the following steps in the sequence indicated 1 Power down the unit 2 Turn off all circuit breakers to the PLC033 3 Ensure that any cables connected to the PLC033 will not become entangled in or caught on anything in the surrounding area When disconnecting a cable pull on its connector or on its strain relief loop not on the cable itself Some cables have a connector with locking tabs when disconnecting this type of cable press in on the locking tabs before disconnecting the cable When pulling connectors apart you should keep them evenly aligned to avoid bending any connector pins Also before connecting a cable make sure both connectors are correctly oriented and aligned PROTECTING AGAINST ELECTROSTATIC DISCHARGE Static electricity can harm delicate components inside the PLC
54. should switch to PLC Central Mode Comm 2 DFS Central Mode is and when it should return to normal operation to check if communications with the HyperTAC II central have been restored Comm 2 DFS Central Mode is false Special Function Register 49951 Comm 2 Time Since Last Comm is a timer measured in seconds that monitors how long it has been since communications were received from the HyperTAC II central If the timer expires the 033 starts operating in PLC Central mode The second timer is a user created central mode timer that monitors how long the station has been in PLC Central mode see line 125 in the ladder on the next page for an example The second timer tells the PLC to return to normal operation after the specified length of time so it can check if communications have been restored 43 Appendix Application Notes The ladder below presents code that can be used for most PLC Central backup mode operations In this example the ladder switches modes based on loss of communication from a HyperTAC II central If register 49951 Comm 2 Time Since Last Comm reaches or exceeds 60 seconds the PLC033 s operation switches to central mode for sixty seconds lines 115 and 120 When the central mode timer reaches 60 seconds lines 125 and 130 the PLC033 returns to normal operation mode register 9951 is reset to false to determine if the central has come back online Logic Builder
55. sures that there are no duplicate or conflicting addresses Once mapping is complete these registers are available for use in ladders and custom screens When doing this type of mapping you need to be aware of the registers that have been set aside for special functions for example controlling the four programmable LEDs and the registers reserved for set points A list of these registers can be found in Chapter 1 Product Overview A second form of mapping DFS Radio mapping is required in order for the PLC033 to be polled by a HyperTAC II system In this process the registers in the Logical Memory Map are mapped to up to 30 DFS modules up to 15 modules per station with a two 2 station maximum For example registers in the 00001 09999 range digital outputs would be mapped to one or several Digital Control Modules DCM003 registers in the 40001 49999 range analog outputs would be mapped to one or several 16 Analog Control Modules 002 The mapped 1 be any combination of physical 1 logical I O generated by ladder programs and special function registers Because the DFS radio link uses a 12 bit protocol with a full scale output of 4095 you must specify how you want to shift the bits in the register when working with any data that is greater than 12 bit that will be sent over the DFS radio link for example 15 bit RIO128 data or 16 bit logical data Details on this process can be found in the section titled
56. system will initiate the shutdown without user intervention e Press the shutdown button on the PLC033 to manually stop the process e Use Special Function Registers Remote Process Start Command 9920 and Remote Process Stop Command 9921 to shutdown the process from a remote location For example you could map these registers to a DFS module point in the PLC s DFS Radio Map and configure the same point in HT3 The registers could then be controlled from a custom screen or a default screen SPECIAL FUNCTI ON REGI STERS The following local and derived I O points are provided as special function registers Most of these registers are for external status queries For example registers 9930 Remote Process Running and 49902 Maximum Ladder Loop Time give you important information on the status of the PLC033 Others such as 9900 Configuration Bit 0 and 9910 LED 0 can be used in ladders to control the behavior of the PLC033 Table 1 1 Special Function Registers Address Function Ladder R W Remote R W 9900 Configuration Bit 0 R R 9905 Configuration Bit 5 R R 9909 General Input 9 R R 9910 Led 0 DS12 RW R 9911 Led 1 DS11 RW R 9912 Led 2 2 0 RW R 9913 Led 3 DS9 RW R 9920 Remote Process Start Command R RW 9921 Remote Process Stop Command R RW 9930 Remote Process Running RW R 9940 Global Alarm R R 9941 Low Memory R R 9942 Low Voltage R R 9943
57. t Output BEM Bus Extender Module DCM Digital Control Module DMM Digital Monitor Module LSB Least Significant Bit MBP Modular Backplane MSB Most Significant Bit NIM Network Interface Module PLC Programmable Logic Controller PMT Process Management Toolkit RIM Radio Interface Module RIO Rail I O RIO128 with 128 I O RIO032 with 32 I O RTU Remote Terminal Unit Chapter 1 PRODUCT OVERVIEW DESCRIPTION The PLC033 is a microprocessor controlled programmable logic controller designed for implementing local logical control at the RTU via an installed ladder logic program Users configure the PLC033 s I O and communication settings and create the ladder logic program using the applications included in the supplied Process Management Toolkit PMT software The PLC033 must be installed in a specially designed RTU one with a modular backplane MBP that has been modified to split the communications bus into two entities the Radio Bus and the Module Bus The MBP is a printed circuit board composed of card edge connectors for the modules module bus circuitry and a connection for the back up battery PLC033 and all other DFS plug in function modules used in the system are plugged into card edge connectors mounted on the RTU s MBP In a typical installation the PLC033 is installed between the RIM Radio Interface Module and up to 15 DFS function modules The PLC033 uses the Radio Bus to communicate w
58. t menu and typing telnet xxx xxx xxx xxx 504 Where xxx xxx xxx xxx 15 the PLC s IP address followed by 504 the network port for this Telnet application If you are using a closed network to connect to the PLC033 crossover cable between the PLC033 and the computer change the network settings for your computer so that it is on the same network as the PLC For example if the PLC was at the factory default IP 192 168 1 10 you could set your computer to 192 168 1 101 and telnet to 192 168 1 10 Type the name of a program folder document or Internet resource and Windows will open it for you telnet 192 168 10 175 504 v OK Cancel Browse 2 Click OK to open a Telnet connection A Telnet window opens with instructions for testing the radio backplane the module backplane or the Modbus COM1 port Telnet 192 168 10 175 Enter R for Radio B for Backplane or M for Modbus continued on next page 31 3 and press the Enter key You should begin seeing transmitted messages and responses Transmitted messages messages sent from the PLC to the Modbus port are green in color and are preceded by a left pointing carat lt Responses messages sent from the COMI port to the PLC are white in color and are preceded by a right pointing carat gt Telnet 192 168 10 175 Monitoring dev ttyS1 9018031000000000000000000000000BBOOBOBOOOBOE45 9 lt 81 81 81 2
59. t registers 6 7 set points 14 shutdown button 39 40 shutdown controlled 18 39 special function registers 7 8 for stopping ladder logic 40 41 specifications 5 board size 5 communication protocols 5 configuration bits 5 LEDs 5 network interface 5 serial interfaces 5 supply current 5 supply voltage 5 supply current 5 supply voltage 5 support obtaining 55 technical specifications See specifications troubleshooting connection refused error 35 determine IP address of PLC033 36 37 module communication problems 31 32 module power loss of 34 reset PLC033 to factory default state 38 RIM locked in transmit mode 35 serial Modbus communication problems 33 34 updating PLC033 firmware 49 warranty 57 58 D Data Flow Systems Data Flow Systems Inc 605 N John Rodes Blvd Melbourne FL 32934 321 259 5009 www dataflowsys com
60. t wide Modbus Registers I Logic Builder DFS HyperTAC II HMI Ladder Logic DFS Protocol V 31762 40097 2 30854 456 38293 07642 00089 06432 Figure 3 1 Typical PLC033 Application DFS 00507 011 01 19 Notes 20 Chapter 4 GETTING STARTED Define the problem What problem are you trying to solve by installing the PLC What kind of I O do you need What do you need to monitor and control in the field What information needs to be sent back to the central computer Install the PLC and all related hardware Discussed in Chapter 5 Hardware Installation Create a new project in the Project Management Toolkit and define the basic settings including IP address and mode PLC or RDP Discussed in the Process Management Toolkit User Manual Define ranges for the physical I O user defined logical I O for example virtual analog inputs and outputs you create in Logic Builder and the logical I O generated internally by Logic Builder Be aware that the high end of the digital output and analog output ranges are reserved for user set points and special functions see Chapter 1 Product Overview for more information We recommend the following Range Type Digital Outputs Digital Inputs Analog Inputs Analog Outputs Physical I O 1 1000 10001 11000 30001 31000 40001 41000 User defined Logical I O 1001 1999 11001 11
61. te an analog output with an address that matches that given to the point in the radio map For example ifthe point was mapped to module A point 1 it would have the same address plus the station number in HyperTAC II C3 Drivers 7 3035 1 el C3 Hdriver 3 9 3 3035 Name RIMDOB Stn 1 Tank Level Ga 3 Stn 1 Tank Li Point Type 3 Templates 7 y Partitions x Alarms Low raw value Low engineering value 2 Auto Controls 819 0 52 Scheduled Controls 52 Keywords 3 2 Users A Phone E mail High raw value High engineering value 52 External Points 4095 100 Resolution Units Qualifier 0 none Slew rate controls only Browse 72 2 3 ac You would then create an auto control for the logical point and use the point at the other station our case the tank level at station 1 which has the address 1B3 as the source 3035A1 AO o Stn 1 Tank Level Controlled B3 Browse Low control value High control value CO invert control logic v Push value Log changes This allows the tank level value to be pushed into the AO point in HyperTAC II which then pushes the value into the PLC s ladder when the logical input is examined continued on next page Installation and Operation Manual 6033 42 Examine Analog object used to bring external data into
62. ules Pump Control Units PCU Hyper Server Modules HSM Network Interface Modules NIM Fiber Interface Modules FIM Network Switch Modules NSM Network Fiber Modules NFM and Back Pack Radios BPR carry an extended two 2 year return to factory warranty This extended warranty does not cover misuse vandalism or Acts of God However these items are warranted against damage due to lightning for the entire three year period NOTICE The intended purpose of the TCU is telemetry control Using the TCU for purposes other than telemetry control is not recommended and will void the warranty QUESTIONS OR COMMENTS ON THIS MANUAL If you find a problem with any of the information in this manual or have suggestions on how it could be improved please contact us at the address below Data Flow Systems Inc Documentation Department 605 N John Rodes Blvd Melbourne FL 32934 Alternatively e mail us at documentation dataflowsys com 55 Notes 56 INDEX battery voltage controlled shutdown 18 39 low 18 9 board size 5 cables how to connect and disconnect 11 communication protocols 5 configuration bits 5 connection refused error 35 connector pins See pins connectors how to connect and disconnect 11 custom screens for monitor and control 18 description of PLC033 3 4 DFS NIM RTU slave 3 15 electrostatic discharge protecting against 12 Ethernet See network factory default state res
63. wn of all PLC033 processes e Surge protected nondestructive e 4 programmable LEDs and 8 hardware firmware controlled LEDs power module receive data module transmit data radio receive data radio transmit data CPU failure PLC033 status and network status On board communications and functional firmware On board voltage regulation Automatically retrieves data from modules on RTU bus Module is removable without disturbing field wiring Keyed to prevent damage Time tagged messages Battery backed clock calendar synchronized by telemetry No adjustments switches or straps self configuring Watchdog timer Gold edge connector fingers TECHNICAL SPECIFICATIONS Board size Supply voltage Supply current Max number of DFS modules supported Network Interface 1 Serial Interface 3 LEDs Configuration bits Protocols 5 25 X 6 88 8to 13 VDC 290 mA 15 10 100base T COMI RS 232 or RS 485 Modbus master or slave COM2 DFS Radio Bus slave COM3 DFS Module Bus master Four programmable LEDs DS9 DS10 DS11 and DS12 8 hardware firmware controlled LEDs power PWR module receive data module transmit data MTX radio receive data RR X radio transmit data RTX CPU failure FLT 033 status STAT and network status LINK Five configuration bits for use in ladder logic programs DFS Modbus ASCII Modbus RTU and Modbus TCP Chapter 1 Product Overview PLCO33 INTERFACE Service Po

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