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Enhanced PLC Gateway Planning, Installation and Service

1. l ASSY NO 51304812 200 l 0 E REV C Field Port1 Interlink Field Port 2 EPLCIVO W Figure 3 3 EPLCI I O Board EPLCG Planning Installation and Service 3 4 5 01 3 2 5 3 2 5 EPLCG Relay Panel Pinning Refer to Figure 3 4 If you are installing a nonredundant EPLCG or if you are assembling a redundant Modbus installation check that the header on the relay panel is in the NORMAL CONFIG socket If you are assembling a redundant EPLCG pair with an Allen Bradley installation and using a PLCI I O board with the relay panel be sure the relay panel header is in the REDUNDANT A B socket 3 2 5 1 EPLCG Relay Panel for CE The relay board is mounted on a bracket on the outside of the module therefore it is not within the shield of the module sheet metal To make it CE compliant several changes were made to minimize EMC These changes include adding a chassis ground layer to both outside exposed layers of the board The connector shield was changed by using a 360 degree shield connector and changing the cables to braid over foil shields with 360 degree shielded back shells NORMAL REDUNDANT CONFIG A B RY1 J2 PORT 1 k FF Oy EPLCG RELAY PAN
2. CIM CIM Allen Bradley Communication Interface Module B Modem Usage Modbus with Redundant Communicati EIA 232 cables wired for A B equipment Short Haul Modem or Modems Converter o 7 Modem or Converter EIA 232 cable Modem or Port 1 Converter Modem or Converter Three multidrop PLCs shown MAI Modem or Maximum 16 Port 2 Modem or Converter EIA 232 cable Converter Modem or Converter Modem or Converter 11893 B Figure 2 7 Port Connections for Redundant EPLCGs with Redundant Communications Figure 2 7 B illustrates use of the PLCG I O card and relay panel with Honeywell or Modbus protocol and redundant communications EPLCG Planning Installation and Service2 14 5 01 INSTALLATION Section 3 This section provides information for unpacking and assembling the EPLCG 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
3. REV CONFIG STATUS SECTOR INIT REASSIG MAIN MENU For Information On Funtions And Options Displayed On this Menu Position The Cursor On the Desired Target And Press HELP E 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 LCN Service 1 binder EPLCG 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 t
4. PLCG EPLCG Configuration for Type 4 Installation 53306 EPLCG Planning Installation and Service 2 5 5 01 2 4 3 Type 5 is used with redundant communications the relay panel Honeywell or Modbus protocols and modem or converter devices for multidrop connections Both ports of the Relay card must use the same protocol and have an equivalent path to all connected PLC devices EPLCG EPLCG PLCI PLCI V O Card I O Card Relay Panel PLC PLC PLC PLC EPLCG Configuration for Type 5 Installation 53307 2 4 3 MP REPLC3 and MP REPLC7 REDUNDANT GATEWAYS WITH A B REDUNDANT COMMUNICATIONS Type 6 can only be configured with 2 EPLCGs EPLCI I Os Interlink cable Allen Bradley Communications Interfaces and uses the Redundant Communications option for Allen Bradley protocol The Interboard link is asynchronous EIA 422 at 38 4 Kbaud and dedicated to primary EPLCG to secondary EPLCG redundant partner communications EPLCG EPLCI Interlink VO cad Cable EPLCG EPLCl V O Card Allen Bradley Communication Interfaces PLC PLC PLC PLC EP
5. DCD 8 DTR 20 So we Transmit and receive data are cross wired in a direct connectic 3072 A Figure 3 10 Cable for Allen Bradley 1779 KFL KFLR and Triconex 4101 EICM 3 2 9 2 Allen Bradley CIM Pinning Methods for pinning CIMs vary between models The parameters listed in Table 3 4 are common to all EPLCG 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 EPLCG 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 EPLCI 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 EPLCG Planning Installation and Service3 12 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 EPLCG modules into their proper receptacles EPLCG Planning Installation and Service3 13 5 01 EPLCG Planning Installation and Service3 14 5 01 CHECKOUT Section 4 This section tells you how to check the EPLCG 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 connect
6. Message Error 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 EPLCG Planning Installation and Service 5 7 5 01 Illegal Function Illegal Data Address Illegal Data Value Device Fault Entered Program Mode Busy Insufficient Buffers NAK Negative Acknowledge 5 4 3 Modbus Presented when the PLC returns the ILLEGAL FUNCTION exception code 01 No retry A B Not used Modbus Presented when the PLC returns the ILLEGAL DATA ADDRESS exception code 02 No retry See subsection 2 5 in the EPLC Gateway Control Functions manual in the mplementation EPLC Gateway binder for hints on avoiding configuration errors A B Posted on receipt of remote error code 50 or 80 Modbus Presented when the PLC returns the ILLEGAL DATA VALUE exception code 03 No retry A B Not used 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 Modbus Presented when the PLC returns the PROGRAM ACKNOWLEDGE exception code 05 The EPLCG considers this response an error because the EPLCG cannot issue the PROGRAM command No retry A B Posted on receipt of remote error code 70 or 80 Modbus Presente
7. 51401945 400 K4LCN Mezzanine Board with 4 Mw for use with 51401946 100 only old design 51304421 200 PLCG Relay Panel Not used in nonredundant EPLCG or redundant EPLCG for redundant A B communications Replaces 51304421 100 panel used in earlier non CE modules Relay Optically Isolated Solid State 51196655 100 Dual Node Power Supply with 3 pin IEC320 power connector used in all CE Mark modules as well as some earlier non CE modules 51402184 100 Dual Node Power Supply with 8 pin Beau Vernitron connector old style Replaces 51401497 100 used in older non CE modules Replaces 51304514 100 51196489 001 SCSI1 to SCSI2 Cable primary EPLCG to relay card used only in some redundant EPLCGs 1 meter cable with 50 pin connector at both ends Replaces 51201420 001or 30731611 001 51196489 002 SCSI1 to SCSI2 Cable secondary EPLCG to relay card used only in redundant EPLCGs 2 meter cable with 50 pin connector at both ends Replaces 51201420 002 or 30731611 002 ORU Level Replacement Item Factory Use Only EPLCG Planning Installation and Service5 11 5 01 EPLCG Planning Installation and Service5 12 5 01 Index Topic Section Heading AC Voltage Options Allen Bradley CIM Pinning 3 Assembly and Cabling LCN Node Pinning Module Installation EPLCG Cabling EPLCG Relay Panel Pinning EPLCI Pinning Baud Rate and Parity TS2 Board Revision TS1 Program Options TS3 Ram Clear
8. Troubleshooting disassembly and assembly procedures for the remaining Dual Node Module and its components are contained in the Five Ten Slot Module Service or Dual Node Module Service manual Although cables are not considered ORU items their part numbers are listed in subsection 5 5 for reference 5 1 1 Module Configuration Standard and CE Compliant EPLCG For module board configuration and part numbers refer to the Five Ten Slot Module Service or Dual Node Module Service manual EPLCG Planning Installation and Service 5 1 5 01 5 2 5 2 FIELD ADJUSTMENT There are no field adjustments for the EPLCG 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 board 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 ensure 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 e Note that the functional boards can be accessed
9. results are transferred to the enabled DHP s database Since the counters are kept by physical PLC all logical PLCs PLC index values referencing the same physical PLC will show the same counter value This is true even if the logical PLCs PLC index values are in different emulated DHPs The counters are allowed to rollover after reaching maximum value Two 8 bit counters are displayed as 6 octal digits When split into 2 counters the 6 octal digits don t break at an octal boundary so the Port 1 upper byte counter at maximum 17748 and the Port 2 lower byte counter at maximum 377 8 both 255 10 The actual value is not important only the apparent rate at which they are incrementing Each counter is only reset when all emulated DHPs that reference its physical PLC are disabled off scan 4 3 2 Last Error Codes In memory addresses 1720 1727 PLC Index 1 8 respectively the EPLCG displays the error code that occurred on the last attempted communication with the PLC on that port When the EPLCI is pinned for nonredundant communications the error codes will be the same as those posted in the Box Status Display at the US when the Hiway Status display indicates DEV FAIL If pinned for redundant communications and only one port has failed the Box Status Display will show no error code Since the EPLCI can still see the PLC through the remaining port it will not indicate a DEV FAIL status and the Box Status Display will not show a
10. 1or2 24 Pin Round Connector 25 Pin Male D Sub ITT Cannon KPTO6F 20 24P or Bendix PTO6E 20 24P SR J J DTR L Transmit and receive data are cross wired in a direct connection 52267 A Figure 3 7 Cable for Direct Connection to Modicon 584 EPLCG Planning Installation and Service 3 9 5 01 3 2 9 3 2 9 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 EPLCG 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 EPLCG uses only the following signals Pin 1 Shield for electrical noise protection Pin 2 Transmit Data TXD output from EPLCG Pin 3 Receive Data RXD input to EPLCG Pin 7 Logic Ground GND EPLCG does NOT support these ETA 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 9 1 Direct Connection to Allen Bradley Controllers For connection to Allen Bradley protocol PLCs as illustrated in Figure 2 3
11. 3 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 0 1vw 2VW 2c 1c 2x 1x AoA A A Port 1 View Code Port 2 View Code View Code Definitions Port 2 Current 0 No Communication Attempted Port1 Current 1 All Communication Bad 2 All Communication Good Port 2 Experimental 3 Communication Mixed Good and Bad Port 1 Experimental Figure 4 3 View Code Word Bit 00 This bit set indicates that the EPLCI firmware is attempting an experimental reconnect to this PLC through Port 1 Bit 01 This bit set indicates that the EPLCI firmware is attempting an experimental reconnect to this PLC through Port 2 Bit 03 This bit set indicates that the EPLCI firmware is currently routing messages to this PLC through Port 1 Bit 04 This bit set indicates that the EPLCI firmware is currently routing messages to this PLC through Port 2 Bits 06 07 These 2 bits contain the EPLCI s last known view of this PLC through Port 2 At the completion of each scan the EPLCI examines the results of communication attempts to this PLC If no accesses were attempted the last known view is not modified If accesses were performed the results of these accesses are saved in this field at the end of each scan Bits 09 10 These 2 bits contain the EPLCI s last known view of this PLC through Port 1 At the completion of each scan the EPLCI examines the results of communicat
12. 5 01 5 4 3 Table 5 2 EPLCI Software Indication Troubleshooting Chart FAILURE POSSIBLE PROBLEM Link Failure Communications protocol violation detected by EPLCI 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 Communications Verify by monitoring RX DATA and RTS indicators on Timeout indicated EPLCG 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 EPLCI pinning of baud rate parity does not match PLC pinning e DHP definition of PLC address does not match that at PLC A B May 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 Configuration Failure The definition of a PLC Modbus or A B unacceptable to the EPLCI No retry Possible causes are e Assigned protocol 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 EPLC Gateway Control Functions manual in the mplementation EPLC Gateway binder for hints on avoiding configuration errors CRC Error The Cyclic Redundancy Check for a reply was incorrect Retries allowed A B Not used
13. 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 free 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 EPLCG Planning Installation and Service3 10 5 01 3 2 9 EPLCG Port 1or2 25 Pin 15 Pin Male D Sub Male D Sub GND Transmit and receive data are cross wired in a direct connectic 3070 A Figure 3 8 Cable for Allen Bradley 1771 KE KF KG and 1785 KE SHL TXD RXD EPLCG Port RT 1or2 3 ie 25 Pin Female D Sub 25 Pin Male D Sub DSR GND DCD 8 DTR 20 ae Ket Transmit and receive data are cross wired in a direct connectic 3071 A Figure 3 9 Cable for Allen Bradley 1770 KF2 and 1775 KA EPLCG Planning Installation and Service3 11 5 01 3 2 9 SHL TXD RXD EPLCG Port RTS 1or2 ol 25 Pin DSR Female D Sub GND
14. Bradley CIM Pinning Installation Wrap Up 4 CHECKOUT Power On Tests Electronics Checks Startup Communications and Performance Statistics PLC Error and Retry Counters Last Error Codes View Words Port Statistics Subslots Processed Per Second Number of Messages Transmitted Second Number of Messages Received Second Number of Bytes Transmitted Second Number of Bytes Received Second Number of Scan Buffers Processed Second Number of Keepalive Buffers Processed Second Number of Output Buffers Processed Second Firmware Freetime Second Counters Number of Unsolicited Buffers Processed Second Number of Output FIFO Entries Available Communication Port Status Points _ oh 4MuOMNOORWNY4 AAAAAD AAA AAR ARARDARARARS OnOanKRARRARARARRARWOWONM AU O 1 Port Status 2 Best View Failover 3 Port Output FIFO Overflow 5 Service Overview 1 Module Configuration Standard and CE Compliant EPLCG Field Adjustment General Troubleshooting EPLCI Troubleshooting EPLCI Hardware Indicators EPLCI Hardware Indicator Troubleshooting Chart EPLCI System Software Indications 1 Battery Failure 2 Device Failure 3 Data Hiway Port Error Codes Spare Parts OI I OI OI O TT N ON ORAR RRR RpRonNn L EPLCG Planning Installation and Service ii 5 01 INTRODUCTION Section 1 This section provides an overview of the EPLCG equipment and lists reference documents available from Honeywell 1 1 GENERAL DESCRIPTION The Enhanced Programmable
15. 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 EPLCG 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 EPLCG Planning Installation and Service 9 97 Table of Contents 1 INTRODUCTION 1 1 General Description 1 2 EPLCG Module for CE 1 3 Honeywell Support Services 1 4 Related Publications 2 SITE PREPARATION Storage Conditions Site Requirements 1 Dimensions and Weight Elec
16. Gard Modems or Communication a ne Interfaces hee ion Bee Hee PEG EES PLo PLC PLC PLC PLCG EPLCG Configuration for Type 1 Installation EPLCG Configuration for Type 2 Installation The Type 2 uses the Redundant Communications option Both ports of the EPLCI I O card must use the same protocol Allen Bradley or Modbus RTU and have an equivalent path to all connected PLC devices The Redundant Communications option is not supported by a PLCI EPLCG Planning Installation and Service 2 3 5 01 2 4 1 1 Nonredundant Gateway Configurations 2 4 1 Figure 2 1 shows an EPLCG connected in a Type nonredundant configuration in a dual node module lower node Each port ports 1 and 2 may service any number of individual Programmable Logic Controllers up to a Honeywell supported total of 16 PLCs per EPLCG up to 64 PLCs can be addressed See subsection 2 6 2 for examples of nonredundant port cabling configurations LCN Coax Cable A I O Cage Upper Node KLCNA Chassis Gnd Logic Gnd y O E oa Om Power Co recto EE Lower Node EPLCI I O RS 485 Terminators LCN Coax Cable B Cables to Communication Interfaces amp Programmable Figure 2 1 EPLCG in a Nonredundant Configuration Logic Controllers Each port may be configured to eithe
17. OANATINNA DRWW RANNNNOMTTAL_ARARRARODARNNONNOTG Muu npoOHnynNwwod BAU RWOONDHEHHUDOONWONAUTNMAHNDHOUHNH oo Go MMA N N A EPLCG Planning Installation and Servicelndex 3 5 01 EPLCG Planning Installation and Servicelndex 4 5 01 FAX Transmittal FAX No 602 313 4212 TO Information Development Reader Comments Title of Document Enhanced PLC Gateway Planning Installation and Service Document Number EP02 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
18. OPEN OPEN OPEN Honeywell factory setting is 9600 baud with odd parity EPLCG Planning Installation and Service 3 2 5 01 3 2 3 Board Revision Socket Do not change SF Program TS2 according to chart in lower right corner of board va All pins SHORTED both ports at 9600 baud with odd transmit receive parity Program TS3 as follows PIN DESCRIPTION PIN DESCRIPTION 8 Always Shorted 4 Always Open 7 Always Shorted 3 Short Max Data Acquision 6 Always Shipped Shorted Open Reduced Bandwidth Open Disable Writing User 2 Short Nonredundant Outputs Communications 5 Always Shorted Open Redundant Communications Enabled Short Redundant EPLCGs must be set in both EPLCGs Open Nonredundant operation 53323 Honeywell factory setting TS2 JUMPERS RAM CLEAR Jumper Do not change z J q 51 400997 200 Figure 3 1 EPLCI Pinning 3 2 3 4 Program Options TS3 Pin 1 If you are installing redundant EPLCGs leave pin 1 shorted it must be shorted on the EPLCI board in both EPLCGs If you are installing a nonredundant EPLCG open pin 1 Pin2 This pin controls the Redundant Communications feature With pin 2 shorted Redundant Communications are not enabled Ports 1 and 2 are treated as two independent paths each with a set of unique PLCs If you want the Redundant Communications feature enabled open pin 2 P
19. be referred to as required and available Publication Title Local Control NetworkPlanning 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 Process Operations Manual EPLCG Specification amp Technical Data EPLCG Control Functions EPLCG Implementation Guidelines EPLCG Parameter Reference Dictionary EPLCG Forms Publicatio n Number SW02 501 SW20 500 SW20 510 HG03 500 LC13 500 LC13 510 SW11 502 SW13 510 SW13 511 SW13 512 SW11 501 EP03 500 EP09 500 EP12 500 EP09 540 EP88 500 EPLCG Planning Installation and Service 1 3 Binder Title System Site Planning 1 LCN Installation LCN Installation System Summary LCN Service 2 LCN Service 2 LCN Service 1 LCN Service 3 LCN Service 3 LCN Service 3 Operation Process Operations System Summary 2 Implementation EPLC Gateway Implementation EPLC Gateway Implementation EPLC Gateway Implementation EPLC Gateway Binder Number 3020 1 3025 3025 3010 2 3060 2 3060 2 3060 1 3060 3 3060 3 3060 3 3050 3010 2 3081 3081 3081 3081 5 01 EPLCG Planning Installation and Service 1 4 5 01 SITE PREPARATION Section 2 This section provides the following information for t
20. display approximations of EPLCI 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 Freetime range is 0 to 1 00 with values below 25 indicating EPLCI overload conditions typically due to excess communication link errors or excess data transfers from other LCN devices 4 4 10 Number of Unsolicited Buffers Processed Second This location 1766 for Port 1 1767 for Port 2 contains the number of times in the previous second that the EPLCG processed an unsolicited write exception reporting from the Port When this location is zero the PLCs on a given port are not transmitting unsolicited messages to the EPLCG These counters are active even if the PLCs are configured for scan mode The EPLCG will always accept an unsolicited message from an Allen Bradley PLC EPLCG Planning Installation and Service 4 8 5 01 4 4 11 4 4 11 Number of Output FIFO Entries Available These locations 1770 and 1771 contain the number of entries available in each of the two Port output FIFOs by port number If the FIFO is empty the maximum available count is displayed If the FIFO is full the count 0 is displayed The EPLCI firmware revision determines the maximum available count EPLCI Revisions Ma
21. 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 PLC Communications Retry Guidelines Retries on transient communication errors will be performed for all messages but timeouts are given special processing The EPLCI 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 with 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 reestablished the EPLCI 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 EPLCG Planning Installation and Service 5 6
22. j gt l l I j Subslots of Bytes of Bytes of Scan of Keepalivd of Output Processed Messages Messages XMIT D Sec Rec d Sec Buffers Buffers Buffers _ Second xMIT D Sec Rec d Sec Port 2 Statistics same as line 174 abov Firmware Minimum P irmware irmware Maximum Unsolicited Unsolicited Freetime 1 Second urrent Freetime Freetime 1 Second Port1 Buffers Port2 Buffers on Record Last Second on Record Processed Processed Port 1 Firmware Hiway Unused Revision Unused Available Security Word Numbers Retry Counters l l Figure 4 3 Hiway Box Memory Data Display EPLCG Planning Installation and Service 4 4 5 01 4 3 1 4 3 1 PLC Error and Retry Counters The EPLCG maintains communications error counters Memory addresses 1700 1707 PLC Index 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 EPLCG 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
23. the length of a substitute relay panel cable must be less than 15 meters 50 feet 2 5 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 EPLCG 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 EPLCG port to the A B controller 2 5 3 Cable Lengths The cables from the EPLCG 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 6 for modem considerations EPLCG Planning Installation and Service 2 9 5 01 2 5 4 2 5 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 EPLCG to the PLC is less than 15 cable meters you can 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 which mates your PLC Subsections 3 2 7 and 3 2 8 show cable wiring scheme
24. the proper plugs to mate your brand and model of equipment This section will aid you in selecting and wiring those plugs EPLCG uses only the following signals Pin 1 Shield for electrical noise protection Pin 2 Transmit Data TXD output from EPLCG Pin 3 Receive Data RXD input to EPLCG Pin 7 Logic Ground GND EPLCG does NOT support these ETA 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 7 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 5 C install a connector on the free end of cable 51304514 100 using Figure 3 5 as a guide Use a standard 25 pin male D Sub connector EPLCG Planning Installation and Service 3 6 5 01 3 2 7 3 2 7 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 e The multidrop modem telephone lines must be 4 wire full duplex with the line driver of the local modem EPLCG end connected to 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 e A single pair of modems point to point must also be 4 wire full duplex with the line driver of each modem co
25. 0 0 1352 4 Wattage BTUs hr 152 5 198 3 305 0 396 6 305 0 396 6 520 0 676 2 1040 0 1352 4 1040 0 1352 4 5 01 2 4 2 4 CONFIGURATIONS Various nonredundant and redundant configurations of the EPLCG connected to PLCs of different manufacture are available Depending upon certain limitations the EPLCG can communicate to the PLCs either through short haul modems or Communication Interface Modules CIMs Six different configurations have been defined for the new EPLCG 2 Nonredundant and 4 Redundant Some overlap occurs with the existing PLCG products and is noted in the following installation type descriptions 2 4 1 MP NEPLC3 and MP NEPLC5 NONREDUNDANT GATEWAYS Both of the nonredundant EPLCG versions use the new EPLCI I O card which eliminates the need for the relay panel The Type 1 version does not use the Redundant Communications option Though it is possible to configure this one with a PLCI EPLCI resident features will not be available With the Type 1 configuration each port of the EPLCI I O card can support Modbus RTU or Allen Bradley protocol independently PLCG af EPLCG EPLCG l li EPLCI Short Haul EPLCI eae eee VO
26. 1 2 6 2 2 6 2 Nonredundant EPLCG Port Connections Figure 2 4 A and B illustrate examples of directly connecting PLCs to a nonredundant EPLCG A maximum of only two PLCs may be connected in this manner Notice the cables can be no longer than 15 meters A Direct Connect Usage Modbus B Direct Connect Usage Allen Bradley Port 1 Port 1 Cables lt 15 meters EIA 232 cables wired for A B equipment CIM PLC Port 2 Port 2 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 cables lt 15 meters Full duplex twisted pair or other Single PLC Port 1 MODEM or cable suitable for modem use CONVERTER MODEM or PLC CONVERTER MODEM or CONVERTER MODEM or poe CONVERTER Standard ElA 232 cables lt 15 meters MODEM or Three multidrop CONVERTER PLCs shown MODEM or CONVERTER D Modem Usage z Allen Bradley EIA 232 cables wired for A B equipment Single PLC Pott cM CIM o PLC A B Data Hiways CIM Po
27. 8cm 19 Depth 61 cm 24 EPLCG Planning Installation and Service 2 1 5 01 2 3 ELECTRICAL REQUIREMENTS The customer selected ac power option is installed in the EPLCG before shipment 2 3 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 Using K2LCN MP NEPLC3 with K2LCN Nonredundant Module MP REPLC3 with K2LCN 2 Redundant Modules Two modules required Without Relay Panel MP REPLC4 with K2LCN 2 Redundant Modules Two modules required With Relay Panel Using K4LCN MP NEPLC5 with K4LCN Nonredundant Module MP REPLC7 with K4LCN 2 Redundant Modules with EPLCI I O Card qty 2 Without Relay Panel MP REPLC8 with K4LCN 2 Redundant Modules with PLCI I O Card qty 2 With Relay Panel typical maximum typical maximum typical maximum typical maximum typical maximum typical maximum Avg 0 939 1 45 1 878 2 90 1 878 2 90 Avg 0 939 1 45 1 878 2 90 1 878 2 90 EPLCG Planning Installation and Service 2 2 True RMS 1 27 1 94 2 54 3 88 3 88 True RMS Peak 6 99 10 35 13 98 20 70 13 98 20 70 Peak 6 99 10 35 13 98 20 70 13 98 20 70 Wattage BTUs hr 152 5 198 3 305 0 396 6 305 0 396 6 520 0 676 2 1040 0 1352 4 104
28. 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 EPLCG Planning Installation and Service5 10 5 01 5 5 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 for the EPLCG are listed in Table 5 4 Table 5 4 Parts List Part Number Description 51196072 100 Cable Assembly EPLCI I O Debug Port Loopback EPLCGs without relay card EPLCI I O Adapter Paddleboard with plastic extractor clips Used only in non CE modules without relay card EPLCI I O Adapter Paddleboard with metal faceplate Used in CE Mark modules PLCI I O Adapter Paddleboard with plastic extractor clips Used only in non CE modules with relay card 51195096 200 EPLCI I O Adapter Paddleboard with metal faceplate for CE Mark modules 51400997 200 EPLCI Gateway 14 x 14 Circuit Board PWA for all EPLCG models
29. DR NNNH NOD NEN EPLCG Planning Installation and Servicelndex 1 5 01 Index Topic Section Heading o Device Failure Dimensions and Weight Direct Connection to Allen Bradley Controllers Direct Connection Electrical Requirements AC Voltage Options Current in Amperes at 120 Vac Frequency Electronics Checks EPLCG Cabling Port Cabling and Pinning for Modems Using Modbus Protocol Modem Cable Modem Pinning Modem Wiring Port Cabling for Direct Connection to Modbus Equipment Port Cabling for Equipment Using Allen Bradley Protocol Direct Connection to Allen Bradley Controllers Allen Bradley CIM Pinning EPLCG Relay Panel Pinning EPLCG to PLC Connections Modem Usage and Selection Nonredundant EPLCG Port Connections Redundant EPLCG Port Connections EPLCI Pinning Baud Rate and Parity TS2 Board Revision TS1 Program Options TS3 Ram Clear J1 EPLCI Hardware Indicator Troubleshooting Chart EPLCI Hardware Indicators EPLCI System Software Indications EPLCI Troubleshooting EPLCI Hardware Indicator Troubleshooting Chart EPLCI Hardware Indicators EPLCI System Software Indications Battery Failure Device Failure Installation of EPLCI I O Board CE Compliant EPLCG Relay Panel CE Compliant Field Adjustment Firmware Freetime Second Counters Frequency General Description General Troubleshooting Honeywell Support Services Installation Wrap Up LCN Node Pinning Limitations Cable Lengths Direct Connection ho w wa wa w G9
30. Data Hiway ports used are addresses 8 through 15 Check that EPLCGs are configured for Hiway addresses 2 and 3 Check that EPLCG is configured to perform the HTD functions Check for hardware configuration errors reread subsections 2 4 2 5 and 3 2 of this manual Substitute known good processor board s If processor board s are OK suspect the EPLCI itself 5 01 5 4 3 5 4 3 EPLCI 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 an emulated DHP This does not indicate a battery failure instead it has been used 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 EPLCG recheck the EPLCI 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
31. EL 51304421 100 Honeywell Figure 3 4 EPLCG Relay Panel EPLCG Planning Installation and Service 3 5 5 01 3 2 6 3 2 6 EPLCG Cabling 1 If you are using an EPLCI and EPLCI I O without the relay panel no intermediate cable is necessary Connect from Port 1 and Port 2 C1 and C2 on the EPLCI I O board to the Short Haul Modem s or Communications Interface Module s 2 If you are using EPLCI and EPLCI I O boards with the relay panel connect a 1 meter 3 ft cable 51201420 001 between J2A on the relay panel to J2 on the EPLCI 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 EPLCI I O board in the secondary module Refer to Figure 2 3 4 If this is a redundant Gateway installation not using the relay panel connect an Interlink cable 51196074 100 from C4 on the EPLCI I O board in the primary module to C4 on the EPLCI I O board in the secondary module If necessary refer to Figure 2 2 5 Be sure the two latches which secure each cable end to its connector are fastened on all of the cables 3 2 7 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 EPLCG You must purchase and install
32. Front View EPLCG Planning Installation and Service 1 1 5 01 1 2 1 2 EPLCG MODULE FOR CE The CE compliant EPLCG I O cage supports the two styles of modules It supports the nonredundant EPLCG and redundant EPLCG The CE compliant modules are capable of accepting both the older and new types of I O board designs The I O file has been modified to make electrical contact with faceplates attached to the I O boards This provides a low impedance ground path for the cable shields The faceplates and the wire mesh covering the fan openings also provide EMI shielding around the module The module is similar in all other respects EPLCI I O CLCNB 52676 Figure 1 2 CE Compliant EPLCG 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 602 313 5558 is available for technical assistance EPLCG Planning Installation and Service 1 2 5 01 1 4 RELATED PUBLICATIONS 1 3 Honeywell s standard documentation is included with the system The following publications apply to the TPS system and should
33. G9 G9 co co Co Co mo TAATVVVVONNNY WNNWWNMNNOOANNNY ANNA TAANNYYFA WBRAAKYHOORARRTRRRWWDONDAADNNOONNNNNY N 0HHWNYV WON RWONWNHWHNONMHANHWHANFWH NH ANWWWANH DAN OWONWANDHANMWHWAR P oo wo VA NORARTAG NM Ow EPLCG Planning Installation and Servicelndex 2 5 01 Index Topic Section Heading Physical Limitations Single vs Multi Drop Cabling Modem Cable Modem Pinning Modem Usage and Selection Modem Wiring Module Installation Nonredundant Configurations Nonredundant EPLCG Port Connections 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 Misses Second Number of Processing Buffer Misses Second Number of Scan Buffer Misses Second Overview Physical Limitations PLC Error and Retry Counters EPLCG Relay Panel Pinning 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 EPLCG Port Connections Related Publications Single vs Multidrop Cabling Site Requirements Dimensions and Weight Spare Parts StartUp Storage Conditions Subslots Processed per Second Unpacking w Www A i PRPRSPPPRPAPNNAONNNNNN l ea COG O9 3G pai
34. Honeywell Enhanced PLC Gateway Planning Installation and Service EP02 500 Tetal Plant Honeywell Implementation EPLC Gateway Enhanced PLC Gateway Planning Installation and Service EP02 500 Release 500 CE Compliant 05 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 Enhanced Programmable Logic Controller Gateway EPLCG Only those components unique to the EPLCG 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 publication supports TotalPlant Solution TPS system network Release 500 and
35. J1 Port Cabling and Pinning for Modems Using Modbus Protocol 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 Best View Failover 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 Buffers Processed Second Number of Messages Received Second Number of Messages Transmitted Second Number of Output Buffers Processed Second Number of Unsolicited Buffers Processed Second 4 Number of Scan Buffers Processed Second Subslots Processed per Second Communication Port Status Points Best View Failover Port Output FIFO Overflow Port Status Configurations MP NEPLC3 and MP NEPLC5 Nonredundant Gateways Nonredundant Gateway Configurations 2 MP REPLC3 and MP REPLC7 Redundant Gateways with A B Redundant Communications MP REPLC4 and MP REPLC8 Redundant Gateways Redundant Gateway Configurations Current in Amperes at 120 Vac NN w e G9 G9 co G9 69 C Oo ni i a e i D w w a a a w a D R o w w w w o Ww ow w See SP a Pe eh eee oR NN w w c ORF BRPANTAGAAR_APRRRRPARRORATWWUWOONNNNNNYWDWWONNNNNWOW ORM BOHAHBRUWONNHEDOONWNADTOR AWWNWHNHHNOONWAENHANWDWU
36. LCG Configuration for Type 6 Installations 53308 EPLCG Planning Installation and Service 2 6 5 01 2 4 4 2 4 4 Redundant Gateway Configurations Figure 2 2 shows two EPLCG dual node modules connected in a redundant configuration Although two nodes can reside in one dual node module a possible back panel failure precludes using a redundant pair of EPLCGs in one dual node module This configuration also supports up to a total of 16 PLCs See subsection 2 6 3 for examples of redundant port cabling configurations LCN Coax Cable A I O Cage Chassis Gnd Sp KLCNA Logic Gnd l k 1 C2 Lower Node es I O Cage Primary EPLCG KLONE Interlink Cable gt LCN Coa amp amp Cable B LC ax Cable A Chassis Gnd Upper Node ogic Gn g OD Lower Node Secondary EPLCG LCN Coax Cable B Cables to Communication Interfaces amp Programmable Logic Controllers 16707 Figure 2 2 Redundant EPLCG Modules with Allen Bradley Redundant Communications If you use Modbus protocol in a redundant EPLCG configuration both ports Port 1 and Port 2 must be configured for Modbus compatible equipment The configuration is again capable of serving up to 16 PLCs on both por
37. Logic Controller Gateway EPLCG is a new version of the PLCG with added features and improvements The EPLCG expands the idea of providing an economical method for connecting various Programmable Logic Controllers to your Honeywell TotalPlant Solution TPS system Its redundant communications option provides two independent communication paths to the PLCs and it features increased output performance A new EPLCI board containing new firmware and new I O hardware for the EPLCG add configurations for additional applications This manual guides you through the planning and installation considerations unique to the EPLCG 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 EPLCG runs under an unmodified HG Hiway Gateway software personality The hardware is similar to HG hardware contained in a standard TPS Dual Node module that supports the Local Control Network LCN In the EPLCG the Data Hiway Interface DHIF board and its I O board are replaced with the Enhanced Programmable Logic Controller Interface EPLCI board and an EPLCI I O board The existing PLCI PLCI I O paddle boards and relay panel will continue to be used for specific applications A redundant EPLCG pair is composed of two EPLCG modules equipped as above Figure 1 1 EPLCG Nonredundant Dual Node Module
38. Refer to Figure 2 1 for an illustration of a nonredundant EPLCG installation Refer to Figure 2 2 for an illustration of a redundant EPLCG installation Note the EPLCG relay panel is only mounted on the primary EPLCG NOTE Some assembly and cabling of this equipment may have been done at the factory If so please check your equipment and verify its installation is similar to that described 3 2 1 Module Installation If you are installing a redundant EPLCG pair you have two EPLCG modules Install the primary EPLCG module first 1 Remove the primary EPLCG module with relay panel if included from its shipping carton 2 Securely fasten the EPLCG 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 EPLCG module Refer to the LCN System Installation manual in the LCN Installation binder for further grounding information 4 Insure the power switch on the front of the EPLCG module is off Install the module power cord supplied Refer to LCN System Installation manual in the LCN Installation binder for power wiring information If this is a redundant installation repeat steps 1 through 4 on the secondary EPLCG module EPLCG Planning Installation and Service 3 1 5 01 3 2 2 3 2 2 LCN Node Pinning For information on LCN node pinning refer to Dual Node Module Ser
39. TER PLCs shown MODEM or CONVERTER D Modem Usage Allen Bradl EIA 232 cables wired EIA 232 cables wired for A B equipment for A B equipment E epee AB Data Hiways overs pc Port 1 Three multidrop Donotuse port 2 PLCs shown Maximum 16 EIA 232 cables wired for A B equipment CIM Allen Bradley 11892 A Communication Interface Module Figure 2 6 Typical Redundant EPLCG Port Connections EPLCG Planning Installation and Service2 13 5 01 2 6 4 2 6 4 Port Connections for Redundant EPLCGs with Redundant Communications Figure 2 7 illustrates typical port connections for redundant EPLCGs for use with the redundant communications feature In A redundant communications are specifically for use with Allen Bradley PLCs connected by Allen Bradley Communication Interface Modules and provide network cable redundancy A CIM Usage Allen Bradley with Redundant Communications EIA 232 cables wired EIA 232 cables wired for A B equipment for A B equipment A B Data Hiways o __ EPLCG Port 1 VO Card Port2 Interlink Cable o Three multidrop pio aM PLCs shown Maximum 16 ae Port 1 e _ Card Port2 EIA 232 cables CIM for A B equipment
40. ant communications feature because the protocol is full duplex and messages can be sent and received simultaneously The redundant EPLCG 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 Notice Figure 2 6 C and D are very similar to those illustrations in Figure 2 4 Allen Bradley full duplex operation prevents Port 2 from being used without the redundant communications feature but there is little loss of capability since up to 16 PLCs can be connected to the same network A Direct Connect Usage Modbus B Direct Connect Usage Allen Brad EIA 232 cables wired Poti for A B equipment Port 1 Cables lt 15 meters Donotuse port 2 Port2 moa _ E On some A B equipment each PLC supports EIA 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 Modbus A cain Standard ElA 232 Full duplex twisted pair or other cables lt 15 meters a cable suitable for modem use Port 1 MODEM or MODEM or CONVERTER EPLOG CONVERTER Single PLC PLC CONVERTER CONVERTER MODEM or j MODEM or MODEM or Three multidrop CONVER
41. ble of serving up to 16 PLCs through Port 1 through an Allen Bradley communications controller See subsection 3 2 5 and Figure 3 5 for a more detailed illustration of the pinning sockets and header If you use the redundant communications feature with PLCI I O and the relay panel do not use the socket marked REDUNDANT A B You must plug the pinning header on the PLCG Relay card into the NORMAL CONFIG socket EPLCG Planning Installation and Service 2 8 5 01 2 5 NOTE The EPLCG can be configured for Redundant Communications which will provide PLC Network Cable redundancy with or without gateway redundancy 2 5 Limitations There are certain limitations and several options which must be considered in planning your installation 2 5 1 Physical Limitations In a redundant EPLCG application the primary and secondary EPLCG modules generally mount in the same rack but cannot be located in the same dual node module They are normally installed close to each other because of interlink or relay panel cable length restrictions If your system uses an interlink cable its length is fixed at 3 meters Alternate cable lengths are not available If your system uses a relay panel the standard cable length to secondary EPLCG 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 must be subtracted from each of the Port 1 and Port 2 cables Obviously
42. d when the PLC returns the BUSY REJECTED MESSAGE exception code 06 Retries allowed A B Posted on receipt of local error code 01 or remote error code 90 Modbus Presented when the PLC returns the NAK NEGATIVE ACKNOWLEDGE exception code 07 No retry A B Not used Continued EPLCG Planning Installation and Service 5 8 5 01 5 4 3 POSSIBLE PROBLEM Modbus Not used A B Posted on receipt of remote error code 60 Modbus Not used A B Posted on receipt of local errors 05 through OF and remote errors AO and CO through FO EPLCG Planning Installation and Service 5 9 5 01 5 4 3 5 4 3 3 Data Hiway Port Error Codes The Device Failure codes listed in Table 5 2 do 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 4 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 1195 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
43. e follows They are listed as shown in the figure from left to right SELF TEST or BOARD FAILURE Red This LED lights under the following conditions Module power coming on Module or EPLCI reset sequence working EPLCI self test in progress Self test failed Local parity errors This LED is extinguished under the following conditions Self test is completed successfully Module or EPLCI reset sequence completed successfully EPLCI Abort Command sequence completed PASSED MODULE TEST Green This LED is lighted after the EPLCI successfully completes the CPU tests EPLCG Planning Installation and Service 5 3 5 01 5 4 1 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 successfully e Module power coming on e Module or EPLCI reset completed e EPLCI Abort Command in process PRIMARY EPLCI Green This LED is lighted when the EPLCI is on line and functioning as the primary HG 10 SEGMENT DISPLAY Yellow Also on the front edge of the EPLCI 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 Port 1 Their functions are 1 TX RTS lIlluminates when the transmit Request To Send is ass
44. e 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 EPLCG may talk at any time Allen Bradley requires use of their own CIMs which interface their own Data Hiway Refer to subsection 3 2 9 and your Allen Bradley manuals for specifics A Modem Usage with Redundant Communicati EIA 232 cables CIM Modem Port 1 CIMModem Port 2 Communication Interfaces or Short Haul Modems Three multidrop PLCsshown Maximum 16 CIM Modem CIM Modem CIM Allen Bradley Communication Interface Module 11891 A Figure 2 5 Port Connections for Nonredundant EPLCGs with Redundant Communications EPLCG Planning Installation and Service2 12 5 01 2 6 3 2 6 3 Redundant EPLCG Port Connections Figure 2 6 A and B illustrate examples of direct connection to PLCs from a redundant EPLCG 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 without the redundant communications feature Port 2 cannot be used with Allen Bradley protocol without the redund
45. ed per second as seen by the EPLCG The number of subslots processed during the last second before the transfer is then displayed in this location 1740 1750 for the respective port NOTE Although TotalPlant Solution TPS system software treats a composite tag as a single data point its implementation requires the use of 2 3 or 4 subslots in the EPLCG Since the EPLCG must collect the data for each subslot in use EPLCG performance must be measured and compared in subslots parameters per second If you wish to convert to TPS tags per second from subslots per second you must use a correction factor which expresses the number of subslots per TPS tag To calculate the correction factor use the equation below If the system being measured contains any composite TPS tags the correction factor will have a value less than one SUBSLOTS overall TAG count TAGs X _ TIME overall SUBSLOT count TIME 4 4 2 Number of Messages Transmitted Second This location 1741 1751 contains the number of complete messages transmitted through this port in the previous 1 second period 4 4 3 Number of Messages Received Second This location 1742 1752 contains the number of complete messages received through this port in the previous 1 second period EPLCG Planning Installation and Service 4 7 5 01 4 4 4 4 4 4 Number of Bytes Transmitted Second This location 1743 1753 contains the number of bytes transmitted thr
46. ed to perform the checks in this section Do not however perform any of these tests until all other parts of the EPLCG have been installed according to Section 3 4 1 1 Electronics Checks Perform these electronics checks on the EPLCG electronics module If this is a redundant EPLCG installation perform these checks on both EPLCG modules 1 Remove the front cover of the EPLCG 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 Dual Node Module Service manual in the LCN Service 1 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 subsection 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 c
47. er system access to the Backup EPLCG which in turn provides a better PLC view to the system To alert the operator when this type of failover occurs the Backup EPLCG will set the Best View Failover status point This alerts maintenance personnel to direct their attention to the communication networks between Primary EPLCG and the PLCs 4 5 3 Port Output FIFO Overflow The EPLCG also indicates the state of the Port Output FIFOs by way of a pair of Status Inputs When the firmware attempts to transfer an output event into a Port Output FIFO but the FIFO is already full the corresponding overflow status input will be set true The point will remain set until the firmware successfully transfers the output event in the Port Output FIFO Note that in Redundant Communications Mode only the Port 1 Output FIFO is used This guarantees that output events are dispatched in the order received EPLCG Planning Installation and Service4 10 5 01 SERVICE Section 5 This section presents service instructions unique to the EPLCG 5 1 OVERVIEW The Enhanced Programmable Logic Controller Gateway EPLCG is housed in a standard TotalPlant Solution TPS Dual Node Module A unique functional circuit board EPLCI an input output card EPLCI I O and a special interlink cable 51196074 100 for redundant EPLCGs have been added to this standard module This manual provides instructions to test troubleshoot and repair those components unique to the EPLCG
48. erted 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 Illuminates 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 EPLCG Planning Installation and Service 5 4 5 01 5 4 2 5 4 2 EPLCI 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 EPLCI Table 5 1 EPLCI Hardware Indicator Troubleshooting 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 EPLCI I O Paddleboard Failed EPLCI or EPLCI I O Board Incorrect Software Release Incorrect Configuration Memory Error EPLCG Planning Installation and Service 5 5 SOLUTION Install EPLCI I O Paddleboard in the correct slot behind EPLCI board Substitute known good boards Check that Software Release 200 or later is being used Check that emulated
49. he EPLCG Storage conditions site requirements electrical requirements and configuration information 2 1 STORAGE CONDITIONS If the EPLCG is to be placed in storage follow these environmental constraints Temperature 35 C to 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 change 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 EPLCG 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 EPLCG dual node module are Height 17cm 7 Weight 21 5 kg 46 Ib Width 4
50. he data See Figure 4 3 EPLCG 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 AREA DEMAND UPDATE HIWAY NUMBER 05 HIWAY BOX ADDRESS 4 0 1 2 3 4 5 6 Retry Counters 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 Last Error Codes 000000 000000 000000 000144 000000 011621 000000 000000 3 000000 000000 000000 000000 000000 000000 000000 000000 View Words 000000 000000 000000 012131 000000 021316 011621 000000 Port 1 Statistics 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 000000 Port 2 Statistics 000000 000000 000000 000000 153450 000000 020203 000000 Error Counters Firmware Loading amp Exception Reports Output FIFOs 1 Each emulated DHP hiway box address Available has its own Data Display Firmware Revisions 2 Each memory word is 16 bits displayed as 6 digit octal For Information On Functions And Options Displayed On This Menu Position The Cursor On The Desired Target And Press HELP PC Index 1 8 0 Port Port Port co 1 Ia 2 pee l l l l t I Last Error Codes j
51. ion attempts to this PLC If no accesses were attempted the last known view is not modified If accesses were performed the results of these accesses are saved in this field at the end of each scan EPLCG Planning Installation and Service 4 6 5 01 4 4 As each message is processed the Experimental routing flag is reset for that port If no error occurs the Current routing flag for this port is set and a port idle timer for this PLC is set to 15 seconds and started If the timer expires the Experimental bit for the port is set to force communications The idle timer guarantees that each port will be tried every 15 seconds This allows more timely fault reporting on the unused port Since a failed port will also be idle the idle timer performs the function of a reconnect timer Future messages to this PLC will be routed through the remaining port If both Current routing flags are clear the Experimental routing flag for the opposite port is set causing the EPLCG to alternate between the ports after both have had errors 4 4 PORT STATISTICS Statistics for both ports are provided as an approximate measure of EPLCG performance 4 4 1 Subslots Processed Per Second Each time the EPLCG processes a subslot parameter assigned to a given port a 16 bit counter is incremented and once per second the results are transferred to the emulated DHP database The counter provides a measured versus calculated value of the number of subslots process
52. n error However the Last Error Code for the failed port will show an error This error code will appear in the byte related to the failed port upper byte for Port 1 lower byte for Port 2 See Table 5 2 for error codes and possible problem explanations If there was no error the display will be zero As soon as a message without error is transferred the display becomes zero The relationship of memory addresses to PLCs is the same as with the PLC Error and Retry Counters above 4 3 3 View Words The view codes are displayed in memory addresses 1730 1737 PLC Index 1 8 respectively and pertain primarily to the redundant communications option and are intended for the maintenance technician s use See Figure 4 3 Notice that bit positions 02 05 08 and 11 have been zero padded to break the word into 3 bit fields to facilitate reading the octal display The normal view word is 002230 8 If the redundant communications option has been enabled View Word information is used to determine port selection and recovery without system software or operator intervention Before queueing a message to a PLC the EPLCG examines the Experimental routing flags If these flags are nonzero the message is queued to the indicated port s If the Experimental bits are zero the EPLCG uses the Current routing flags If the Current routing flags are also zero the firmware queues the message to both ports EPLCG Planning Installation and Service 4 5 5 01 4 3
53. nd 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 For direct connection to Modbus protocol PLCs as illustrated in Figure 2 3 A or 2 5 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 6 Modicon 184 with J347 interface Figure 3 6 Honeywell Modicon 384 with J347 interface Figure 3 6 Modicon 584 Figure 3 7 Modicon 884 Figure 3 6 Modicon 984 Figure 3 6 Triconex 4101 EICM Figure 3 10 This device employs the Modbus protocol but uses a cable identical to one used for Allen Bradley devices EPLCG Planning Installation and Service 3 8 5 01 3 2 8 SHL 25 Pin TXD Male D Sub 25 Pin EPLCG Port PXD Male D Sub 1or2 RTS CTS DSR GND DCD DTR Se SE Transmit and receive data are cross wired in a direct connectio 52266 A Figure 3 6 Cable for Direct Connection to Modicon 884 984 and Others EPLCG Port Male
54. nnected to the line receiver of the other modem SHL TXD RXD EPLCG Port RTS 1or2 CTS 25 Pin 25 Pin 7 Male D Sub DSR Male D Sub ran GND DCD DTR Figure 3 5 Cable for a Modem Serving Modbus Protocol 3 2 7 3 Modem Pinning Use the instruction manual provided with your modems to properly pin your modems Be sure they meet the following criteria e The local EPLCG 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 e 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 This RTS CTS delay is required for the line drivers to be enabled properly and avoid loss of data bits EPLCG Planning Installation and Service 3 7 5 01 3 2 8 3 2 8 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 EPLCG You must purchase and install the proper plugs to mate your brand and model of equipment This section will aid you in selecting a
55. ondition 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 EPLCG Planning Installation and Service 4 1 5 01 4 2 4 2 STARTUP The EPLCG software performs exactly like an HG Hiway Gateway and looks exactly like an HG to the operator To continue further load the EPLCG with the HG personality use EPLCG 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 Manual in the Operation Process Operations binder 4 3 COMMUNICATIONS AND PERFORMANCE STATISTICS To assist installation and on going performance monitoring the EPLC Gateway provides information about EPLCG communications and certain EPLCG 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 through 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 3 DD MM YY HH MM SMCC MAIN MENU MODULE MEMORY HIWAY BOX MEMORY PROBE FAILED MODULE SYSTEM MAINT JOURNAL ACTIVE MAINT JOURNAL MODULE ERROR
56. orts 1 and 2 will then be treated as redundant communications paths to a single set of PLCs Pin 3 If you want the EPLCG 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 Pin4 Always leave this pin open Pin6 Always shipped shorted If open the EPLCG becomes a Read Only device will not write user outputs Pins 5 7 amp 8 Always leave these pins shorted EPLCG Planning Installation and Service 3 3 5 01 3 2 4 3 2 4 CE Installation of EPLCI I O Board The EPLCI I O board provides the interfaces to a network of Programmable Logic Controllers The cabling connections are now bulkhead mounted into the card faceplate which provides a contiguous shield from module to cable The faceplate is shown in Figure 3 2 The cables have all been redesigned to braid over foil shields and metalized plastic shield back shells This extends the shield of the sheet metal module out along the cable thereby minimizing emissions and susceptibility EPLCI I O FELDPORT1 FIELD PORT 2 Ol lo A joj jo d JO Figure 3 2 EPLCI I O Faceplate BAR COD
57. ough this port in the previous one 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 4 5 Number of Bytes Received Second This location 1744 1754 contains the number of bytes received through this port in the previous one 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 receive bandwidth used 4 4 6 Number of Scan Buffers Processed Second This location 1745 1755 contains the number of scan buffers processed in the previous second 4 4 7 Number of Keepalive Buffers Processed Second This location 1746 1756 contains the number of times in the previous second that the EPLCG built and sent a Keep Alive refresh message for this port 4 4 8 Number of Output Buffers Processed Second This location 1747 1757 contains the number of times in the previous second that the EPLCG built and sent a User Output message for this port 4 4 9 Firmware Freetime Second Counters These three counters 1760 1761 1762 1763 1764 1765
58. r the Modbus or Allen Bradley A B protocol That is in the nonredundant EPLCG configuration with nonredundant communication you may have one port connected to a Modbus and the remaining port connected to A B equipment or both ports configured to the same bus type EPLCG Planning Installation and Service 2 4 5 01 2 4 2 2 4 2 MP REPLC4 and MP REPLC8 REDUNDANT GATEWAYS The remaining 4 types are redundant EPLCGs with a Primary gateway and its backup Secondary The first 2 are configured with PLCI I O and the high reliability relay panel not using the Redundant Communications option In these two 2 PLCIs can be configured in place of the EPLCIs with the resultant loss of EPLCI resident features mentioned above Please note that the PLCG and EPLCG are NOT compatible for redundant gateways Type 3 is used with nonredundant communications Honeywell or Modbus protocols and Short Haul Modems or Communications Interfaces Type 4 is used with nonredundant communications Allen Bradley protocol and Communications Interfaces This configuration Type 4 is the only one for which the pinning header on the relay panel is plugged into the socket marked REDUNDANT A B PLCG PLCG or or EPLCG EPLCG PLCI PLCI O Care I O Car Relay Allen Bradley Pane x Communication ae a Interfaces of PLC PLC PLC PLC
59. rt 2 EIA 232 cables wired for A B equipment Three multidrop PLCs shown CIM Allen Bradley Communication Interface Module CIM PLC Note In all nonredundant gateway configurations Note Both ports of an EPLCG support a totalof 16 PLCs one port may support ModBus while the other port uses A B protocol provided the cables are 11890 B wired to match the equipment Figure 2 4 Typical Nonredundant EPLCG Port Connections EPLCG Planning Installation and Service2 11 5 01 2 6 2 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 4 C and D illustrate examples of modem usage from a nonredundant EPLCG The modems used in illustration C are the short haul modems previously discussed The single PLC connected by two modems to Port 1 illustrate a maximum length configuration which will service a PLC at the greatest distance from the EPLCG 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 EPLCG 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 th
60. s for several types of PLCs and interface devices 2 6 EPLCG TO PLC CONNECTIONS 2 6 1 Modem Usage and Selection Direct connection short haul modems sometimes called line driver or signal converter devices can be used with the EPLCG As mentioned earlier direct connection is limited to a maximum of 15 cable meters between EPLCI I O or Relay card Signal converters are devices that convert signals between EIA 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 EPLCG 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 EPLCG because they severely limit bandwidth and their necessary low speeds baud rate might degrade EPLCG performance The EPLCG 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 specialist or vendors for devices and cabling appropriate to your application EPLCG Planning Installation and Service2 10 5 0
61. the digital input status points can be referenced by tag name anywhere the system allows a digital input point EPLCG Planning Installation and Service 4 9 5 01 4 5 1 4 5 1 Port Status Both a service bit and a failure bit are provided for each port If the service bit is set it indicates that at least one PLC cannot be reached through this port If the failure bit is set it indicates that none of the PLCs can be reached on this port The table below shows the relationship between the subslot and its use in port status indication Subslot 16 Primary EPLCG port 1 failure Subslot 15 Primary EPLCG port 1 service Subslot 14 Primary EPLCG port 2 failure Subslot 13 Primary EPLCG port 2 service Subslot 12 Backup EPLCG port 1 failure Allen Bradley only Subslot 11 Backup EPLCG port 1 service Allen Bradley only Subslot 10 Backup EPLCG port 2 failure Allen Bradley only Subslot 09 Backup EPLCG port 2 service Allen Bradley only Subslot 08 Best View Failover Allen Bradley only Subslot 07 Port 2 Output FIFO Overflow Subslot 06 Port 1 Output FIFO Overflow 4 5 2 Best View Failover Once per second redundant EPLCGs running the Allen Bradley communications protocol compare their PLC visibility If the number of PLCs visible to the Backup EPLCG exceeds the number of PLCs visible to the Primary EPLCG for 20 consecutive seconds the Backup EPLCG will order a Primary EPLCG shutdown The Primary s shutdown will transf
62. 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 EPLCI 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 EPLCG Planning Installation and Service 5 2 5 01 5 4 5 4 EPLCI TROUBLESHOOTING The EPLCI 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 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 EPLCI Hardware Indicators GRN _ YELLOW pri 10 SEGMENT MARY DISPLAY 51400997 200 t RED RED SELF BUS TEST TRANS ERROR ERROR Figure 5 1 EPLCI Test and Status Indicators There are four LEDs located on the front left edge of the EPLCI board see Figure 5 1 Each LED s definition and a brief description of its us
63. trical Requirements 1 AC Voltage Options 2 Frequency 3 Current in Amperes at 120 Vac Configurations 1 MP NEPLC3 and MP NEPLC5 Nonredundant Gateways 1 1 Nonredundant Gateway Configurations 2 MP REPLC4 and MP REPLC8 Redundant Gateways 3 MP REPLC3 and MP REPLC7 Redundant Gateways with A B Redundant Communications 4 Redundant Gateway Configurations Limitations 1 Physical Limitations 2 Single vs Multidrop Cabling 3 Cable Lengths 4 Direct Connection EPLCG to PLC Connections 1 Modem Usage and Selection 2 Nonredundant EPLCG Port Connections 3 Redundant EPLCG Port Connections 4 Port Connections for Redundant EPLCGs with Redundant Communications DORE DS DN TOI TOTO DN DTN O TO MT MMDMDONAGAAGAR ARARARWHWWWNND 3 INSTALLATION 3 1 Unpacking 3 2 Assembly and Cabling 3 2 1 Module Installation 3 2 2 LCN Node Pinning 3 2 3 EPLCI Pinning 3 2 3 1 Ram Clear J1 3 2 3 2 Board Revision TS1 3 2 3 3 Baud Rate and Parity TS2 3 2 3 4 Program Options TS3 3 2 4 CE Installation of EPLCI I O Board 3 2 5 EPLCG Relay Panel Pinning 3 2 5 1 EPLCG Relay Panel for CE 3 2 6 EPLCG Cabling 3 2 7 Port Cabling and Pinning for Modems Using Modbus Protocol 3 2 7 1 Modem Cable EPLCG Planning Installation and Service i 5 01 Table of Contents 1 2 Modem Wiring 7 3 Modem Pinning 8 Port Cabling for Direct Connection to Modbus Equipment 9 Port Cabling for Equipment Using Allen Bradley Protocol 9 1 Direct Connection to Allen Bradley Controllers 9 2 Allen
64. ts The pinning header on the PLCG Relay card must be plugged into the NORMAL CONFIG socket See subsection 3 2 5 and Figure 3 5 for a more detailed illustration of the pinning sockets and header EPLCG Planning Installation and Service 2 7 5 01 2 4 4 LCN Coax Cable A 4 I O Cage Chassis Gnd Upper Node KLCNA Logic Gnd O Q Power Connector S y E Gel Lower Nod 1 O Cage KLCNB PLCI I RS 485 Terminators LCN Coax Cable B Cables to Communication LCN Coax Cable A Interfaces amp Programmable Logic Controllers I O Cage Chas amp s Gnd H KLCNA Logic Gn o Q Power ConnectoS I O Cage PLCI I O KLCNB ki f o RS 485 Terminators PLCG Relay Panel LCN Coax Cable B oi Figure 2 3 Redundant EPLCG Modules for ModBus or Honeywell Protocol with or without Redundant Communications If you use Allen Bradley protocol in a redundant EPLCG configuration with PLCI I O and the relay panel without the Redundant Communications pinning only Port 1 can be used You must plug the pinning header on the Relay card into the REDUNDANT A B socket and be sure no cable is connected to Port 2 This configuration is capa
65. vice manual subsection 2 7 Field Adjustment 3 2 3 EPLCI Pinning Refer to Figure 3 1 to locate the pinning headers and jumpers in the following steps If you are installing a redundant EPLCG pair both EPLCI boards must be pinned the same way 3 2 3 1 Ram Clear J1 Locate J1 and insure that a jumper is installed 3 2 3 2 Board Revision TS1 Do not alter TS1 the Board Revision header 3 2 3 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 of board in Figure 3 1 See Table 3 1 or the table on the EPLCI 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 EPLCI Board PORT 2 PORT 1 PIN 2 PIN 3 PIN 4 PIN 6 PIN 7 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
66. ximum FIFO Entries R through T 40 displayed octal count 32 decimal U and later 1000 displayed octal count 512 decimal Note The EPLCI firmware revision can be displayed using the Engineering Main menu and selecting the SMCC Maintenance target followed by the Rev Config Status target and EPLCG model number on the LCN Look across row PLCI to the FW REV column In redundant communications mode only the Port 1 FIFO is used In this mode events from the Port 1 FIFO are removed and distributed to both ports based on port loading and the current state of the port routing bits See subsection 4 3 3 View Words for port routing bit definitions 4 5 COMMUNICATION PORT STATUS POINTS To monitor the communication port status the user can configure optional Digital Input points These points must be located in slot 31 of each emulated DHP and are updated once per second by the EPLCG To prevent conflict with PLC data points the following conditions must be met 1 The emulated DHP must be processing on scan 2 Slot 31 must be configured as a digital input slot 3 Each port status digital input subslot must be configured as with no connection to the PLC database word address 0 and bit 0 for Allen Bradley or address 0 and specifier 0 for Modbus or Honeywell protocol To make these digital input status points visible to the TPS system a tag must be built for each point The tag s name can be anything the user wishes Once built

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