INTERFACING A PANELVIEW 660 TO A CONTROL LOGIX 5550
Contents
1. establish communications between the older generation PanelView and the ControlLogix controller as graphically depicted by Figure 4 Minor Faults Date Time Advanced Fie Redundancy Nonvolatile Memory General Serial Port System Protocol User Protocol Major Faults Error Detection Protocol DH485 Ca CRC 3 DF1 Master Station Address IV Enable Duplicate Detectior Max Station Address DEI A DH4 Token Hold Factor fi Cancel Help Figure 5 DH 485 system protocol selection In order for the older generation PanelView to communicate with the ControlLogix controller and vice versa the ControlLogix s controller system protocol must be changed to DH485 This configuration of the ControlLogix controller is illustrated in figure 5 The power to the controller must be recycled in order for the settings to take effect The addressing principle of data inside the SLC must be understood in order to emulate the SLC structure within the ControlLogix controller similarly the structure of the ControlLogix must be fully understood in order to implement the mapping of the SLC into the ControlLogix controller When 16 bit data in the SLC controller is required by the ControlLogix controller and the data in the SLC controller is for example stored in registers N7 0 to N7 4 the data can be mapped into the ControlLogix controller by making use of the RsLogix 5000 software From the menu bar LOG2. functionality but merely as a result of the different control structure that the ControlLogix controllers utilise This new control structure that the ControlLogix uses is no longer compatible with the PanelView 600 HMI control structure and these two process control devices can no longer communicate with each other All PanelView terminals have catalogue numbers The catalogue numbers that end with a numeric five 5 have a single RS 232 communications interface This RS 232 communications interface was intended for communication between a single 5 03 5 04 or 5 05 SLC controller Channel O port or a MicroLogix 1000 1200 or 1500 controller using point to point communications as depicted in Figure l and not with the newer generation ControlLogix which requires two communication interfaces in order to function The one communications port is used to upload or download PanelView applications which means the PanelView HMI Point to Point Connection Figure 1 HMI to SLC connection engineering of the graphics on the Panel View by means of PanelBuilder software The other serial communication port is used for communications between the ControlLogix controller and the Panel View HMI As the newer ControlLogix technology became available Iscor Vanderbijlpark Steel upgraded the Allen Bradley SLC controllers to the more advanced ControlLogix controllers The manufacturer specifications and technical plant personnel on
3. possible to fully utilise the older generation PanelView HMI and interface it with the newer generation ControlLogix controller without adding any additional interfaces by emulating the SLC controller structure by mapping the SLC data tables within the confines of the ControlLogix controller in the form of a one dimensional array and by doing so the older PanelView HMI s operate with full functionality There are only two drawbacks to the implementation of this methodology as described in this paper The first 1s the internal manipulation of data that will be required to performed within the ControlLogix controller when a timer or counter s data needs to be transferred between the two devices This is a result of the different architectures that are implemented in the older generation PanelView 48 bits as opposed to the ControlLogix 96 bits Once this conversion is done the two systems will operate transparently The second drawback is that if the Ethernet card is damaged or becomes non functional all the communications between the various ControlLogix control systems and the programming terminal will cease In order to gain access from the programming terminal the following action needs to be implemented The ControlLogix processor can be removed and placed in another functional back plane Communications with the processor will be established via the Ethernet card in the new back plane The primary communication of
4. site confirmed that the older PanelView HMI s were no longer compatible with the new ControlLogix controllers and that all the PanelView HMI s needed to be replaced at great cost Additional interface units between the ControlLogix controller and the PanelView HMI where suggested in order to save on the replacement costs of replacing all PanelView HMI s In order to reduce or eliminate this additional cost which was unplanned for seeing as only the control systems where planned for an upgrade an interfacing technique was researched developed tested and implemented to interface the PanelView HMI s to the newly acquired ControlLogix system without any additional cost of glue logic or firmware upgrades 2 METHODOLOGY As previously stated the PanelView in question has only one RS232 DH 485 interface while the new PanelView that is designed for use with the ControlLogix controller has two communication interfaces namely OU One RS232 DH 485 communication interface used exclusively for the interfacing of the PanelView to a computer for downloading of the graphical engineering software to build the graphics on the PanelView A One Allen Bradley proprietary network port used exclusively for the interfacing of the PanelView to the Control Logix controller in order to pass the variables to and from the HMI The methodology that was followed hinged around this differentiation for if the graphical engineering software commun
5. transfer of parameters and data with the result being a fully functional older generation PanelView HMI directly interfaced to the ControlLogix controller When choosing a driver from the ControlLogix software RSLinx for this specific older generation PanelView the 1747 PIC driver must be selected RSLinx may not run as a service while configuring the 1747 PIC driver It must be selected to run as an application as depicted in figure 3 RSLinx Launch Control Panel IOl x Configure 1747 PIC AIC device Ax EE Application is not running eae Start OOo Comm Port amigi 7 Station Number Dec 00 Baud Rate 19200 X Max Station Number 1 31 31 Dinar Run s Service eserve COM Port for Exclusive use by this Driver Select Language System Default y Cancel Delete Help Figure 3 RSLinx settings The Reserve COM Port for Exclusive use by this Driver checkbox must be enabled This ensures that RSLinx works properly 1f it is running as a service RSLinx can be forced to start as a service by selecting Start gt Programs gt Rockwell Software gt RSLinx gt RSLinx Launch Control Panel DTE PC 00000 Oc 0 00 0 Required Pins DCE Panel View D0000 Oc 0 00 O Required Pins 2 TXD 2 TXD 3 RXD 3 amp XD 5 SG E u 35 56 Figure 4 Communication interface connections The same cable that is used to download the Panel Builder application into the PanelView is used to
6. ControlLogix controller the crux of the research focussed on this fact In order for the SLC controller to communicate with the ControlLogix controller the data mapping needs to be the same This implies that a form of emulation is taking place on the part of the ControlLogix controller The SLC control structure can be implemented within the confines of the ControlLogix structure the older generation PanelView which only communicates with the SLC controller would thus be able to communicate with the ControlLogix controller as the ControlLogix controller would appear to be a SLC controller to the older generation PanelView 3 IMPLEMENTATION The principle described above was utilised in layman s terms the ControlLogix controller is fooled into thinking that it is communicating to a SLC controller and the older generation PanelView is fooled into thinking it is communicating with a SLC thus emulation is achieved Without affecting any of the functions of the ControlLogix controller the data tables of the SLC controller were mapped into the ControlLogix controller so that data exchange would occur in the same way as that of the SLC controller The older generation PanelView requires a specific one dimensional data array formatted according to the SLC contention This is exactly what was mapped into the ControlLogix controller thus emulating the SLC within the confines of the ControlLogix controller allowing the
7. IC gt MAP PLC SLC MESSAGES FILE NUMBER 7 TAG NAME SLC_DATA See Figure 6 Files N7 0 to N7 4 inside the SLC controller s N7 register must be mapped inside the ControlLogix controller in a one dimensional integer array with a length of 5 as shown in table 1 and 2 If the function of timers and counters are required the values of these elements must be manipulated within the ControlLogix controller in order to fit inside 16 bit registers which must then be mapped into the SLC data structure SLC Address N7 0 N7 1 N7 2 N7 3 N7 4 PLC2 3 5 SLC Mapping E x Table 2 ControlLogix mapping PLC 3 5 SLC Mapping Jie unter TN TP sic Tag name SLC DATA CLX 16 Bit Data Address SLC_DATA 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 SLC_DATA 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 SLC_DATA 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 2 SLC_DATA 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 3 SLC_DATA 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 4 Cancel Help rl Delete Map PLE 2 Mapping Status Tags Control Tags Time Date PY600 Advanced Power Up Tag Name Terminal Setup Project Display Maintenance External Fonts Printer Terminal Name Panelview Comms Setup Selected Terminal x Figure 6 SLC mapping 2711 K6C5 PY600 Color Key FAN 4 10 4 xx m Panelview The ControlLogix timers and counters can t be Type Protocol directly mapped to the SLC controller as the PV1000 Gray En D SLC con
8. INTERFACING A PANELVIEW 660 TO A CONTROL LOGIX 5550 CONTROLLER PA Gouws TA Harrison PC Pelser Iscor Flat Steel Products Vanderbijlpark Steel Technical Training This paper describes how an Allen Bradley PanelView 600 Human Machine Interface HMI intended for use on the serial port of an Allen Bradley SLC processor for point to point RS 232 DH 485 communications can be connected point to point to a ControlLogix 5555 controller using the serial port on the front panel of the controller by mapping the data tables of the SLC controller into the ControlLogix controller in order to emulate the SLC controller so that communication can be established between the HMI and the ControlLogix controller Copyright 2002 IFAC Keywords PanelView ControlLogix Human machine interface HMI DH 485 MicroLogix 1 INTRODUCTION In the technological age we find ourselves in it is inevitable that hardware and software upgrades in the industrial control environment will always be prevalent in order to replace control equipment with new releases that have more advanced features be it hardware or software This s also the case with the Allen Bradley 2711 K6C5 PanelView human machine interface HMI which are designed to function with the Allen Bradley SLC controllers With the birth of the ControlLogix controller which replaces the SLC controller the previous versions of the PanelView HMI have became obsolete not as a result of their
9. icated from a computer to the new generation PanelView via a RS 232 communication port then the same software could be used via the previously mentioned RS 232 port on the older generation PanelView Once the engineering of the graphics has been done and downloaded to the new generation PanelView the RS232 communication port essentially become obsolete as the communication between the new generation PanelView and the ControlLogix controller takes place via the proprietary network port The older generation PanelView has only the single RS 232 communication port and all variables that where passed between the SLC controller and the old generation PanelView where passed via this interface Logic thus dictates that if the older generation PanelView could receive the variables via the RS232 communication interface then with additional commands the same data should be able to be communicated via the RS232 communication port on the ControlLogix instead of the standard proprietary network port The older generation PanelView HMI must have a dedicated point to point RS232 DH 485 physical connection with the ControlLogix system which requires the ControlLogix s RS232 communication interface s protocol to be changed to DH 485 as depicted in figure 2 and 5 This has the disadvantage that the RS 232 communication interface on the front panel of the ControlLogix controller will now be exclusively reserved for the use of the older gene
10. ject Display Maintenance Extemal Fonts Printer protocol 2 l Terminal Name _ Panelview gt Comms Setup If a message operates on a file number that has no Selected Terminal mapping associated with it the message will fail Bit addressing within the structure is not possible this Communications Setup DH485 2 7 Terminal means mapping a specific element number or bit is Node Address des Baud Rate Per ance an illegal operation and will not execute with the 2 my Fiszo0 y a result that no communication will take place only a p Network Nodes file number may be used in the transmission of NodeName Hode Address Hode Type variables between the older generation PanelView T r TT and the ControlLogix controller eerie Table 1 SLC controller mapping 16 Bit Data o o ooo o o ooo o o ooo o o ooo o o ooo ommno ooo ommno ooo ommno ooo Figure 7 Panel View set up The tag mapped to a SLC file must be a controller scoped tag As many tags as required may be mapped using this structure Figure 7 depicts the initial set up of the older generation PanelView The specific series and catalogue number should be selected from the list provided The node address of the SLC processor starts at 1 and the node type selected is SLC 5 05 The PanelView node address will be 2 4 CONCLUSION This paper shows that it is
11. ration PanelView Point to Point Connection MCC with LCP The PanelView indicates diagnostic and fault information of the MCC Figure 2 Point to point serial connection However due to the fact that the ControlLogix controller normally communicates via Ethernet the lack of this additional communication interface has no effect on the normal operation of the ControlLogix controller The RS 232 communication interface is normally only used when configuring the ControlLogix controller which defaults to the RS232 communication interface Once the communication interface has been selected as Ethernet the ControlLogix controller will not require the use of the RS232 communication interface unless communications with the Ethernet card has been lost Simply rerouting the variables that need to be passed to the older generation PanelView via the ControlLogix controller s RS 232 communication interface will not allow compatibility as the older generation PanelView was designed to operate with the SLC control structure The methodology that needed to be followed was twofold OU Make use of the ControlLogix s RS 232 communication interface to pass the HMI variables O Emulate the SLC control structure within the confines of the ControlLogix controller The SLC controller can indeed communicate with the ControlLogix controller if the SLC controller s data tables are mapped into the
12. the processor must be reset to RS232 DH485 The processor must be returned to the original back plane The older generation PanelView s communication cable must be removed and replaced with the serial cable of the programming terminal Communication will now be established with the processor and a new Ethernet card can be placed into the back plane and configured via the programming terminal The older generation PanelView reconnected and all communications will be restored REFERENCES PanelView operator terminal user manual Publication 2771 6 1
13. troller uses a 48 bit architecture and the Tach ControlLogix controller uses a 96 bit architecture C Keypad amp Touch Multiple Language Support French German Italian Spanish and English The mapping inside the older generation PanelView is exactly the same as for a SLC controller If the Auxiliary Port Usage Download C Printing tag inside the older generation PanelView requests access to data originating from Integer Files N7 0 to Catalog amp Revision Numbers N7 4 in the ControlLogix controller N7 should be available and mapped as SLC data inside the ControlLogix to a one dimensional integer array with a length of five Catalog Numbers E m Catalog and Version 2711 K6C2 PY600 Color Key FAN 4 10 4 xx 2711 K6C3 P Y600 Color Key FAN 4 10 4 sx 2711 K6C5 PV 600 Color Key FAN 4 10 4 2711 K6C9 P 600 Color Key FAN 4 10 4 sx The SLC structure allows for valid file numbers ranging from 0 to 999 Only one data file may be d Th 1 d Ports mappeg to a ungue tag ee generation Physical AS232 Protocol DH485 PanelView will communicate with this data structure Physical None Protocol None within the ControlLogix controller via the RS 232 Application Settings Resear X communication interface of the ControlLogix La a controller which is set up to use the DH485 A Status Tags ler RSNA PV 600 Advanced ane Terminal Setup Pro
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