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PLC Gateway Planning, Installation and Service

1. 51304421 100 CG a O LG Honeywell Cables to Programmable Logic Controllers NVA Figure 2 1 PLCG in a Nonredundant Configuration Each port may be configured to either the Modbus or Allen Bradley A B protocol That is in the nonredundant configuration you may have Port 1 connected to a Modbus and Port 2 connected to A B equipment or both ports configured to the same bus type In all nonredundant configurations the pinning header on the PLCG relay panel must be plugged into the OTHERS socket on the relay panel Newer relay panels have this header labeled as NORMAL CONFIG See subsection 3 2 6 and Figure 3 7 for a more detailed illustration of the pinning sockets and header PLCG Planning Installation and Service 2 3 5 01 2 4 2 2 4 2 Redundant Configurations Figure 2 2 shows two PLCG 5 slot modules connected in a redundant configuration This configuration also supports up to a total of 16 PLCs Notice only one PLCG Relay Panel is used In this configuration the PLCG electronics within the modules are redundant with the relay panel the only nonredundant part of the system Again connections for a dual node module configuration are the same the single relay panel is mounted horizontally To reduce the possibility of failure of the relay panel the relay used is a special high reliability device See subsection
2. The following is the board complement for the 68020 based PLCG Slot Front P N Rear P N 5 PLCI 51400997 100 PLCI I O 51195096 100 4 3 2 LLCN 51401291 100 LCNI O O 51107403 100 1 HPK2 2 51401288 100 The following is the board complement for an 2 slot node Dual Node Module based PLCG Slot Front P N Rear P N 2 PLCI 51400997 100 PLCI I O 51195096 100 1 K2LCN 51401288 100 KLCNA 51304542 100 PLCG Planning Installation and Service 5 1 5 01 5 2 The following is the board complement for a 3 slot node Dual Node Module based PLCG Slot Front P N Rear P N 3 PLCI 51400997 100 PLCI I O 51195096 100 2 1 K2LCN 51401288 100 KLCNB 51304544 100 One of the following PLCG Relay Panels is mounted on the rear of the PLCG module PLCG RELAY 51304154 100 Early custom production can t use PANEL A B protocol in redundant configuration PLCG RELAY 51304421 100 Current Production required for the PANEL Dual Node Module based unit 5 1 1 Module Configuration Standard and CE Compliant PLCG For module board configuration and part numbers refer to the Five Ten Slot Module Service or Dual Node Module Service manual 5 2 FIELD ADJUSTMENT There are no field adjustments for the PLCG When replacing a board you may have to change some pins or jumpers on the board to make the board correspond with the counterpart it is replacing Do not alter pinning on a board revision socket the revision number might have changed on the newer boa
3. Number of Messages Received Second Number of Messages Transmitted Second Number of Output Buffer Misses Second Number of Processing Buffer Misses Second Number of Scan Buffer Misses Second Overview Physical Limitations PLC Error and Retry Counters PLCG Cabling PLCG Relay Panel Pinning PLCG to PLC Connections Modem Usage and Selection Nonredundant PLCG Port Connections Redundant PLCG Port Connections PLCI Hardware Indicator Troubleshooting Chart PLCI Hardware Indicators PLCI Pinning PLCI System Software Indications PLCI Troubleshooting PLCI Hardware Indicator Troubleshooting Chart PLCI Hardware Indicators EN NO wo ANNY oO Ww A IWVIINNN WBWAKR WP WWHWWWWHYNWANNYYNNwW Ni ARRAN RRTTAINNYNWOWBANLNYNNYNNYYNUTAN BUMDANWAMAWNTNNHA WWWNW NAUA NON OON H nDOANWNABROD HH H NH WH WNHWWWOHINONDARWNMHH_ NW _WHA an PLCG Planning Installation and Servicelndex 2 5 01 Index Topic PLCI System Software Indications Battery Failure Device Failure Port Cabling and Pinning for Modems Using Modbus Protocol Port Cabling for Direct Connection to Modbus Equipment Port Cabling for Equipment Using Allen Bradley Protocol Port Statistics Power On Tests Electronics Checks Program Options TS3 Ram Clear J1 Redundant Configurations Redundant PLCG Port Connections Related Publications Single vs Multidrop Cabling Site Requirements Dimensions and Weight Spare Parts StartUp Storage Conditions Subslots Processed per Second U
4. refresh message for this port but did not have a buffer available This value is typically nonzero indicating that PLCG Keep Alive writes are running faster than the connected I O subsystem network 4 3 2 8 Number of Output Buffer Misses Second This location 1727 1737 contains the number of times in the previous second that the PLCG was ready to build a User Output message for this port but did not have an Output buffer available This value is typically nonzero indicating that PLCG output writes are running faster than the connected I O subsystem network PLCG Planning Installation and Service 4 6 5 01 4 3 2 4 3 2 9 Firmware Freetime Second Counters These three counters 1740 1741 1742 1743 1744 1745 display approximations of PLCI processor free time The MINIMUM value indicates the least free time per second on record which equates to the heaviest loading The MAXIMUM value indicates the most free time per second on record which equates to the lightest loading The CURRENT value indicates the free time during the previous 1 second period 4 3 2 10 Number of Processing Buffer Misses Second This location 1746 contains the number of times in the previous second that the PLCG was ready to process a requested PLC reply or unsolicited write exception reporting from the PLC but none was pending When this location is nonzero the PLCG is running faster than the connected I O subsystem network is transferring data PLCG
5. 2 4 Number of Bytes Transmitted Second This location 1723 1733 contains the number of bytes transmitted through this port in the previous l second period It includes all control header trailer and BCC CRC bytes Multiplying this parameter by 11 1 start bit 8 data bits 1 parity bit 1 stop bit 11 and dividing by the port s baud rate will yield an approximate indication of port utilization on transmit as a fraction of the baud rate selected for this port bandwidth used 4 3 2 5 Number of Bytes Received Second This location 1724 1734 contains the number of bytes received through this port in the previous l period It includes all control header trailer and BCC CRC bytes Multiplying this parameter by 11 1 start bit 8 data bits 1 parity bit 1 stop bit 11 and dividing by the port s baud rate will yield an approximate indication of port utilization on receive bandwidth used 4 3 2 6 Number of Scan Buffer Misses Second This location 1725 1735 contains the number of times in the previous second that the PLCG was ready to build a Data Request to a PLC on this port but did not have a Scan Buffer available This value is typically nonzero indicating that PLCG data acquisition is running faster than the connected I O subsystem network 4 3 2 7 Number of Keepalive Buffer Misses Second This location 1726 1736 contains the number of times in the previous second that the PLCG was ready to build a Keep Alive
6. 2 5 3 for examples of redundant port cabling configurations Primary PLCG REDUNDANT AB NOTUSED Jeo vO LCNB LCN vO yep J y o PORT 1 PORT 2 C E C E PLOG MELAY PANEL Secondary PLCG 51304421 100 P CG O LG Honeywell NOT USED iz vo C 2 LCN A LCNB LCN VO OTEN CELS Q s SKEWE Cables to Programmable Logic Controllers Figure 2 2 PLCG Modules in a Redundant Configuration If you use Modbus protocol in the redundant configuration both ports Port 1 and Port 2 must be connected to Modbus compatible equipment The configuration is again capable of serving up to 16 PLCs through both ports The pinning header on the PLCG relay panel must be plugged into the OTHERS socket Newer relay panels have this header labeled as NORMAL CONFIG See subsection 3 2 6 and Figure 3 7 for a more detailed illustration of the pinning sockets and header PLCG Planning Installation and Service 2 4 5 01 2 4 3 If you use A B protocol in a redundant configuration only Port 1 may be used You must plug the pinning header on the PLCG relay panel into the REDUNDANT A B socket and be sure no cable is connected to Port 2 This configuration is capable of serving up to 16 PLCs through Port 1 through an Allen Bradley communic
7. Codes The Device Failure codes listed in Table 5 2 does not show all error codes that may appear on the journals Table 5 3 provides a list of the Data Hiway Port DHP error codes Table 5 3 Data Hiway Port Error Codes CODE MNEMONIC 1105 DHP FAIL Link Card Initialization Link Card Initialization failure Error 1106 DHP FAIL Unknown Failure Unknown Failure to L L L 110F DHP FAIL Unknown Failure Unknown Failure 1191 BAT FAIL Battery Failure Memory Battery failure This is a nonfatal failure device status remains OK 1192 OVERLOAD Processor Overload Processor Overload 1193 SAVED In Hard Save Primary IPC HIM failure 1194 RC FAIL RC Failure Backup IPC HIM failure 1195 SF Incorrect CPU IPC HIM firmware not at proper Configuration revision 1196 UNDEFINE Undefined Error Probable cause is failure of box I F card Continuous Notification Writes from the box and no response to the HG callup 1198 ALM FAIL Box Reporting Failure Box reporting failure detected Detected 1199 ALM FAIL Box Reporting Failure Alarm reporting device changed Detected 11A0 F NULL Slot failures 01 16 11B0 F NULL Slot failures 01 16 11BC DEV FAIL Device failure Device failure See Table 5 2 1 Device Link Failure 2 Device Box or Communications Failure 3 Device Configuration Error 4 to F Unknown Device Failure Box Number Not applicable to Honeywell 620 HIM PLCG Planning Installation and Service 5 10 5 01 5 5
8. Planning Installation and Service 4 7 5 01 PLCG Planning Installation and Service 4 8 5 01 SERVICE Section 5 This section presents service instructions unique to the PLCG 5 1 OVERVIEW The Programmable Logic Controller Gateway PLCG is housed in a standard TDC 3000X five slot module or in a newer also standard Dual Node Module A PLCG Relay Panel a unique functional circuit board PLCI an input output card PLCI I O and special cabling have been added to this standard module This manual provides instructions to test troubleshoot and repair those components unique to the PLCG Troubleshooting disassembly and assembly procedures for the remaining five slot module and its components are contained in the Five Ten Slot Module Service or Dual Node Module Service manual in the LCN Service 1 binder The PLCG Relay Panel contains special high quality high reliability components and is relatively expensive It is an ORU Optimum Replaceable Unit item and must be replaced if found faulty however attempt to prove the relay panel has truly failed before replacing it indiscriminately Although cables are not considered ORU items their part numbers are listed in subsection 5 5 for reference The following is the board complement for the 68000 based PLCG Slot Front P N Rear P N 5 PLCI 51400997 100 PLCI I O 51195096 100 4 EMEM 51400910 100 3 EMEM 51400910 100 2 LCN 51400667 100 LCN I O 51107403 100 1 EMPU 51400901 100
9. also be local error code 02 or remote error codes 20 and 30 Also check DHP definition of PLC address may not match that selected at the PLC The definition of a PLC unacceptable to the PLCI No retry Possible causes are e Assigned protocol Modbus or A B conflicts with PLC e The model code for a physical PLC conflicts with the model code already assigned to that physical PLC e Any of the currently defined DHP configuration errors see subsection 2 5 in the PLC Gateway Control Functions manual in the mplementation PLC Gateway binder for hints on avoiding configuration errors The Cyclic Redundancy Check for a reply was incorrect Retries allowed A B Not used The received reply was incorrect for the query sent Retries allowed Possible causes are e Wrong PLC answered e Reply size incorrect for number of parameters requested e Message length inconsistent with message count byte A B Posted on receipt of remote error code 10 Continued PLCG Planning Installation and Service 5 7 5 01 5 4 3 Illegal Function Modbus Presented when the PLC returns the ILLEGAL FUNCTION exception code 01 No retry A B Not used Illegal Data Address Modbus Presented when the PLC returns the ILLEGAL DATA ADDRESS exception code 02 No retry See subsection 2 5 in the PLC Gateway Control Functions manual in the Implementation PLC Gateway binder for hints on avoiding configuration errors A B Posted on receipt
10. installation is similar to that described 3 2 1 Module Installation If you are installing a redundant PLCG pair you have two PLCG modules Install the primary PLCG module first 1 Remove the primary PLCG module with relay panel from its shipping carton 2 Securely fasten the PLCG module to its rack mount with the hardware provided 3 Connect ground straps or leads from the base of the cabinet or a nearby module to the appropriate chassis ground and logic ground connections on the rear of the PLCG module Refer to the LCN System Installation manual for further grounding information 4 Insure the power switch on the front of the PLCG module is off Install the module power cord supplied Refer to LCN System Installation manual for power wiring information If this is a redundant installation repeat steps through 4 on the secondary PLCG module PLCG Planning Installation and Service 3 1 5 01 3 2 2 3 2 2 LCN Node Pinning By convention the node address for a nonredundant PLCG is even The node addresses for a redundant pair is even for the primary PLCG and numerically one higher odd for the secondary PLCG If you are installing a nonredundant PLCG perform the following steps on the PLCG module If this is a redundant PLCG installation perform these steps twice using a node address on the secondary PLCG one higher from that of the primary PLCG LCN I O BOARD FROM REAR SLOT 2 51107403 100 Binary Weight Jum
11. of remote error code 50 or 80 Illegal Data Value Modbus Presented when the PLC returns the ILLEGAL DATA VALUE exception code 03 No retry A B Not used Device Fault Modbus Presented when the PLC returns the FAILURE IN ASSOCIATED DEVICE exception code 04 No retry A B Posted on receipt of remote error code 40 Entered Program Modbus Presented when the PLC returns the PROGRAM Mode ACKNOWLEDGE exception code 05 The PLCG considers this response an error because the PLCG cannot issue the PROGRAM command No retry A B Posted on receipt of remote error code 70 or 80 Busy Insufficient Modbus Presented when the PLC returns the BUSY Buffers REJECTED MESSAGE exception code 06 Retries allowed A B Posted on receipt of local error code 01 or remote error code 90 NAK Negative Modbus Presented when the PLC returns the NAK Acknowledge NEGATIVE ACKNOWLEDGE exception code 07 No retry A B Not used Continued PLCG Planning Installation and Service 5 8 5 01 5 4 3 Table 5 2 PLCI Software Indication Troubleshooting Chart Continued FAILURE POSSIBLE PROBLEM Access Blocked Modbus Not used A B Posted on receipt of remote error code 60 Not used by either Modbus or A B protocol Unspecified Error Modbus Not used A B Posted on receipt of local errors 05 through OF and remote errors AO and CO through FO PLCG Planning Installation and Service 5 9 5 01 5 4 3 5 4 3 3 Data Hiway Port Error
12. relay card 1 meter cable with 50 pin connector at both ends Replaces 51201420 001or 3073161 1 001 SCSI1 to SCSI2 Cable secondary PLCG to relay card used only in redundant PLCGs 2 meter cable with 50 pin connector at both ends Replaces 51201420 002 or 30731611 002 ORU Level Replacement Item PLCG Planning Installation and Service 5 11 5 01 PLCG Planning Installation and Service 5 12 5 01 Index Topic Section Heading 9 D Or OTA NPN DO G2 Go O ANWOON MMNy AC Voltage Options Allen Bradley CIM Pinning Assembly and Cabling LCN Node Pinning Module Installation PLCG Cabling PLCG Relay Panel Pinning PLCI Pinning Baud Rate and Parity TS2 Board Revision TS1 Program Options TS3 Ram Clear J1 Port Cabling and Pinning for Modems Using Modbus Protocol 2 Nu w w w w Modem Cable Modem Pinning Modem Wiring Port Cabling for Direct Connection to Modbus Equipment Port Cabling for Equipment Using Allen Bradley Protocol Allen Bradley CIM Pinning Direct Connection to Allen Bradley Controllers Battery Failure Baud Rate and Parity TS2 Board Revision TS1 Cable Lengths Communications and Performance Statistics PLC Error and Retry Counters Port Statistics Firmware Freetime Second Counters Number of Bytes Received Second Number of Bytes Transmitted Second Number of Keepalive Buffer Misses Second Number of Messages Received Second Number of Messages Transmitted Second Number of Output Buffer M
13. to show the REDUNDANT PARTNER IS NOT ON LINE This indication is only valid when the corresponding emulated DHP is enabled on scan The status of the redundant partner is also indicated by the 10 segment display see subsection 5 4 1 If you get this BATT FAIL indication when using a nonredundant PLCG recheck the PLCI pinning in subsection 3 2 3 5 4 3 2 Device Failure The Device Failure codes listed in Table 5 2 are posted in the Box Status Display at the US when the Hiway Status display indicates DEV FAIL The error code presented at the US is in the form 11DC where D Device Number PLC index and C Error Code in Table 5 2 NOTE Table 5 2 indicates Modbus protocol errors presented by Modicon controllers Other brands of controllers may not present the same errors as Modicon under the same circumstances or may not present any error at all Check the instruction manuals with your controller to verify the similarities and differences in error codes NOTE PLCI Communications Retry Guidelines Retries on transient communication errors will be performed for all messages but timeouts are given special processing The PLCI will perform retries until three consecutive timeouts have accumulated against a PLC Data collection from the PLC is suppressed for the remainder of the current scan On the next scan it will attempt to collect the suspect PLC s data but with Timeout Retries still suppressed If any response is received even wi
14. 5 5 SPARE PARTS Spare parts for the Five Slot Module or the Dual Node Module and its components fan power supply boards etc are listed in the Five Ten Slot Module Service manual or in the Dual Node Module Service manual in the LCN Service 1 binder Spare parts unique to the PLCG are listed in Table 5 4 Table 5 4 Parts List Part Number Description 51195096 100 31304542 100 31305072 200 51304981 100 51304544 100 51305072 300 51304982 100 51402615 200 51401946 100 51401945 400 51402755 100 51201795 400 31403519 160 51304421 200 51190516 100 51190526 100 51196655 100 51402184 100 51308106 100 51196489 001 51196489 002 PLCI I O Adapter Paddleboard with plastic extractor clips Used only in non CE modules with relay card K4LCN Mezzanine Board with 4 Mw for use with 51401946 100 only old design K4LCN K4SS Motherboard with 4 Mw K4LCN Memory Module with 4 Mw for use with 51402755 100 onl K4LCN K4SDR Motherboard with 16Mw only replaces 51402755 100 PLCG Relay Panel Replaces 51304421 100 relay panel used in earlier non CE modules Dual Node Power Supply with 3 pin IEC320 power connector used in all CE Mark modules as well as some earlier non CE modules Dual Node Power Supply with 8 pin Beau Vernitron connector old style Replaces 51401497 100 used in older non CE modules Replaces 51304514 100 SCSI1 to SCSI2 Cable primary PLCG to
15. AREA DEMAND UPDATE HIWAY NUMBER 05 HIWAY BOX ADDRESS 4 0 L 2 3 4 iS 6 000000 000000 000000 000000 000000 000000 000000 000000 Error Counters 000000 000000 000000 000000 000000 000000 000000 000000 Retry Counters 000000 000000 000000 000144 000000 011621 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 Port 1 Statistics 000000 000000 000000 012131 000000 021316 011621 000000 000000 000000 000000 000000 000000 000000 000000 000000 Port 2 Statistics 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 153450 000000 020203 000000 Unused For Information On Functions And Options Displayed On This Menu Unused Position The Cursor On The Desired Target And Press HELP Each emulated DHP hiway box address has its own Data Display Each memory word is 16 bits displayed as 6 digit octal 3 4 Error Counters of Scan of of Output Buffer Keepalive Buffer Misses Firmware Minimum PLCI Firmware Firmware Maximum Number of Freetime 1 Second Current Freetime Freetime 1 Second Processing on Record Last Second on Ac Buffer Misses a Reserved for Firmware Hiway Unused Revision Unused Security Word Numbers Figure 4 3 Hiway Box Memory Data Display PLCG Planning Installation and Service 4 4 5 01 4 3 1 4 3 1 PLC Error and Retry Counters The PLCG maintains communications error counters Memory addresses 1700 1707 PLC In
16. CN Service 1 binder PLCG Planning Installation and Service 4 2 5 01 4 3 Selection of the HIWAY BOX MEMORY target of the SMCC s Main Menu brings up a screen requiring specific data to be filled in See Figure 4 2 04 Sep 94 08 51 16 1 HIWAY BOX MI ER PARAMETERS ER Hiway Number Decimal 1 To 20 ER Hiway Box Address Decimal 1 To 63 ER First Memory Address Octal ER Cyclic Update Interval 0 to 60 Seconds Or Off ER Change Detect ON OFF For Information On Funtions And Options Displayed On this Menu Position The Cursor On the Desired Target And Press HELP Figure 4 2 Hiway Box Memory Selection Display Enter the correct Data Hiway number in the first port Add 32 decimal to the DHP box number and enter the result in the next port Enter 1700 for the First Memory Address Also enable Cyclic Update Interval and Change Detect if desired Press the Enter key to display the data See Figure 4 3 PLCG Planning Installation and Service 4 3 5 01 4 3 04 Jun 91 08 55 00 HIWAY BOX MEMORY DATA CHANGE DETECT RESET PRINT DATA SPI 64 CONSECUTIVE WORDS ARE DISPLAYED STARTING WITH FIRST ADDR PRESS MENU KEY TO RETURN TO MAIN MENU PRESS PAGE FWD PAGE BACK KEY TO ADVANCE OR BACKUP DATA PRESS ENTER KEY TO RE DISPLAY SAME
17. CTION 1 1 General Description 1 2 PLCG Module for CE 1 3 Honeywell Support Services 1 4 Related Publications 2 SITE PREPARATION Storage Conditions Site Requirements Dimensions and Weight Electrical Requirements AC Voltage Options Frequency Current in Amperes at 120 Vac Configurations Nonredundant Configurations Redundant Configurations Limitations Physical Limitations Single vs Multidrop Cabling Cable Lengths Direct Connection PLCG to PLC Connections _ UN w w w w wN NANANINANININININININININININININ N N anane eee D e a t w to w h N AUN 1 Modem Usage and Selection 2 Nonredundant PLCG Port Connections 3 Redundant PLCG Port Connections 3 INSTALLATION 3 1 Unpacking 3 2 Assembly and Cabling 3 2 1 Module Installation 3 2 2 LCN Node Pinning 3 2 3 CLCN Node Pinning 3 2 4 CE Equipment Installation 3 2 5 PLCI Pinning 3 2 5 1 Ram Clear J1 3 2 5 2 Board Revision TS1 3 2 5 3 Baud Rate and Parity TS2 3 2 5 4 Program Options TS3 3 2 6 PLCG Relay Panel Pinning 3 2 7 PLCG Cabling 3 2 8 Port Cabling and Pinning for Modems Using Modbus Protocol 3 2 8 1 Modem Cable 3 2 8 2 Modem Wiring 3 2 8 3 Modem Pinning 3 2 9 Port Cabling for Direct Connection to Modbus Equipment PLCG Planning Installation and Service i 5 01 Table of Contents 3 2 10 Port Cabling for Equipment Using Allen Bradley Protocol 3 2 10 1 Direct Connection to Allen Bradley Controllers 3 2 10 2 Allen Bradley CIM Pinning 3 3 Installation Wrap
18. Honeywell PLC Gateway Planning Installation and Service PL02 500 Tetal Plant Honeywell Implementation PLC Gateway PLC Gateway Planning Installation and Service PL02 500 Release 500 CE Compliant 5 01 Tetal Plant Copyright Trademarks and Notices Copyright 1995 1997 by Honeywell Inc Revision 03 May 22 2001 While this information is presented in good faith and believed to be accurate Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer In no event is Honeywell liable to anyone for any indirect special or consequential damages The information and specifications in this document are subject to change without notice TotalPlant and TDC 3000 are U S registered tradmarks of Honeywell Inc Other brand or product names are trademarks of their respective owners About This Publication This publication is provided to guide the user in planning installing and servicing the Programmable Logic Controller Gateway PLCG Only those components unique to the PLCG are covered in detail It is not intended to be a substitute for standard LCN Site Planning System Installation and Service manuals which are referenced for further detail This manual describes PLCI board 51400997 100 with Firmware Revision J and PLCG relay panel 51304421 100 Early
19. Universal Station to report software indications of hardware failures This section explains the function of these hardware software indicators and will guide you in finding a failure 5 4 1 PLCI Hardware Indicators YELLOW 10 SEGMENT DISPLAY 51400997 100 RED RED SELF BUS TEST TRANS ERROR ERROR Figure 5 1 PLCI Test and Status Indicators 3106 There are four LEDs located on the front left edge of the PLCI board see Figure 5 1 Each LED s definition and a brief description of its use follows They are listed as shown in the figure from left to right PLCG Planning Installation and Service 5 3 5 01 5 4 1 SELF TEST or BOARD FAILURE Red This LED lights under the following conditions e Module power coming on e Module or PLCI reset sequence working e PLCI self test in progress e Self test failed e Local parity errors This LED is extinguished under the following conditions e Self test is completed successfully e Module or PLCI reset sequence completed successfully e PLCI Abort Command sequence completed PASSED MODULE TEST Green This LED is lighted after the PLCI successfully completes the CPU tests TRANSACTION ERROR Red This LED lights under the following conditions e Module bus data parity error e Bus error occurred during DMA access to module RAM This LED is extinguished under the following conditions e Self test is completed
20. Up 4 CHECKOUT 4 1 Power On Tests 4 1 1 Electronics Checks 4 2 Startup 4 3 Communications and Performance Statistics 4 3 1 PLC Error and Retry Counters 4 3 2 Port Statistics 4 3 2 1 Subslots Processed Per Second 4 3 2 2 Number of Messages Transmitted Second 4 3 2 3 Number of Messages Received Second 4 3 2 4 Number of Bytes Transmitted Second 4 3 2 5 Number of Bytes Received Second 4 3 2 6 Number of Scan Buffer Misses Second 4 3 2 7 Number of Keepalive Buffer Misses Second 4 3 2 8 Number of Output Buffer Misses Second 4 3 2 9 Firmware Freetime Second Counters 4 3 2 10 Number of Processing Buffer Misses Second 5 SERVICE 5 1 Overview 5 1 1 Module Configuration Standard and CE Compliant PLCG 5 2 Field Adjustment 5 3 General Troubleshooting 5 4 PLCI Troubleshooting 5 4 1 PLCI Hardware Indicators 5 4 2 PLCI Hardware Indicator Troubleshooting Chart 5 4 3 PLCI System Software Indications 5 4 3 1 Battery Failure 5 4 3 2 Device Failure 5 4 3 3 Data Hiway Port Error Codes 5 5 Spare Parts INDEX PLCG Planning Installation and Service ii 5 01 INTRODUCTION Section 1 This section provides an overview of the PLCG equipment and lists reference documents available from Honeywell 1 1 GENERAL DESCRIPTION The Programmable Logic Controller Gateway provides a method of economically connecting various Programmable Logic Controllers to your Honeywell TotalPlant Solution TPS system This manual guides you through the planning and instal
21. ard PLCG Planning Installation and Service 3 3 5 01 3 2 4 3 2 4 CE Equipment Installation The I O board interfaces both LCN cable A and cable B to the KxLCN board or LLCN ina Dual Node Module New I O boards and inteface cabling was developed to support the CE community standards Figures 3 3 through 3 5 illustrate the CE Compliant hardware J TERM 1 TERM 2 Q tonal O Lone Figure 3 3 CLCN A B Faceplate ASSY NO 51305072 200 REV Aj W Q Q O c lt ao J1 J2 LCN A 2 2 LCN B 53368 A ie Figure 3 4 CLCNA I O Board PLCG Planning Installation and Service 3 4 5 01 BAR CODE ASSY NO 51305072 300 REV A inn d B J2 LCN B 3 2 4 LA Figure 3 5 CLCNA I O Address Pinning O PLCG Planning Installation and Service 3 5 53392 B 5 01 3 2 5 3 2 5 PLCI Pinning Refer to Figure 3 6 to locate the pinning headers and jumpers in the following steps If you are ins
22. ata Terminal Ready DTR Data Set Ready DSR Carrier Detect CD or Data Carrier Detect DCD PLCG Planning Installation and Service 3 9 5 01 3 2 8 3 2 8 1 Modem Cable For connection to a Modicon J478 modem or other short haul modem serving a Modbus port as illustrated in Figure 2 3 C or 2 4 C install a connector on the free end of cable 51304514 100 using Figure 3 8 as a guide Use a standard 25 pin male D Sub connector SHL TXD RXD PLCG Port 1or2 BIS CTS 25 Pin 25 Pin Male D Sub Male D Sub DSR R GND DCD DTR ae Figure 3 8 Cable for a Modem Serving Modbus Protocol PLCG Planning Installation and Service 3 10 5 01 3 2 8 3 2 8 2 Modem Wiring Use the instruction manual provided with your modems to install modem wiring between all of the modems Be sure the wiring meets the following criteria The multidrop modem telephone lines must be 4 wire full duplex with the line driver of the local modem PLCG end in parallel with the line receivers of all remote modems PLC ends Likewise the line drivers of all remote modems are connected to the line receiver of the local modem A single pair of modems point to point must also be 4 wire full duplex with the line driver of each modem connected to the line receiver of the other modem 3 2 8 3 Modem Pinning Use the instruction manual provided with your modems to properly pin yo
23. ations controller See subsection 3 2 6 and Figure 3 7 for a more detailed illustration of the pinning sockets and header NOTE Ports 1 and 2 are independent ports in either nonredundant or redundant configurations and as such cannot support the same tag names on different ports For this reason PLCG redundancy applies to the electronics modules within the TPS equipment and cannot be configured to provide PLC Network Cable redundancy 2 4 3 Limitations There are certain limitations and several options which must be considered in planning your installation 2 4 3 1 Physical Limitations In a redundant application the primary and secondary PLCG modules generally mount in the same rack or in the same dual node module They are normally installed close to each other because the interconnect cable between primary and secondary PLCGs is only 2 meters long If you have a specific reason for separating the PLCG modules further thereby substituting a longer interconnect cable you must reduce the cable length of each cable connected to Port 1 and Port 2 by the same amount that you have increased the length of the interconnect cable Obviously the length of a substitute interconnect cable must be less than 15 meters If your system uses a relay panel the standard cable length to secondary PLCG is 2m but alternate cable lengths are available However if a longer relay panel cable is used the amount added to the relay panel cable mus
24. dex 1 8 respectively and communications retry counters 1710 1717 PLC Index 1 8 respectively for each configured physical PLC on each port In each memory location the 6 octal digits displayed represent two 8 bit counters The upper 8 bits 15 through 08 of each memory word are for Port 1 and the lower bits 07 through 00 are for Port 2 When a communication error is detected between the PLCG and the physical PLC and retry is permitted the retry counter is incremented before the retry is performed If retry is not permitted or retry attempts have been unsuccessful the error counter is incremented Once a second the counters results are transferred to the enabled DHP s database Since the counters are kept by physical PLC all logical PLCs PC index values referencing the same physical PLC will show the same counter value This is true even if the logical PLCs PC index values are in different emulated DHPs The counters are allowed to rollover after reaching maximum value 16 bit counters at maximum displayed as 6 octal digits 177777 8 65 535 10 and are only reset when all emulated DHPs that reference a given physical PLC are disabled off scan 4 3 2 Port Statistics Statistics for both ports are provided as an approximate measure of PLCG performance 4 3 2 1 Subslots Processed Per Second Each time the PLCG processes a subslot parameter assigned to a given port a 16 bit counter is incremented and once per second the resu
25. e less than 6 per hour These storage and shipping requirements are for one year duration only provided the equipment is properly packaged and contains an adequate amount of desiccant moisture removing agent 2 2 SITE REQUIREMENTS The PLCG is designed for a Class A General Industrial environment It must be operated in a temperature environment of 0 50 C 32 122 F While operating components of this system are not designed to withstand greater vibration than 1g This equipment is intended for use in a controlled environment Although TotalPlant Solution TPS system equipment will operate at 0 50 C Honeywell recommends a normal environment of 25 C 77 F with a relative humidity of 40 50 to realize maximum life and enhanced reliability 2 2 1 Dimensions and Weight The approximate dimensions and weight for each PLCG 5 slot module are Height 17cm 7 Weight 21 5 kg 46 Ib Width 48cm 19 Depth 61 cm 24 PLCG Planning Installation and Service 2 1 5 01 2 3 2 3 ELECTRICAL REQUIREMENTS The customer selected ac power option is installed in the PLCG before shipment The inrush current to each electronics module is limited to 15 A 120 V 30 A 240 V 2 3 1 AC Voltage Options 120 220 240 Vac 10 15 2 3 2 Frequency 47 Hz to 63 Hz 2 3 3 Current in Amperes at 120 Vac Avg True RMS Peak Wattage BTUs hr MP PLCGN1 68000 based typical 1 34 1 82 8 86 217 8 742 7 Nonredundant Module maxim
26. ee end of cable 51304514 100 Table 3 3 Allen Bradley Protocol Cable Wiring Locator PROGRAMMABLE CONTROLLER FIGURE MAKE amp MODEL NUMBER Allen Bradley 1770 KF2 Allen Bradley 1771 KE Allen Bradley 1771 KF Allen Bradley 1771 KG Allen Bradley 1775 KA Allen Bradley 1779 KFL Allen Bradley 1779 KFLR Allen Bradley 1785 KE PLCG Planning Installation and Service 3 14 5 01 3 2 10 15 Pin Male D Sub PSR 6 Male D Sub GND 7 DCD 8 DTR 20 GND Transmit and receive data are cross wired in a direct connection Figure 3 11 Cable for Allen Bradley 1771 KE KF KG and 1785 KE PLCG Port RTS 1or2 ai 25 Pin DSR Female D Sub 25 Pin Male D Sub GND DCD 8 DTR 20 NA ee Transmit and receive data are cross wired in a direct connection 16819 Figure 3 12 Cable for Allen Bradley 1770 KF2 and 1775 KA PLCG Planning Installation and Service 3 15 5 01 3 2 10 xX PLCG Port 1or2 25 Pin Female D Sub 7 8 20 Not Nee Transmit and receive data are cross wired in a direct connection Figure 3 13 Cable for Allen Bradley 1779 KFL KFLR and Triconex 4101 EICM 3 2 10 2 Allen Bradley CIM Pinning Methods for pinning CIMs vary between mod
27. els The parameters listed in Table 3 4 are common to all PLCG A B configurations use them as a guide Table 3 4 Allen Bradley Communications Interface Module Settings PARAMETER SETTING BAUD RATE Set the same as the PLCG field port Do not set above 9600 baud on the KF2 The KE KF may be set to 19 2 kbaud see A B manual PARITY Match PLCI setting on TS2 header BCC CRC BCC Block Check Character HANDSHAKING OFF DH DH As required by A B devices EIA 232 422 EIA 232 DIAGNOSTICS Execute diagnostics locally do not pass through EMBEDDED RESPONSES ON DUPLICATE MESSAGE DETECT ON PLCG Planning Installation and Service 3 16 5 01 3 3 3 3 INSTALLATION WRAP UP Dress all cables neatly and out of the way to protect them from accidental damage Plug all modems and PLCG modules into their proper receptacles PLCG Planning Installation and Service 3 17 5 01 PLCG Planning Installation and Service 3 18 5 01 CHECKOUT Section 4 This section tells you how to check the PLCG after it has been installed plugged in and is ready to go 4 1 POWER ON TESTS You do not need to have the PLC equipment installed or connected to perform the checks in this section Do not however perform any of these tests until all other parts of the PLCG have been installed according to Section 3 4 1 1 Electronics Checks Perform these electronics checks on the PLCG electronics module If this is a redundant PLCG installation perfo
28. es use of their own CIMs which interface their own Data Hiway Refer to subsection 3 2 8 and your Allen Bradley manuals for specifics 2 5 3 Redundant PLCG Port Connections Figure 2 4 A and B illustrate examples of direct connection to PLCs from a redundant PLCG Note there can be only two PLCs connected in this manner if you are using Modbus protocol or only one PLC if you are using the Allen Bradley protocol Port 2 cannot be used with Allen Bradley protocol because the protocol is full duplex and messages may be sent and received simultaneously The redundant PLCG firmware uses that port to listen to outgoing messages while Port 1 is receiving messages Modbus protocol is half duplex and messages are not sent and received simultaneously PLCG Planning Installation and Service 2 9 5 01 2 5 3 Notice Figure 2 4 C and D are very similar to those illustrations in Figure 2 3 Allen Bradley full duplex operation prevents Port 2 from being used but there is little loss of capability since up to 16 PLCs may be connected to the same network A Direct Connect Usage Modbus B Direct Connect Usage Allen Bradley EIA 232 cables wired for A B equipment Cross wired ElA 232 Cables lt 15 meters Do not use port 2 On some A B equipment each PLC supports ElA 232 by including the CIM within the PLC The DF 1 Protocol must be used Note When wired direct connect each port serves a single PLC C Modem Usage M
29. g Chart INDICATION SELF TEST ON after power up or reset sequence SELF TEST goes OFF then ON after the HG personality has been loaded TRANSACTION ERROR ON POSSIBLE CAUSE Missing PLCI I O Paddleboard Failed PLCI or PLCI I O Board Incorrect Software Release Incorrect Configuration Memory Board Error PLCG Planning Installation and Service 5 5 SOLUTION Install PLCI I O Paddleboard in the correct slot behind PLCI board Substitute known good boards Check that Software Release 200 or later is being used Check that emulated Data Hiway ports used are addresses 8 through 15 Check that PLCGs are configured for Hiway addresses 2 and 3 Check that PLCG is configured to perform the HTD functions Check for hardware configuration errors re read Sections 2 4 2 5 and 3 2 of this manual Substitute known good memory board s If memory board s are OK suspect the PLCI itself 5 01 5 4 3 5 4 3 PLCI System Software Indications System software indications that indicate hardware failures are presented in the Hiway Status display on the Universal Station US The Hiway Status display lists those brief error statements and codes and describes where they came from 5 4 3 1 Battery Failure The Hiway Status display at the US Universal Station indicates BATT FAIL when a slot 16 failure has been posted from a emulated DHP This does not indicate a battery failure instead it has been used
30. ich mates your PLC Subsections 3 2 7 and 3 2 8 show cable wiring schemes for several types of PLCs and interface devices PLCG Planning Installation and Service 2 6 5 01 2 5 2 5 PLCG TO PLC CONNECTIONS 2 5 1 Modem Usage and Selection Direct connection short haul modems sometimes called line driver or signal converter devices can be used with the PLCG As mentioned earlier direct connection is limited to a maximum of 15 cable meters between PLCI I O or Relay card Signal converters are devices that convert signals between EJA 232 an EIA 422 or 485 and are commonly used to provide extended distance or multidrop configurations A short haul modem presents an EIA 232 hardware interface to the PLCG or PLC similar to that presented by conventional telephone modems The short haul modem however uses dedicated lines not telephone lines and may take liberties with interface protocol that would not be acceptable in conventional telephone modem communications Conventional telephone modems are not typically used with the PLCG because they severely limit bandwidth and their necessary low speeds baud rate might degrade PLCG performance The PLCG also does not support the handshake signals commonly required for modems including Request To Send RTS Clear To Send CTS Carrier Detect CD Data Set Ready DSR and Data Terminal Ready DTR Various device and cable configurations are feasible Consult with a communication link special
31. irect connection 46817 Figure 3 10 Cable for Direct Connection to Modicon 584 PLCG Planning Installation and Service 3 13 5 01 3 2 10 3 2 10 Port Cabling for Equipment Using Allen Bradley Protocol NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs If wiring information is not given here for your equipment check with Honeywell s Multivendor Interface Program If an MVI Program Test Report is available for that equipment cable wiring information will be given in that report PLCG uses only the following signals Pin 1 Shield for electrical noise protection Pin 2 Transmit Data TXD output from PLCG Pin 3 Receive Data RXD input to PLCG Pin 7 Logic Ground GND PLCG does NOT support these EIA 232 handshake signals Request To Send RTS Clear To Send CTS Data Terminal Ready DTR Data Set Ready DSR Carrier Detect CD or Data Carrier Detect DCD 3 2 10 1 Direct Connection to Allen Bradley Controllers For connection to Allen Bradley protocol PLCs as illustrated in Figure 2 3 B or D and 2 4 B or D use Table 3 3 to find the model number of the equipment you are using From the table locate the figure which will aid you in obtaining the proper connector then install it on the fr
32. isses Second Number of Processing Buffer Misses Second Number of Scan Buffer Misses Second Subslots Processed per Second Configurations Limitations Cable Lengths Direct Connection Physical Limitations Single vs Multidrop Cabling Nonredundant Configurations Redundant Configurations Current in Amperes at 120 Vac Device Failure Dimensions and Weight Direct Connection to Allen Bradley Controllers o oo OWA De CW A NN Poe Pee ae No Gos Cosco Gort ADR DD OA RRE IN 0 O ng G90 G00 COCO RR Re RON ean 2 TO NOs TOTO 9592509 02 09 SCNOWBRAWHHOHOANNNLNVYUNNNNYNHWATAUWOO L N o 0 o Ph MP Pp on LLun AWWA HADODONWNAMTONAWWNWAANOONW o ro PLCG Planning Installation and Servicelndex 1 5 01 Index Topic Section Heading N A Direct Connection Electrical Requirements AC Voltage Options Current in Amperes at 120 Vac Frequency Electronics Checks European Compliance CE for PLCG CLCN Node Pinning CE Equipment Installation Field Adjustment Firmware Freetime Second Counters Frequency General Description General Troubleshooting Honeywell Support Services Installation Wrap Up LCN Node Pinning Limitations Modem Cable Modem Pinning Modem Usage and Selection Modem Wiring Module Configuration Standard and CE Compliant PLCG Module Installation Non Redundant Configurations Non Redundant PLCG Port Connections Number of Bytes Received Second Number of Bytes Transmitted Second Number of Keepalive Buffer Misses Second
33. ist or vendors for devices and cabling appropriate to your application PLCG Planning Installation and Service 2 7 5 01 2 5 2 2 5 2 Nonredundant PLCG Port Connections Figure 2 3 A and B illustrate examples of directly connecting PLCs to a nonredundant PLCG A maximum of only two PLCs may be connected in this manner Notice the cables can be no longer than 15 meters Also note the cables must be wired so that both the PLCG and the PLCs think they are connected to a modem Details of this cross wiring will be covered in subsections 3 2 7 and 3 2 8 A Direct Connect Usage Modbus B Direct Connect Usage Allen Bradley Cross wired ElA 232 EIA 232 cables wired Cables lt 15 meters for A B equipment On some A B equipment each PLC supports Note When wired direct connect each port serves a single PLC EIA 232 by including the CIM within the PLC The DF 1 Protocol must be used C Modem Usage Modbus Standard EIA 232 Full duplex twisted pair or other cables lt 15 meters Single PLC Standard ElA 232 cables lt 15 meters Three multidrop PLCs shown D Modem Usage Allen Bradley EIA 232 cables wired for A B equipment Single PLC A B Data Hiways Port 2 EIA 232 cables wired for A B equipment Three multidrop PLCs shown CIM Allen Bradley Communication Interface Module In all nonredundant configurations one port may Note Both ports of a PLCG support a total of 16 PLCs support ModBus while the
34. lation considerations unique to the PLCG equipment However this manual is not intended to be a substitute for the LCN Site Planning manual and LCN System Installation manual listed in the standard LCN publications referenced in subsection 1 3 of this manual The PLCG runs under an unmodified HG Hiway Gateway software personality The hardware is similar to HG hardware contained in a standard TPS five slot equipment module that supports the Local Control Network LCN In the PLCG the Data Hiway Interface DHIF board and its I O board are replaced with the Programmable Logic Controller Interface PLCI board and its I O board A PLCG relay panel is installed on the rear of the module A redundant PLCG pair is composed of two PLCG modules equipped as above but sharing one relay panel Figure 1 1 PLCG Nonredundant Dual Node Module Front View PLCG Planning Installation and Service 1 1 5 01 1 2 1 2 PLCG MODULE FOR CE The CE compliant PLCG and PLCI I O cage supports the three styles of modules It supports the nonredundant PLCG the redundant PLCG and the communications redundant PLCG The CE compliant modules are capable of holding both the older and newer types of I O board designs The I O File has been modified to make electrical contact with face plates attached to the I O boards This provides low impedance ground path for the cable shields The face plates and the wire mesh covering the fan openings also provides EMI
35. lts are transferred to the emulated DHP database The counter provides a measured versus calculated value of the number of subslots processed per second as seen by the PLCG The number of subslots processed during the last second before the transfer is then displayed in this location 1721 1731 for the respective port NOTE Although TDC 3000X system software treats a composite tag as a single data point its implementation requires the use of 2 3 or 4 subslots in the PLCG Since the PLCG must collect the data for each subslot in use PLCG performance must be measured and compared in subslots parameters per second If you wish to convert to TDC tags per second from subslots per second you must use a correction factor which expresses the number of subslots per TDC tag To calculate the correction factor use the equation below If the system being measured contains any composite TDC tags the correction factor will have a value less than one SUBSLOTS overall TAG count TAGs Fe ee a 2 TIME overall SUBSLOT count TIME PLCG Planning Installation and Service 4 5 5 01 4 3 2 4 3 2 4 3 2 2 Number of Messages Transmitted Second This location 1721 1731 contains the number of complete messages transmitted through this port in the previous 1 second period 4 3 2 3 Number of Messages Received Second This location 1722 1732 contains the number of complete messages received through this port in the previous 1 second period 4 3
36. npacking PLCG Planning Installation and Servicelndex 3 Section Heading ool w w w OT NONNA AHYWCORSD NOB OVVATNNOATAGAAS aL NN w w e gt w SBAUUNpPOH NNARAWONDH pha hanoo0ooNn Ww 5 01 PLCG Planning Installation and Servicelndex 4 5 01 FAX Transmittal FAX No 602 313 4212 TO Information Development Reader Comments Title of Document PLCG Planning Installation and Service Document Number PLO2 500 Issue Date 05 01 Comments Recommendations FROM Name Date Title Company Address City State ZIP Telephone FAX Honeywell Inc You may also call 1 800 343 0228 available in the 48 Industrial Automation and contguous states Control 16404 N Black Canyon Hiway Phoenix AZ 85023 Honeywell Industrial Automation and Control 16404 N Black Canyon Hiway Phoenix Arizona 85023
37. oard Revision Socket Do not change TS1 TS3 Program TS3 as follows PIN DESCRIPTION Program TS2 according to chart in lower Always Shorted right corner of board All pins Always Shorted SHORTED both ports at 9600 baud Short Enable User Outputs with odd transmit receive parity Open Disable User Outputs Always Shorted Always Open TS2 JUMPERS Short Max Data Acquision Open Reduced Bandwidth Short Allow PLCG Output to track changes to PLC Ladder Open Don t track changes to PLC Ladder Short Redundant operation must be set in both PLCGs Open Nonredundant operation RAM CLEAR Jumper Do not change N Jl 51400997 100 Figure 3 6 PLCI Pinning Honeywell factory setting 3 2 5 4 Program Options TS3 Pin 1 If you are installing a redundant PLCG leave pin 1 shorted it must be shorted on the PLCI board in both PLCGs If you are installing a nonredundant PLCG open pin 1 Pin 2 This pin is only recognized in applications involving Modbus protocol If you want the PLCG to track changes to the digital outputs made by the PLC ladder logic leave pin 2 shorted The PLCG will include the digital outputs in its periodic scan If you do not want changes in the ladder logic tracked open this pin Note that in this mode the Modbus digital outputs are scanned immediately after the emulated DHP Enable Processing command Thereafter digital outp
38. odbus 4 EIA 232 cables lt 1 Full duplex twisted pair or other Standard 82 cables 15 PA os PLC Three multidrop PLCs shown D Modem Usage Allen Bradley EIA 232 cables wired for A B equipment EIA 232 cables wired for A B equipment A B Data Hiways Three multidrop Do not PLCs shown use port 2 Maximum 16 EIA 232 cables wired for A B equipment CIM Allen Bradley Communication Interface Module Figure 2 4 Typical Redundant PLCG Port Connections PLCG Planning Installation and Service 2 10 5 01 INSTALLATION Section 3 This section provides information for unpacking and assembling the PLCG 3 1 UNPACKING When the equipment arrives at the system site open each shipping box remove the protective wrapping and carefully inspect each piece for any physical damage If damaged immediately notify the carrier and your Honeywell sales representative as to the extent and type of damage Also check each piece of equipment against the invoice list for any missing items 3 2 ASSEMBLY AND CABLING Refer to Figure 2 1 for an illustration of a nonredundant PLCG installation Note the PLCG relay panel located on the rear of the module Refer to Figure 2 2 for an illustration of a redundant PLCG installation Note that only one PLCG relay panel is mounted on the primary PLCG NOTE Some assembly and cabling of this equipment may have been done at the factory If so please check your equipment and verify its
39. or direct connection to Modbus protocol PLCs as illustrated in Figure 2 3 A or 2 4 A use Table 3 2 to find the model number of the equipment you are using From the table locate the Figure which will aid you in obtaining the proper connector then install it on the free end of cable 51304514 100 Table 3 2 Modbus Protocol Cable Wiring Locator PROGRAMMABLE CONTROLLER FIGURE MAKE AND MODEL NUMBER Honeywell 620 with 620 0043 CIM Figure 3 9 Modicon 184 with J347 interface Figure 3 9 Honeywell Modicon 384 with J347 interface Figure 3 9 Modicon 584 Figure 3 10 Modicon 884 Figure 3 9 Modicon 984 Figure 3 9 Triconex 4101 EICM Figure 3 13 This device employs the Modbus protocol but uses a cable identical to one used for Allen Bradley devices PLCG Planning Installation and Service 3 12 5 01 3 2 9 25 Pin TXD Male D Sub 25 Pin PLCG Port PXP Male D Sub 1or2 RTS CTS DSR GND DCD DTR cy Naot Transmit and receive data are cross wired in a direct connection 16816 Figure 3 9 Cable for Direct Connection to Modicon 884 984 and Others SHL TXD RXD PLCG Port Male 1or2 RTS 24 Pin Round CTS Connector 25 Pin Male D Sub DSR ITT Cannon GND KPTO6F 20 24P or DCD Bendix PTO6E 20 24P SR DTR DTR L Transmit and receive data are cross wired in a d
40. other port uses A B protocol provided the cables are wired to match the equipment 3103 A Figure 2 3 Typical Nonredundant PLCG Port Connections PLCG Planning Installation and Service 2 8 5 01 2 5 3 Allen Bradley includes their CIM Communications Interface Module inside some PLC models allowing the direct connection shown in B See Section 3 for detailed wiring of this cable Figure 2 3 C and D illustrate examples of modem usage from a nonredundant PLCG The modems used in illustration C are the short haul modems previously discussed The single PLC connected via two modems to Port 1 illustrate a maximum length configuration which will service a PLC at the greatest distance from the PLCG The multidrop PLCs connected to Port 2 in illustration C show a typical network of PLCs using the Modbus protocol These drops are connected half duplex with the local modem connected to the PLCG and remote modems connected to the PLCs The local is a master which commands each remote to respond at a specific time Additional loading caused by several modems on the network may reduce the overall length of the network twisted pair cable consult the manuals for your modem for particulars Illustration D shows Allen Bradley equipment connected in similar arrangements to illustration C Allen Bradley protocol is full duplex that is any PLC or the PLCG may talk at any time Allen Bradley requir
41. per Removed 1 Parity Overall number of jumpers 64 cut including the parity jumper must be an odd number This example indicates node address 03 NOTE THE SOFTWARE WILL ALLOW ONLY NODE ADDRESSES 1 64 AT THIS TIME Figure 3 1 LCN I O Board Address Jumpers PLCG Planning Installation and Service 3 2 5 01 3 2 3 3 2 3 CLCN Node Pinning By convention the node address for a nonredundant PLCG is even The node addresses for a redundant pair is even for the primary PLCG and numerically one higher odd for the secondary PLCG If you are installing a nonredundant PLCG perform the following steps on the PLCG module If this is a redundant PLCG installation perform these steps twice using a node address on the secondary PLCG one higher from that of the primary PLCG ASSY NO 51305072 100 REV A BAR CODE 0 Ji J2 LCN LCN A o o LCN B Address p fe Figure 3 2 LCN I O Board Address Jumpers 1 Remove the LCN I O paddleboard from rear slot 2 in the PLCG module Refer to Figure 3 2 for instructions and the location of the pinning header on the LCN I O board Pin the node address as shown Be sure to adjust the parity jumper as required 2 Reinstall the LCN I O paddlebo
42. production relay panel 51304154 100 may be used in all applications except Allen Bradley protocol using redundant PLCGs This publication supports TotalPlant Solution TPS system network Release 500 and CE Compliant hardware TPS is the evolution of TDC 3000 Any equipment designated as CE Compliant complies with the European Union EMC and Health and Safety Directives All equipment shipping into European Union countries after January 1 1996 requires this type of compliance denoted by the CE Mark PLCG Planning Installation and Service 5 01 Scope ATTENTION CAUTION 53893 53894 1 DANGER SHOCK HAZARD W 9 DANGER HIGH VOLTAGE 53895 53896 j 53897 Standard Symbols The following defines standard symbols used in this publication Notes inform the reader about information that is required but not immediately evident Cautions tell the user that damage may occur to equipment if proper care is not exercised Warnings tell the reader that potential personal harm or serious economic loss may happen if instructions are not followed Ground connection to building safety ground Ground stake for building safety ground Electrical Shock Hazard can be lethal Electrical Shock Hazard can be lethal Rotating Fan can cause personal injury PLCG Planning Installation and Service 5 01 Table of Contents 1 INTRODU
43. rd 5 3 GENERAL TROUBLESHOOTING Before investigating deeply into a problem make some preliminary checks e Is power applied to the module Check switches fuses and circuit breakers on all equipment to insure they are functioning WARNING DO NOT REMOVE OR REPLACE CIRCUIT BOARDS WITH THE POWER ON Do not remove handle or transport circuit boards without observing proper Electrostatic Discharge ESD procedures To review ESD procedures see the LCN Site Planning manual in the LCN Site Planning amp Installation binder PLCG Planning Installation and Service 5 2 5 01 5 4 e Note that the functional boards can be accessed through the front of each module by removing the front cover Inspect the confidence indicators on each processor board and the EPLCI board Check power supply and fan confidence indicators Double check the pinning on the EPLCI board shown in subsection 3 2 3 e The PLCI I O KLCN_CA or KLCN_CB paddleboards are accessed from the rear of the module To isolate a failed board power supply fan assembly or other Optimum Replaceable Unit ORU follow the service procedures provided in the Five Ten Slot Module Service manual or the Dual Node Module Service manual in the LCN Service 1 binder 5 4 PLCI TROUBLESHOOTING The PLCI board has unique indicators on its front edge to offer confidence that the board is working and to provide assistance in case of a failure The board also communicates with the
44. rm these checks on both PLCG modules 1 Remove the front cover of the PLCG module Before turning power on ensure the LO NOM HI jumper or switch on the front of the power supply is in the center or NOM position 2 Set the POWER switch to ON while observing the LEDs on the power supply fan assembly and on the individual cards in the unit Note that the red LEDs on the boards light for a few seconds it takes less than 30 seconds to complete the power up tests then they turn off and the green LEDs turn on If any red LEDs on the boards remain on some portion of the power up tests have failed trecord the alphanumeric status display code and proceed to Five Ten Slot Module Service manual in the Service binder If the power up test is successfully completed for all nodes all green LEDs on all boards are on there may also be some yellow LEDs on or flashing and the alphanumeric status display indicates the node address you set in Section 3 2 2 of this manual 3 Check the power supply status LEDs POWER OK and ERROR and the FAN ALARM LED Note that the FAN ALARM and ERROR LEDs are off and the POWER OK LED is on it is a fault condition if both the ERROR and POWER OK LEDs are ON 4 Press the momentary RESET switch Note the power up tests are initiated similar to step 2 and the results are satisfactory 5 Replace the front cover PLCG Planning Installation and Service 4 1 5 01 4 2 4 2 STARTUP The PLCG software perform
45. s exactly like an HG Hiway Gateway and looks exactly like an HG to the operator To continue further load the PLCG with the HG personality use PLCG configuration rules and later use HG operations Configuration information is in the remaining publications in this binder Loading and operating procedures are in the Process Operations binder 4 3 COMMUNICATIONS AND PERFORMANCE STATISTICS To assist installation and on going performance monitoring the PLC Gateway provides information about PLC communications and certain PLCG performance statistics Once per second the information is transferred to the database of each on scan emulated DHP making it available at the Universal Station via the System Maintenance Control Center SMCC To prevent interference with off line operations statistical information is not transferred to the database of an emulated DHP which is not enabled on scan See Figure 4 1 DD MMM YY 08 45 30 SMCC MAIN MENU MODULE MEMORY HIWAY BOX MEMORY PROBE FAILED MODULE SYSTEM MAINT JOURNAL ACTIVE MAINT JOURNAL MODULE ERROR REV CONFIG STATUS SECTOR INIT REASSIGN MAIN MENU For Information On Funtions And Options Displayed On this Menu Position The Cursor On the Desired Target And Press HELP Figure 4 1 System Maintenance Control Center Main Menu Display General information on use of the SMCC is in Maintenance Test Operations section of the L
46. shielding around the module The module is similar in all other respects PLCI I O CLCNB Figure 1 2 CE Compliant PLCG Nonredundant Dual Node Module Back View 1 3 HONEYWELL SUPPORT SERVICES Optional Installation Support Field Services and Technical Support are available during the on site installation and checkout of TPS system equipment Honeywell representatives are available to assist in interpreting this manual and to help resolve problems or situations not covered by this manual A toll free number 800 822 7673 in Arizona 602 863 5558 is available for technical assistance PLCG Planning Installation and Service 1 2 5 01 1 4 RELATED PUBLICATIONS 1 4 Honeywell s standard documentation is included with the system The following publications apply to the TPS system and should be referred to as required and available Publication Title Local Control Network Planning LCN System Installation LCN System Checkout Hiway Gateway Specification and Technical Data Five Ten Slot Module Service Dual Node Module Service Maintenance Test Operations Test System Executive Hardware Verification Test System Core Module Test System Maintenance Test Operations Process Operations Manual PLCG Specification amp Technical Data PLCG Control Functions PLCG Implementation Guidelines PLCG Parameter Reference Dictionary PLCG Forms Publica
47. stallation and Service 3 8 5 01 3 2 7 3 2 7 PLCG Cabling 1 Connect a l meter 3 ft cable 30731611 001 between J2A on the relay panel and J2 on the PLCI I O board in same PLCG module CE Compliant hardware uses a 3 meter cable 51196074 100 Refer to Figure 2 1 2 If you are using PLCI and PLCI I O boards with the relay panel connect a 1 meter 3 ft cable 51201420 001 between J2A on the relay panel and J2 on the PLCI I O board at the rear of the module Refer to Figure 2 2 3 If this is a redundant Gateway installation using the relay panel connect a 2 meter 6 ft cable 51201420 002 between J2B on the relay panel and J2 on the PLCI I O board in the secondary module Refer to Figure 2 3 4 Besure the two latches which secure each cable end to its connector are fastened on all of the cables 3 2 8 Port Cabling and Pinning for Modems Using Modbus Protocol NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs PLCG uses only the following signals Pin 1 Shield for electrical noise protection Pin 2 Transmit Data TXD output from PLCG Pin 3 Receive Data RXD input to PLCG Pin 7 Logic Ground GND PLCG does NOT support these EIA 232 handshake signals Request To Send RTS Clear To Send CTS D
48. successfully e Module power coming on e Module or PLCI reset completed e PLCI Abort Command in process PRIMARY PLCI Green This LED is lighted when the PLCI is on line and functioning as the primary HG 10 SEGMENT DISPLAY Yellow Also on the front edge of the PLCI board there is a 10 Segment display composed of yellow LEDs see Figure 5 1 The function of each LED in this display numbered 1 to 10 from left to right are Segments 1 2 and 3 monitor Field Port 1 Their functions are 1 TX RTS Illuminates when the transmit Request To Send is asserted 2 RX DATA Illuminates when Receive Data goes to a spacing condition 3 DSR CD Illuminates when Data Set Ready and Carrier Detect are asserted Segments 4 5 and 6 monitor Field Port 2 Their functions are 4 TX RTS lIlluminates when the transmit Request To Send is asserted 5 RX DATA Illuminates when Receive Data goes to a spacing condition 6 DSR CD Illuminates when Data Set Ready and Carrier Detect are asserted Segments 7 8 and 9 are used at the factory They have no use in field troubleshooting 10 REDUNDANT PARTNER Illuminates when the redundant partner is on line PLCG Planning Installation and Service 5 4 5 01 5 4 2 5 4 2 PLCI Hardware Indicator Troubleshooting Chart Use Table 5 1 to aid you in determining the cause of a failure detected by the two fault indicators on the PLCI Table 5 1 PLCI Hardware Indicator Troubleshootin
49. t be subtracted from each of the Port 1 and Port 2 cables Obviously the length of a substitute relay panel cable must be less than 15 meters 50 feet PLCG Planning Installation and Service 2 5 5 01 2 4 3 2 4 3 2 Single vs Multidrop Cabling There must be only a single cable from a port to the PLC modem or communications controller that port is to service If you want to use a Modbus protocol multidrop arrangement you must place a local modem at the PLCG with remote modems connected to each of the PLCs in the network Allen Bradley A B protocol multidrop arrangements always connect through an Allen Bradley communications controller a CIM for Communications Interface Module Since this communications controller supplies the multidrop connections only a single cable is needed from the PLCG port to the A B controller 2 4 3 3 Cable Lengths The cables from the PLCG ports cannot be longer than 15 cable meters 50 cable feet If the distance to a PLC or communications controller exceeds this limit you must use short haul modems See subsection 2 5 for modem considerations 2 4 3 4 Direct Connection If you are connecting a single PLC or an A B communications controller to one of the ports and the cable length from the PLCG to the PLC is less than 15 cable meters you may use an EJA 232 direct connection no modems In this arrangement the EIA 232 cable supplied by Honeywell must be specifically wired to a connector wh
50. talling a redundant PLCG pair both PLCI boards must be pinned the same way 3 2 5 1 Ram Clear J1 Locate J1 and insure that a jumper is installed 3 2 5 2 Board Revision TS1 Do not alter TS1 the Board Revision header 3 2 5 3 Baud Rate and Parity TS2 The baud rate of the two serial interfaces serving Ports 1 and 2 are set up with the jumpers on TS2 near right center in Figure 3 6 See Table 3 1 or the table on the PLCI board for the pinning information Be sure the baud rate for a given port matches the PLC s it is communicating with The baud rates of the ports may be set at different speeds Notice Port 1 uses the higher numbered pins The transmit and receive data parity for Ports 1 and 2 are set by jumpers 5 and 1 respectively To send and receive odd parity on a port its respective jumper must be shorted Conversely even parity is obtained by the jumper being open Make sure the parity of a port agrees with the parity sent and expected by the PLC s to which it is connected Table 3 1 Baud Rate Pinning on PLCI Board PORT 2 PORT 1 PIN 2 PIN 3 PIN 4 PIN 6 PIN 7 PIN 8 OPEN SHORT OPEN SHORT SHORT OPEN SHORT OPEN SHORT SHORT SHORT SHORT OPEN OPEN OPEN OPEN OPEN SHORT OPEN SHORT SHORT OPEN SHORT OPEN SHORT SHORT SHORT SHORT OPEN OPEN OPEN OPEN Honeywell factory setting is 9600 baud with odd parity PLCG Planning Installation and Service 3 6 5 01 3 2 5 B
51. th an error Timeout Retries are enabled and normal data collection attempts are resumed Infrequent transient errors will allow communications to be restored before three consecutive timeouts occur and will cause minimal impact on scan times If communication cannot be re established the PLCI will wait for the next scan to try again Retries are not allowed on certain errors where they are deemed unlikely to succeed Each error code explanation in Table 5 2 indicates whether retries are allowed or not PLCG Planning Installation and Service 5 6 5 01 5 4 3 Table 5 2 PLCI Software Indication Troubleshooting Chart FAILURE Link Failure Communications Timeout Configuration Failure CRC Error Message Error POSSIBLE PROBLEM Communications protocol violation detected by PLCI Possible errors are Receive Buffer Overflow Parity Error Framing Error etc Retries allowed A B Posted on receipt of local error code 03 or 04 Verify by monitoring RX DATA and RTS indicators on indicated PLCG field port see subsection 5 4 1 Timeout indicated by RTS blinking while RX DATA is dark Retries allowed Possible causes are e PLC cable disconnected or connected to wrong field port e PLCI pinning of baud rate parity does not match PLC pinning e DHP definition of PLC address does not match that at PLC e PLCI I O paddleboard not cabled to relay panel e Relay panel failure see pinning in subsection 3 2 3 A B May
52. tio n Number SW02 501 SW20 500 SW20 510 HG03 500 LC13 500 LC13 510 SW11 502 SW13 510 SW13 511 SW13 512 SW11 502 SW11 501 PLO3 500 PLO9 500 PL12 500 PLO9 540 PL88 500 PLCG Planning Installation and Service 1 3 Binder Title System Site Planning 1 LCN Installation LCN Installation System Summary 2 LCN Service 2 LCN Service 2 LCN Service 1 LCN Service 3 LCN Service 3 LCN Service 3 LCN Service 1 Operation Process Operations System Summary 2 Implementation PL C Gateway Implementation PL C Gateway Implementation PL C Gateway Implementation PL C Gateway Binder Number 3020 1 3025 3025 3010 2 3060 2 3060 2 3060 1 3060 3 3060 3 3060 3 3060 1 3050 3010 2 3080 3080 3080 3080 5 01 PLCG Planning Installation and Service 1 4 5 01 SITE PREPARATION Section 2 This section provides the following information for the PLCG Storage conditions site requirements electrical requirements and configuration information 2 1 STORAGE CONDITIONS If the PLCG is to be placed in storage follow these environmental constraints Temperature 35 70 C Humidity RH 10 80 max wet bulb 20 30 C Shock 3 0 g for 10 milliseconds When enclosed in the original shipping container Note that the temperature relative humidity cannot be cycled such that moisture or condensation occurs on the equipment keep the rate of chang
53. um 2 06 2 78 13 14 283 1 965 4 MP PLCGR1 68000 based typical 2 68 3 64 17 72 435 6 1485 4 2 Redundant Modules maximum 4 12 5 56 26 28 566 2 1930 8 Two modules required MP PLCGN3 68020 based typical 0 939 1 27 6 99 152 5 520 0 Nonredundant Module maximum 1 45 1 94 10 35 198 3 676 2 MP PLCGR3 68020 based typical 1 878 2 54 13 98 305 0 1040 0 2 Redundant Modules maximum 2 90 3 88 20 70 396 6 1352 4 Two modules required PLCG Planning Installation and Service 2 2 5 01 2 4 2 4 CONFIGURATIONS Various nonredundant and redundant configurations of the PLCG connected to PLCs of different manufacture are available Depending upon certain limitations the PLCG may communicate to the PLCs either through short haul modems or by a direct connection 2 4 1 Nonredundant Configurations Figure 2 1 shows a PLCG connected in a nonredundant 5 slot module configuration Connections for a dual node module configuration are the same but the PLCG relay panel is mounted horizontally on the rear of the module Each PLC port PORT 1 and PORT 2 in the figure may service any number of individual Programmable Logic Controllers up to a Honeywell supported total of 16 PLCs per PLCG See subsection 2 5 2 for examples of nonredundant port cabling configurations NOT USED PLCI VO N REDUNDANT NO RS A B CONNECTION LCN A LCN B LCN I O a IOl sore C J PLCG MM RELAY PANEL
54. ur modems Be sure they meet the following criteria The local PLCG end modem must be pinned to hold its transmitter enabled at all times normally by putting RTS CTS in the ON position The local modem must also be pinned to hold RXD in the marking state in the absence of a valid carrier Each remote PLC end multidrop modem must be pinned to enable its transmitter only when the PLC raises RTS All remote modems must also be pinned for an RTS CTS delay of approximately 5 to 15 milliseconds This delay can be determined empirically by the user based upon the hardware he has chosen We have found the LD485A Black Box modems Table 2 1 operate satisfactorily using the 5 millisecond delay RTS CTS delay need not be pinned in the local modem of a multidrop network and is also immaterial in a point to point arrangement PLCG Planning Installation and Service 3 11 5 01 3 2 9 3 2 9 Port Cabling for Direct Connection to Modbus Equipment NOTE Two 51304514 100 field port cables each without a plug on one end have been shipped with your PLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs If wiring information is not given here for your equipment check with Honeywell s Multivendor Interface Program If an MVI Program Test Report is available for that equipment cable wiring information will be given in that report F
55. uts are updated using PLC write echo data PLCG Planning Installation and Service 3 7 5 01 Pin 3 Pin 4 Pin 5 Pin 6 3 2 6 If you want the PLCG to acquire data at the maximum rate leave pin 3 shorted If you want the acquisition rate reduced open this pin Note that with this pin shorted data is double buffered when the pin is opened one data buffer is disabled For slower PLC devices open this pin to reduce data transfer rate Always leave this pin open Always leave this pin shorted If you want the PLC to receive user outputs via Analog outputs Digital outputs and Timer Counters leave Pin 6 shorted If you want to suppress user outputs to the PLC open Pin 6 Pins 7 amp 8 Always leave these pins shorted 3 2 6 PLCG Relay Panel Pinning Refer to Figure 3 7 If you are installing a nonredundant PLCG or if you are assembling a redundant Modbus installation check that the header on the relay panel is in the OTHERS socket Newer relay panels have this header labeled as NORMAL CONFIG If you are assembling a redundant Allen Bradley installation be sure the relay panel header is in the REDUNDANT A B socket NORMAL REDUNDANT CONFIG A B RY1 J2 PORT 1 knd bed PLCG RELAY PANEL 51304421 100 O Oc Honeywell Figure 3 7 PLCG Relay Panel PLCG Planning In

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