J-3644-2 Toledo Scale Interface Module
Contents
1. Module Module in a Local Rack 32 Bit Register Reference Use the following method to reference 32 bits as a single register 32 bit register reference is commonly used to read indicated weight or tare weight The symbolic name of each register should be as meaningful as possible nnnnn IODEF SYMBOLIC SLOT s REGISTER r When referenced as a long register of 32 bits register is the most significant 16 bits and register r 1 is the least significant 16 bits E 1 E 2 16 Bit Register Reference Use the following method to reference a 16 bit register 16 bit register reference is commonly used to reference message number and status The symbolic name of each register should be as meaningful as possible nnnnn IODEF SYMBOLIC_NAME SLOT s REGISTER r Bit Reference Use the following method to reference individual inputs on the module Single bit reference is used to reference link status The symbolic name of each bit should be as meaningful as possible nnnnn IODEF SYMBOLIC_NAME SLOT s REGISTER r BIT b where nnnnn BA2. PIO failed power up diagnostic l b Watchdog failed power up diagnostic C Communication line status Displayed only if the link has not been configured by a DCS application task System backplane watchdog failed Board is operational but will not receive data until the watchdog is reset E Power failure This code is normally displayed from the time that a power failure is detected until power is lost Figure 2 2 LED Fault Codes 2 8 3 0 3 1 3 2 25 PIN INSTALLATION This section describes how to install and remove the module and its cable assembly Wiring The installation of wiring should conform to all applicable codes To reduce the possibility of electrical noise interfering with the proper operation of the control system exercise care when installing the wiring from the system to the external devices For detailed recommendations refer to IEEE 518 Initial Installation Use the following procedure to install the module Step 1 Turn off power to the system All power to the rack as well as all power to the wiring leading to the module should be off Step 2 Fasten the two field wires to a 25 pin male D shell connector Typical field connections are shown in figure 3 1 Make certain that the other end of the cable is connected to the proper connector on the Toledo Scale digital indicator Refer to figure 3 2 for the proper digital indicator connection Refer to Appendix C for the arrangement
3. 1 1 2 0 2 1 2 2 MECHANICAL ELECTRICAL DESCRIPTION The following is a description of the faceplate LEDs field termination connectors and electrical characteristics of the field connections Mechanical Description The Toledo Scale Interface module is a printed circuit board assembly that plugs into the backplane of the DCS5000 AutoMax rack It consists of a printed circuit board a faceplate and a protective enclosure The faceplate contains tabs at the top and bottom to simplify removing the module from the rack Module dimensions are listed in Appendix A The faceplate of the module contains a 25 pin D shell connector for an RS 232C serial I O link For diagnostic purposes the faceplate contains one seven segment LED and a green status light that indicates when the board is operational ON or malfunctioning OFF There are also two thumbwheel switches on the faceplate of the module These switches are not used in this application See figure 2 1 The back of the module contains two edge connectors that attach to the system backplane Electrical Description The interface module contains a 4 mhz Z80 microprocessor Processor memory consists of 16K bytes of EPROM memory for the communication software 8K bytes of RAM for local data storage and 4K words of dual port memory The module is equipped with a RS 232C serial I O port a programmable baud rate generator and the necessary circuitry to interface with the
4. Required Parity Even Start bits 1 Bits character 11 Stop bits 2 e Baud rate 1200 2400 4800 9600 19200 user configurable A 1 Appendix B Module Block Diagram TOLEDO SCALE INTERFACE MODULE 57C428 Address Bus V Dual Port Arbitration 4 and Control Wait Read Write OK CPU EXA Watchdog Logic le A Address Address and Control Bus 8K Byte Dual Port Memory Thumbwheel Switches 16K Byte EPROM 4 Channel Counter Timer Serial Interface XMIT 2 lt ea DTR RUN B 1 Appendix C Field Connections Connector Gateway Conn Pin No Function Signal Ground Appendix D Toledo Scale Continuous Output Message Format A valid message begins with a start of message character ASCII STX The message contains three bytes of status information six bytes of indicated weight and six bytes of tare weight The message is terminated by a carriage return A single byte checksum follows the carriage return The checksum is calculated by taking the 2 s complement of the sum of bits 0 6 of all characters preceding the c
5. and run the ReSource Software Use the I O MONITOR function If a baud rate other than 4800 is required configure the serial port by writing the baud rate used by the transmitting device to register 21 and then writing the value 255 to register 20 The seven segment LED should now be blank Monitor registers 14 16 17 and 18 using the ReSource Software Register 14 should be changing at the rate that messages are being received Module Replacement Use the following procedure to replace a module Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Turn off power to the rack and all connections Use a screwdriver to loosen the screws holding the connector to the module Remove the connector from the module Loosen the screws that hold the module in the rack Remove the module from the slot in the rack Place the module in the anti static bag it came in being careful not to touch the connectors on the back of the module Place the module in the cardboard shipping container Take the new module out of the anti static bag being careful not to touch the connectors on the back of the module Insert the module into the desired slot in the rack Use a screwdriver to secure the module into the slot Attach the D shell connector to the mating half on the module Make certain that the connector is the proper one for this module Use a screwdriver to secure the connector to the module Turn on powe
6. declare those names COMMON 4 7 4 8 4 3 1 4 3 2 Configuring the Module The module must be configured whenever you turn on power to the system or change the baud rate of the serial interface If the module has not been configured it will display the letter C on its LED The following is an example of the BASIC statements required in an application task to configure the module 400 410 420 430 440 450 480 490 600 610 620 630 1000 1010 1020 1030 1040 1050 1060 1070 COMMON LINK_STATUSO COMMON LINK_CONF COMMON BAUD_RATE COMMON RQST_STATUS COMMON MSG_NO COMMON STATUS_A COMMON INDICATED_WT COMMON TARE_WEIGHT LOCAL OLD_MSG_NO LOCAL WEIGHT LOCAL TARE LOCAL EXPONENT REM Link configuration status Link configuration request Baud rate Message request MMessage number Status byte A Indicated weight Tare weight Old data check Weight in eng units Tare weight in eng units Power of ten scaling REM Initialize Interface Execute this section only 1 time REM BAUD_RATE 9600 LINK_CONF DELAY 1 TICK IF NOT LINK_STATUS THEN 1050 OLD_MSG_NO 1 Reading the Data Request link configuration Wait for link config For old data check The following is an example of the BASIC statements required to read the data from the module 2000 2010 2020 2030 2047 2048 2049 2050 2055 2060 2070 2075 2080 2085 2090 2095 2100 210
7. in registers 65 72 Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out modules After each swap if the problem is not corrected replace the original module before swapping out the next module First replace the input module Next replace the Processor module s If the problem persists take all of the modules out the backplane except one Processor module and the interface module If the problem is now corrected one of the other modules in the rack is malfunctioning Reconnect the other modules one at a 5 3 time until the problem reappears If none of these tests reveals the problem replace the backplane Bus Error Problem A 31 or 51 54 appear on the processor module s LED These error messages indicate that there was a bus error when the system attempted to access the module The possible causes of this error are a missing module a module in the wrong slot or a malfunctioning module It is also possible that the user is attempting to write to read only registers on the module Use the following procedure to isolate a bus error Step 1 Step 2 Step 3 Step 4 Verify that the input module is in the correct slot Refer to figure 3 3 Verify that the slot number being referenced agrees with the slot number defined in the configuration task Verify that the register numbers that have been assigned to the variables agree with the defi
8. of terminal board connections All field wires should be fastened securely TOLEDO SCALE MALE CONNECTOR DIGITAL INDICATOR a 8 7 6 5 4 3 2 4 TRANSMIT Figure 3 1 Typical Field Signal Connections 3 1 8132 J19 8142 JN 8530 JN Figure 3 2 Toledo Scale Digital Indicator Xmit Connector 8140 J7 or J12 Step Take the module out of its shipping container Take it out of the anti static bag being careful not to touch the connectors on the back of the module Step 4 Insert the module into the desired slot in the rack Refer to figure 3 3 Use a screwdriver to secure the module into the slot Typical 16 Slot Rack Typical 10 Slot Rack Figure 3 3 Rack Slot Numbers Step 5 Connect the D shell on the end of the field wires to the connector on the faceplate of the module Use a screwdriver to secure the connector to the module Step 6 Turn on power to the system Step 7 Verify the installation by checking the status of the seven segment LED and the Ok light When the power is turned on the module will automatically execute its power up diagnostics After the module has finished its diagnostics the seven segment LED on the faceplate should be off if the diagnostics were completed successfully The link is configured for 4800 baud on power up The green light should be on in either case 3 2 3 3 Step 8 Connect the programmer to the system
9. only if the start of message character STX is recognized by the module Typically these registers are used for diagnosing the serial link when problems occur Refer to figure 4 3 bits 15 14 13 12 11 10 9 8 7 0 register 14 number of good messages received gt 16 number of checksum or parity errors 17 number of overrun errors number of framing errors Figure 4 3 Receive Message Status Register 20 is the configuration update request register The module continually monitors this register and will re configure the link anytime the update flag is set Refer to figure 4 4 bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 register 20 EBEBEBED update request DP d Non zero for update request Figure 4 4 Configuration Update Request Register Register 21 defines the serial port baud rate The baud rate may be 1200 2400 4800 9600 or 19 200 Refer to figure 4 5 Register 22 defines the link inactive time out value to aid the user in detecting link failures Each time a start of message character STX is received a timer is initiated with this value If the timer expires the next request by the application program for the scale data will result in link inactive status being returned The time out value is specified in seconds with a minimum value of one and a maximum value of 10 The default value is five See figure 4 5 4 2 bits register 21 4 1 2 22 15 14 13 12 1110 9 8 7 6 5 baud rate 1200 960
10. system backplane Refer to the block diagram in Appendix B This module also contains a watchdog timer used to detect hardware failures The watchdog is enabled whenever power is turned on to the module If a processor is unable to reset the watchdog an interrupt will be generated to stop the processor The dual port memory will be disabled so that it cannot be accessed by the user s application software There is one green status light and one 7 segment LED on the faceplate of the module The status light is labeled OK When the light is on the module has passed its power up diagnostics and the watchdog timer has not timed out 2 1 TOLEDO SCALE INTERFACE 57 428 gt lt gt F lt RELIANCE ELECTRIC Figure 2 1 Module Faceplate 2 2 The 7 segment LED provides detailed information on the status of the module If the LED displays any number from 0 through 9 inclusive or b the module is malfunctioning and has not passed one of its power up diagnostics Three other possible displays indicate that the module has not been set up properly or that there is a fault somewhere else in the system See figure 2 2 for an explanation of fault codes Fault Code Explanation o opu aed powerup diagnostic EemoMeledpowerupdagnosic sid rales powerup diagnostic 6 DPMfaledpowerupdiagnostic MMU failed power up diagnostic
11. the programming statements to configure the module Step 2 Verify that the module is connected to the correct transmitter Check the cabling between the module and the transmitter Make certain that the proper devices are connected together that all the connections are secure and that the proper signals are connected together Refer to Appendix C for D shell connections and to figure 4 for the proper connector on the transmitting device Step 3 Verify that the serial link is working Connect an oscilloscope to the transmitter terminals on the Toledo Scale digital indicator The oscilloscope should display a square wave with periods equal to the values in figure 5 1 when the device is transmitting If it does not display a square wave the transmitter is malfunctioning 1200 baud 833 microseconds 2400 baud 417 microseconds 4800 baud 208 microseconds 9600 baud 104 microseconds 19200 baud 52 microseconds k time gt Figure 5 1 Pulse Time for Different Baud Rates 5 1 If the transmitter is working correctly repeat this process on the connector on the interface module If the oscilloscope displays a square wave again the interface module is malfunctioning Otherwise troubleshoot the cabling 5 2 Incorrect Data Problem The data is either always off always on or different than expected The possible causes of this problem are a module in the wrong slot a programming error or a malfunctioni
12. the request status register indicates an error condition Refer to figure 4 6 for an explanation of error codes for register 64 Data is received continuously by the module The data is placed in dual port memory only when requested via the request status register register 64 The data that will be stored in dual port memory will be the last valid message that was received by the module Registers 66 77 are not updated if an error status is returned 4 3 bits 15 14 13 12 11 10 register 64 request status Value 1 User request to update information in registers 65 77 0 Update completed without error 1 The checksum calculated by the module did not match the checksum character in the received message 2 A non numeric character was detected when converting the Indicated Weight or Tare Weight data to binary 3 A message with valid start of message and end of message characters did not contain 18 bytes 4 No link activity A start of message character was not received in the time specified in Register 22 5 A positive value greater than one was detected in the request status register 6 A checksum character was not received within 16 msec after a valid end of message character was received Check that the scale is configured for transmitting a checksum Figure 4 6 Request Status Register Error Codes Register 65 is incremented by the module each time it receives a start of messa
13. 0 link time out 1 10 seconds Figure 4 5 Control Registers register 23 Setpoint Update Request register 24 25 Setpoint 1 register 26 27 Setpoint 2 register 28 29 Setpoint 3 register 30 31 Setpoint 4 register 32 33 Setpoint 5 register 34 35 Setpoint 6 register 36 37 Setpoint 7 register 38 39 Setpoint 8 Registers 24 through 39 may contain eight double integer Setpoint values The Setpoint values must be specified with the same implied decimal point as the Indicated Weight from the Indicator The values are first stored in registers 24 to 39 Then register 23 must be set to a non zero value to initiate the update in the Interface The Interface software will set register 23 to a zero value after the update is complete Setpoint values may be changed at any time but you must to set register 23 to initiate the update The Setpoints are initialized to zero On power up Toledo Scale Data Registers The Toledo Scale status and weight data registers contain the data transmitted from the Toledo Scale digital indicator All registers are read only with the exception of register 64 Register 64 is used to initiate an update of registers 65 77 In order to read the scale data status and weight first set the request status register to a value of one Next monitor the register for a value less than or equal to zero A value of zero indicates valid data which may be read by the BASIC task A negative value in
14. 5 2110 2500 3000 3100 3200 3300 RQST_STATUS 1 DELAY 1 TICK RQST_STATUS 1 THEN 2010 RQST_STATUS lt 0 THEN 3000 REM REM Valid data process weight data REM REM OLD_MSG_NO MSG_NO REM REM Set request flag for data Check for returned status Branch if error MSG_NO OLD_MSG_NO THEN 2110 If old data skip conversion Update old message number EXPONENT 10 2 STATUS_A AND 07H Get power of 10 F EXPONENT gt 1 THEN EXPONENT 1 0 V If x1 or more no scaling req d WEIGHT INDICATED WT EXPONENT REM TARE TARE WEIGHT EXPONENT REM Error status returned Decode error status END Convert weight data to REAL amp account for decimal point 4 4 4 5 4 5 1 4 5 2 4 5 3 Message Transmission Time The time required for a message to be transmitted is Time in milliseconds 198 000 Baud Rate The module requires less than 1 millisecond to receive the message and store it in dual port memory Restrictions This section describes limitations and restrictions on the use of this module Remote Racks This module should not be used in a remote rack Reading Toledo Scale Data Registers 65 72 should not be read without first performing a request update via register 64 Writing Data to Registers This module contains registers that are read only Attempts to write to them will cause a bus error S
15. Appendix C Field Connections u pave FERRO NEP C 1 Appendix D Toledo Scale Continuous Output Message Format D 1 Appendix E Defining Variables in the Configuration Task E 1 List of Figures Figure 2 1 Module Faceplate 2 2 Figure 2 2 LED Fault Codes 2 3 Figure 3 1 Typical Field Signal Connections 3 1 Figure 3 2 Toledo Scale Digital Indicator Xmit Connector 3 2 Figure 3 3 Rack Slot Numbers 3 2 Figure 4 1 Dual Port Memory Organization 4 1 Figure 4 2 Status and Control Registers 4 1 Figure 4 3 Receive Message Status 4 2 Figure 4 4 Configuration Update Request Register 4 2 Figure 4 5 Control Registers 4 3 Figure 4 6 Request Status Register Error 4 4 Figure 4 7 Message Counter Register 4 4 Figure 4 8 Status Byte 4 5 49 Status Byte B oops wees 4 5 Figure 4 10 Status Byte C 4 6 Figure 4 11 Weight and Tare Registers 4 6 Figure 4 12 Setpoint Flag Register 4 6 Figure 5 1 Pulse
16. EGISTER 20 1020 ODEF BAUD_RATE SLOT 5 REGISTER 21 1030 ODEF RQST_STATUS SLOT 5 REGISTER 64 1040 ODEF MSG_NO SLOT 5 REGISTER 65 1050 ODEF STATUS_A SLOT 5 REGISTER 66 1060 ODEF STATUS_B SLOT 5 REGISTER 67 1070 ODEF STATUS_C SLOT 5 REGISTER 68 1080 ODEF INDICATED SLOT 5 REGISTER 69 1090 ODEF WEIGHT SLOT 5 REGISTER 71 Each application task that references the symbolic names assigned to the interface module must declare those names COMMON For additional information 1 Allen Bradley Drive Mayfield Heights Ohio 44124 USA Tel 800 241 2886 or 440 646 3599 http www reliance com automax www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Produ
17. SIC statement number This number may range from 1 32767 SYMBOLIC_NAME A symbolic name chosen by the user and ending with This indicates a long integer data type and all references will access registers r and r 1 SYMBOLIC_NAME A symbolic name chosen by the user and ending with 96 This indicates an integer data type and all references will access register 1 SYMBOLIC_NAME A symbolic name chosen the user and ending with O This indicates a boolean data type and all references will access bit number b in the register r SLOT Slot number that the module is plugged into This number may range from 0 15 REGISTER Specifies the register that is being referenced This number may range from 0 72 BIT Used with boolean data types only Specifies the bit in the register that is being referenced This number may range from 0 15 Examples of I O Definitions The following statement assigns the symbolic name TARE_WEIGHT to register 71 on the module located in slot 4 1020 IODEF TARE_WEIGHT SLOT 4 REGISTER 71 The following statement assigns the symbolic name LINK_STATUS to register 4 bit 0 on the module located in slot 7 2050 IODEF LINK_STATUS SLOT 7 REGISTER 4 BIT 0 Sample Configuration Task The following is an example of a configuration task for the interface module 1000 ODEF LINK_STATUS SLOT 5 REGISTER 4 BIT 0 1010 ODEF LINK_CONF SLOT 5 R
18. Time for Different Baud Rates 5 1 1 0 INTRODUCTION The products described in this instruction manual are manufactured or distributed by Reliance Electric Company or its subsidiaries The Toledo Scale Interface Module provides a single RS 232C serial port for receiving data from Toledo Scale digital indicators model numbers 8132 8140 8142 and 8530 that communicate via RS 232C with the Toledo Scale Continuous Output protocol The serial data is stored in dual port memory where it can be read by application software This manual describes the functions and specifications of the module It also includes a detailed overview of installation and servicing procedures as well as examples of programming methods Related publications that may be of interest J 3630 AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 1 0 J 3649 AutoMax CONFIGURATION TASK MANUAL e J 3650 AutoMax PROCESSOR MODULE INSTRUCTION MANUAL J 3675 AutoMax ENHANCED BASIC LANGUAGE INSTRUCTION MANUAL J 3676 AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION MANUAL J 3677 LADDER LOGIC LANGUAGE INSTRUCTION MANUAL J 3684 PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 2 0 J 3750 ReSource AutoMax PROGRAMMING EXECUTIVE INSTRUCTION MANUAL VERSION 3 0 518 GUIDE FOR THE INSTALLATION OF ELECTRICAL EQUIPMENT TO MINIMIZE ELECTRICAL NOISE INPUTS TO CONTROLLERS FROM EXTERNAL SOURCES
19. Toledo Scale Interface Module M N 57C428 Instruction Manual J 3644 2 ae ELECTRIC The information in this user s manual is subject to change without notice WARNING THIS UNIT AND ITS ASSOCIATED EQUIPMENT MUST BE INSTALLED ADJUSTED AND MAINTAINED BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL EQUIPMENT IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY CAUTION THIS MODULE CONTAINS STATIC SENSITIVE COMPONENTS CARELESS HANDLING CAN CAUSE SEVERE DAMAGE DO NOT TOUCH THE CONNECTORS ON THE BACK OF THE MODULE WHEN NOT IN USE THE MODULE SHOULD BE STORED IN AN ANTI STATIC BAG THE PLASTIC COVER SHOULD NOT BE REMOVED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT Toledo Scale is a trademark of Toledo Scale Inc Reliance is a registered trademark of Reliance Electric Company or its subsidiaries 1 0 2 0 3 0 4 0 5 0 Table of Contents Introduction eter rr Ee ROCA 1 1 Mechanical Electrical Description 2 1 2 1 Mechani
20. cal Description 2 1 2 2 Electrical Description saari aran sia ee eme er eene 2 1 Installation aaa ehm mh SR C 3 1 31 WING rn 3 1 3 2 Initial Installation eek 3 1 3 3 Module 111 3 3 Programming eet aan aie ii enii 4 1 4 1 Register Organization 4 1 4 1 1 Status and Control Registers 4 1 4 1 2 Toledo Scale Data Registers 4 3 4 2 Configuration 2 videos nets nee ak 4 7 4 3 Reading Data in Application Tasks 4 7 4 3 1 Configuring the Module 4 8 4 3 2 Reading the Data 4 8 4 4 Message Transmission Time 4 9 4 5 Restrictions u greek hecha nr err YU 4 9 415 1 Remote rn reb eR ae 4 9 4 5 2 Reading Toledo Scale 4 9 4 5 3 Writing Data to Registers 4 9 Diagnostics and Troubleshooting 5 1 5 1 No Activity on Serial Line 5 1 5 2 Incorrect Data es oss e Rer eR e Exe ak nema 5 2 5 9 BUSEM a eDreams ins 5 3 Appendices Appendix A Technical Specifications A 1 Appendix B Module Block Diagram sii xe rr en a Rr a B 1
21. cts Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstra e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Publication J 3644 2 June 1991 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in U S A
22. evere system error The following are examples from programs that write to the module and should therefore be avoided if they involve read only registers a Referencing the module from the coil in a ladder logic task b Referencing the module on the left side of an equal sign in a LET statement in a control block or BASIC task c Referencing the module as an output in a control block function 4 9 5 0 5 1 DIAGNOSTICS AND TROUBLESHOOTING This section explains how to troubleshoot the module and field connections If you cannot determine the problem the unit is not user serviceable No Activity on Serial Line Problem No data is being received on the serial line You can confirm this by monitoring the values in register 14 18 If they do not change regularly no data is being received The possible causes of this error are a programming error or a malfunctioning module It is also possible that the transmitter is malfunctioning or that the serial line is not connected or is connected to the wrong transmitter Use the following procedure to isolate the problem Step 1 Verify that the module has been configured correctly The LED on the module faceplate should be blank If it is verify that the baud rate in register 21 is the same as the baud rate of the transmitting device If the LED on the module faceplate displays the letter C the module has not been configured correctly Review your rack configuration as well as
23. ge character on the serial interface The value will range from 0 255 Use this register to determine whether the data contained in registers 66 77 has changed from the last time it was read Refer to figure 4 7 bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 meme Figure 4 7 Message Counter Register Registers 66 72 contain the data that was received in the last message from the Toledo Scale digital indicator 44 Register 66 contains status byte Refer to figure 4 8 bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A Location Model Dependent Model Dependent Model Dependent Figure 4 8 Status Byte Register 67 contains status byte Refer to figure 4 9 bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Model Dependent Units 0 pounds 1 kilograms Motion 0 no motion 1 in motion Range 0 in range 1 overrange Weight is 0 Positive 1 Negative Mode 0 Gross 1 Net Figure 4 9 Status Byte B 4 5 Register 68 contains status byte Refer to figure 4 10 bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Dependent Print Button Pushed Model Dependent Model Dependent Figure 4 10 Status Byte C Registers 69 72 contain the indicated weight and tare weight respectively These values are stored as 32 bit long integers See figure 4 11 bits 15 14 13 12 1 10 9 8 register 69 Indicated Weigh
24. hecksum character 10 11 12 13 14 15 16 17 18 1 2 3 4 SW SW SW X JA D 1 Appendix E Defining Variables in the Configuration Task Before any application programs can be written it is necessary to configure or set the definitions of system wide variables i e those that must be globally accessible to all tasks This section describes how to configure the system variables on this input module Refer to the figure below Note that this procedure is only used if you are using the Programming Executive Software Version 2 1 or earlier Processor Module O O O 275W POWER SUPPLY POWER ON PS READY SYSTEM READY BLOWN FUSE NORMAL O ruse BATTERY BACKUP
25. ng a Configuration task For Version 3 0 and later you define system wide variables using the AutoMax Programming Executive After these variables are defined you can generate the configuration file automatically which eliminates the requirement to write a configuration task for the rack If you are using AutoMax version 2 1 or earlier refer to Appendix E for examples that show how to define variables in the configuration task If you are using AutoMax Version 3 0 or later see the AutoMax Programming Executive J 3750 for information about configuring variables Reading Data in Application Tasks The frequency with which tasks read their inputs depends on the language being used Ladder logic and control block tasks read inputs once at the beginning of each scan and write outputs once at the end of each scan regardless of how often the inputs are referenced in the task BASIC tasks read an input and write an output for each reference throughout the scan In order for the interface module to be referenced by application software it is necessary to assign symbolic names to the registers on the module In AutoMax Version 2 1 and earlier this is accomplished by IODEF statements in the configuration task Refer to Appendix for a example In AutoMax Version 3 0 and later you can assign symbolic names using the Programming Executive Each application task that references the symbolic names assigned to the interface module must
26. ng module It is also possible that the input is not wired or is wired to the wrong device Use the following procedure to isolate the problem Step 1 Step 2 Step 3 Step 4 Step 5 5 2 Verify that the serial link is working correctly Refer to the procedure in section 5 1 Verify that the input module is in the correct slot Refer to figure 3 3 Verify that the slot number being referenced agrees with the slot number defined in the configuration Verify that the register numbers that have been assigned to the variables agree with the definitions in the configuration task Verify that the module can be accessed Connect the programmer to the system and run the ReSource Software Stop all tasks that may be running Using the I O MONITOR toggle register 64 and verify that the data in register 65 changes and that the data in registers 65 72 is the correct scale data If the programmer is able to read the data the problem lies in the application software refer to step 4 If the programmer cannot read the data the problem lies in the hardware refer to step 5 Verify that the user application program is correct Verify that the application program that uses the symbolic names assigned to the module has defined them as COMMON Compare your application program with the examples given in sections 4 3 2 and 4 3 3 In your program make certain that you are toggling register 64 before attempting to read the data
27. nitions in the configuration task Verify that the module can be accessed Connect the programmer to the system and run the ReSource Software Monitor register 14 on the module If the programmer is able to monitor it the problem lies in the application software refer to step 3 If the programmer cannot monitor the register the problem lies in the hardware refer to step 4 Verify that the user application program is correct The error log will contain the number of the BASIC program statement in which the error occurred Verify that any variables in a statement identified in the error log that alter the contents of memory refer only to registers 20 thru 39 These are the only registers that can be written to by an application task Verify that the hardware is working correctly Systematically swap out the the interface module the Processor module s and the backplane After each swap determine if the problem has been corrected before swapping out the next item 5 3 Appendix A Technical Specifications Ambient Conditions e Storage temperature 40C 85C Operating temperature OC 60C Humidity 5 90 non condensing Maximum Module Power Dissipation 13 Watts Dimensions Height 11 75 inches Width 1 25 inches Depth 7 375 inches System Power Requirements 5 Volts 2400 mA 12 Volts 53 mA 12 Volts 8 mA Serial Line Characteristics Transmission mode 7 bit ASCII Checksum
28. r to the rack 3 3 4 0 4 1 4 1 1 bits register 4 PROGRAMMING This section describes how data is organized in the module and provides examples of how the module is accessed by the application software For more detailed information refer to the AutoMax Enhanced BASIC Language Instruction Manual J 3675 Register Organization The Toledo Scale Interface module contains a dual port memory that can be accessed by your application software as well as the microprocessor that controls the module The dual port memory contains the control and status information as well as the Toledo Scale data See figure 4 1 for the dual port memory map Register 0 through Status and Control Register 39 Register 64 through Toledo Scale Data Register 77 Figure 4 1 Dual Port Memory Organization Status and Control Registers Use the status and control registers to configure the serial communication port and then monitor its operation All registers are read only with the exception of registers 20 39 Register 4 contains the link configuration status It will be set to 1 after you have properly configured the module Refer to figure 4 2 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Link Status 0 not configured 1 configured Figure 4 2 Status and Control Registers 4 1 Registers 14 through 18 contain information on the number and quality of messages received on the serial link These counters will be incremented
29. t 70 71 Tare Weight 72 Figure 4 11 Weight and Tare Registers register 73 74 signed Gross Weight register 75 76 absolute Gross Weight register 77 Setpoint Comparison Flags bis 15 14 13 12 1110 9 8 7 6 5 4 3 2 register 77 setpoint flag 8 setpoint flag 7 setpoint flag 6 setpoint flag 5 setpoint flag 4 setpoint flag 3 setpoint flag 2 setpoint flag 1 Figure 4 12 Setpoint Flag Register 4 6 4 2 4 3 Two Gross Weight calculations are made by the Interface software The signed Gross Weight is computed by first applying the sign bit from Status Word B to the Indicated Weight and then adding the Tare Weight The result is stored as a double integer in registers 73 74 The absolute value of the signed Gross Weight is stored in registers 75 76 A comparison of the signed Gross Weight is made with each of the eight Setpoints in registers 24 39 If the signed Gross Weight is less than the Setpoint the flag bit in register 77 is set to a 1 TRUE otherwise the bit is set to zero FALSE The comparison flag for Setpoint 1 is in bit 0 Setpoint 2 in bit 1 etc Configuration Before any application programs can be written it in necessary to configure or set the definitions of system wide variables i e those that must be globally accessible to all tasks For DCS 5000 and AutoMax Version 2 1 and earlier you define system wide variables by writi
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