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Reliance electric AutoMax 57C328 Instruction Manual

Remote i/o communications
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AutoMax
Remote I/O
Communications
M/N 57C328
M/N 57C329
M/N 57C330
M/N 57C416
M/N 57C554
Instruction Manual J 3606 4

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  • Page 1 AutoMax Remote I/O Communications M/N 57C328 M/N 57C329 M/N 57C330 M/N 57C416 M/N 57C554 Instruction Manual J 3606 4...
  • Page 2 Kermitt is a trademark of the trustees of Columbia University. ReSourcet, and Sharkt are trademarks of Reliance Electric Company or its subsidiaries. Reliancer, AutoMaxr and AutoMater are registered trademarks of Reliance Electric Company or its subsidiaries. E Copyright Reliance Electric Industrial Company 1996.
  • Page 3 Table of Contents Introduction ..........1.1 Related Publications .
  • Page 4 3.5.4 Installing the Remote Drive Interface Head (M/N 57C329) ........3 25 3.5.5 Remote I/O Network Emergency Stop Considerations 3 27...
  • Page 5 Diagnostics And Troubleshooting ......6.1 The Remote I/O Module's OK LED is Off ....6.2 Error Code A is on the Remote I/O Module's 7 Segment Display .

  • Page 6: Table Of Contents

    List of Figures Figure 1.1 A Typical Coaxial Cable Remote I/O Network ... . . Figure 1.2 A Typical Fiber Optic Cable Remote I/O Network ..Figure 1.3 Multiple Remote I/O Network Connections (Coax) .
  • Page 7 Figure 5.1 Drop Status Monitoring ....... . Figure 6.1 AutoMax Rail Fault LED Codes .
  • Page 8 Appendices Appendix A Hardware Technical Specifications ......Appendix B Block Diagrams ..........Appendix C RS 232 Port Pinout .

  • Page 9: Figure 1.1 A Typical Coaxial Cable Remote I/O Network

    1.0 INTRODUCTION The products described in this manual are manufactured or distributed by Reliance Electric Industrial Company. The AutoMaxr Remote I/O network interconnects an AutoMax or DCS 5000 Processor with remote AutoMax racks, Remote I/O Heads, or remote Sharkt racks. The AutoMax Remote I/O Communications module (M/N 57C416) is the interface between the AutoMax or DCS 5000 Processor and the remote I/O on the network.

  • Page 10: Figure 1.2 A Typical Fiber Optic Cable Remote I/O Network

    The fiber optic cable network is organized in an active star configuration. With this type of topology, each node is connected to a multi port central point, also referred to as a hub," containing active re transmitting devices as shown in figure 1.2. Master Drop Fiber Optic...

  • Page 11: Figure 1.3 Multiple Remote I/O Network Connections (Coax)

    Master Drop Remote I/O Remote I/O Network A Network B Slave Drop Slave Drop Slave Drop Processor Module Remote I/O Communications Module Figure 1.3 Multiple Remote I/O Network Connections (Coax) The master initiates and controls all data transmissions on the network by polling every slave drop in a round robin sequence.
  • Page 12 Related Publications Related publications that may be of interest: D J 3012 AutoMate/AutoMax Digital I/O Rail and Modules Manual D J 3650 AutoMax Processor Module Instruction Manual D J 3675 AutoMax Enhanced Basic Language Instruction Manual D J 3676 AutoMax Control Block Language Instruction Manual D J2 3094 AutoMax Enhanced Ladder Language Instruction Manual D J 3809...
  • Page 13 Related Hardware and Software Model number (M/N) 57C416 contains one Remote I/O Communications module. M/N 57C554 contains one AutoMax Remote I/O Shark Interface module. M/N 57C328 and M/N 57C330 each contain one AutoMax Remote I/O Head. M/N 57C329 contains one AutoMax Remote Drive Interface Head. The Remote I/O Communications module, the AutoMax Remote I/O Head, the AutoMax Remote Drive Interface Head, and the AutoMax Remote I/O Shark Interface module can be used with all versions of...
  • Page 14 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 15 2.0 MECHANICAL/ELECTRICAL DESCRIPTION This section describes the mechanical and electrical characteristics of the Remote I/O module, Remote I/O Head, Remote Drive Interface Head, and the Shark Interface module. Mechanical Description This section describes the faceplates, connectors, indicators, and switches of the Remote I/O module, Remote I/O Head, Remote Drive Interface Head, and the Shark Interface module.

  • Page 16: Figure 2.1 Remote I/O Module Faceplate

    FAULT CODE DROP NUMBER Figure 2.1 Remote I/O Module Faceplate...

  • Page 17: Figure 2.2 Automax Remote I/O Shark Interface Module Faceplate

    2.1.2 Shark Interface Module (M/N 57C554) The Shark Interface module is a printed circuit board assembly that plugs into the backplane of a Shark rack in the first slot to the right of the power supply. It consists of a printed circuit board and a faceplate. The faceplate contains tabs at the top and bottom to simplify removing the module from the rack.
  • Page 18 2.1.3 Remote I/O Head (M/N 57C328) The Remote I/O Head can be used as an interface between the AutoMax Remote I/O network and the AutoMate rail I/O system, which consists of Local Heads, digital or analog rails, LED modules, or Thumbwheel Switch Modules. Note that although the Remote I/O Head can be used as an interface to drives with rail type interface ports (such as the Reliance GP 2000/VTAC V controller), it is recommended that only the Remote Drive Interface Head...

  • Page 19: Figure 2.3 Automax Remote I/O Head Faceplate (M/N 57C328 And M/N 57330)

    Note that during power up diagnostics, the bottom four LEDs (CPU, READY, FAULT MSB, FAULT LSB, and RAIL FAULT) will stay on long enough to allow verification that they will light. AutoMaxR REMOTE I/O HEAD POWER CPU READY FAULT MSB FAULT LSB RAIL FAULT FUSE TYPE...
  • Page 20 The Remote I/O Head can control up to 4 digital rails, analog I/O rails, or Local Heads. Each Local Head can in turn control up to 4 AutoMate digital rails. Therefore, a Remote I/O Head with 4 Local Heads connected to it can control a maximum of 16 digital rails. The digital rails must be all inputs or all outputs.
  • Page 21 2.1.5 Remote Drive Interface Head (M/N 57C329) The Remote Drive Interface Head can be used only as an interface between the AutoMax Remote I/O network and drives with rail type interface ports (such as the Reliance V S GP 2000/VTAC V controller).

  • Page 22: Figure 2.4 Automax Remote Drive Interface Head Faceplate

    AutoMaxR REMOTE DRIVE INTERFACE HEAD 57C329 POWER CPU READY FUSE TYPE 250V AGC 2 AMP Figure 2.4 AutoMax Remote Drive Interface Head Faceplate Electrical Description This section describes the electrical characteristics of the Remote I/O module, the Shark Interface module, the AutoMax Remote I/O Head, and the AutoMax Remote Drive Interface Head.
  • Page 23 At power up, the on board processor will run diagnostics on the microprocessor, EPROM, RAM, serial I/O, memory management unit, and dual port memory, as well as perform system level diagnostics. As each test is run, a number is written out to the seven segment display.
  • Page 24 2.2.4 Remote I/O Head (M/N 57C330) The Remote I/O Head has an on board power supply that provides all voltages necessary to power the Remote I/O Head and the I/O system. The power supply has an input voltage of 120/240 VAC. The Remote I/O Head contains a microprocessor that connects to the four I/O ports via the I/O interface circuitry.

  • Page 25: Figure 2.5 Remote I/O Network Drop Numbers

    Drop Numbers Drop numbers are used to uniquely identify every rack on the Remote I/O network; therefore, a drop and a rack are the same entity on a Remote I/O network. There are a maximum of seven slave drops on a Remote I/O network, each identified by the rotary switch (Shark) or thumbwheel switches (Remote I/O module, Remote Drive Interface Head, and Remote I/O Heads) on the faceplate.

  • Page 26: Figure 2.6 Mutually Exclusive Drop Numbers

    Note that drop numbers 1 through 7 and 9 through F are interpreted as being equivalent. In other words, you can assign a drop number of 1 or 9 on a network, but not both; you can assign a drop number of 2 or A, but not both, etc.
  • Page 27 Guidelines for fiber optic cable installation are provided in Appendix K. For information regarding other types of installations, contact Reliance Electric. Refer to section 3.5.1 for Remote I/O module installation procedures. Refer to section 3.5.2 for Shark Interface module installation procedures.
  • Page 28 D RG 59/U Coaxial Cable An example of the Remote I/O cable system is shown in figure 3.1. Appendix G lists the components recommended by Reliance Electric. Appendix H lists the network specifications. The following sections describe each of the components in more detail.

  • Page 29: Figure 3.1 Remote I/O Network Coaxial Cable System

    Figure 3.1 Remote I/O Network Coaxial Cable System...

  • Page 30: Figure 3.3 Coaxial Cable

    3.1.1 Drop Cable and Communications Passive Tap The Drop Cable (M/N 57C381) and the Communications Passive Tap (M/N 57C380) are used to connect the Remote I/O module and the Shark Interface module to the network coaxial cabling. The drop cable is a three foot long multiconductor cable with a 9 pin D shell connector at each end.

  • Page 31: Figure 3.4 Dual Crimp Bnc Plug Connector

    3.1.3 BNC Plug Connector Coaxial cable segments are terminated with BNC plug connectors for attachment to the taps. See figure 3.4. See Appendix G for the recommended part. CONTACT FERRULE Figure 3.4 Dual Crimp BNC Plug Connector 3.1.4 BNC Tee Adapter The BNC Tee Adapter (M/N 45C70) is used to attach the Remote I/O Head (M/N 57C328 and M/N 57C330) and the Remote Drive Interface Head (M/N 57C329) to the Remote I/O network.

  • Page 32: Figure 3.6 75 Ohm Terminating Load

    3.1.5 75 Ohm Terminating Load The Remote I/O system must be terminated with 75 ohm terminating loads (M/N 45C71) attached to the taps or adapters located at both ends of the coaxial cable network. This minimizes the signal reflections which could interfere with other signals being transmitted on the network.
  • Page 33 Remote I/O system failure. Step 7. Calculate the number of required cable system components. Refer to Appendix G for a list of components recommended by Reliance Electric. Step 8. Select the tools and instruments necessary to perform the cable system installation.
  • Page 34 Cable System Protection and Isolation Recommendations Installation of the cable should conform to all applicable codes. To reduce the possibility of noise interfering with the control system, exercise care when installing cable from the system to external devices. 3.3.1 Coaxial Cable Protection Coaxial cable must be handled properly prior to and during installation.
  • Page 35 3.3.3 Chemical and Thermal Isolation The Remote I/O coaxial cable system must be protected from damage caused by the following factors: D Oil, grease, acids, caustics, and other harsh and/or hazardous chemicals that might damage the cable's outer jacket, adapters, connectors, and terminating loads.

  • Page 36: Figure 3.8 Ferrule On The Rg 59/U Cable

    3.4.2 Cable Pulling The cable should be pulled manually, allowing sufficient slack in the cable so that there is no tension on the cable or connectors when installed. Do not snap" or apply sudden tension to the cable. Never use a powered cable puller without consulting the cable manufacturer and monitoring the pulling tension.

  • Page 37: Figure 3.10 Connector Installation Step 3 For Rg 59/U Cable

    INSERT CENTER CONTACT INTO PARTIALLY CLOSED CRIMPING DIES CENTER CONTACT SLIPPED OVER CENTER CONDUCTOR FLANGE ON END OF CENTER CONTACT BUTTS AGAINST DIE FLANGE ON OF CONTACT CRIMPING DIE Figure 3.10 Connector Installation Step 3 for RG 59/U Cable 3 11...

  • Page 38: Figure 3.11 Connector Installation Step 6 For Rg 59/U Cable

    Step 4. Crimp the center contact by holding the cable in place and closing the tool handles until the rachet releases. Step 5. Remove the crimped contact from the dies. Step 6. Verify that the shield braid wire does not touch the center contact.

  • Page 39: Figure 3.14 Connector Installation Step 9 For Rg 59/U Cable

    SHOULDER ON CONNECTOR BODY BUTTS AGAINST DIE FERRULE ON ANVIL OF CRIMPING DIE TYPICAL BNC CONNECTOR Figure 3.14 Connector Installation Step 9 for RG 59/U Cable Step 10. Hold the assembly in place and close the crimp tool handles until the rachet releases. Step 11.

  • Page 40: Figure 3.16 Cable Splicing

    3.4.5 Constructing Long Cable Segments To construct a cable segment longer than the standard maximum cable spool length (over 1,000 feet for Belden 9259), use a BNC jack to jack in line splicing adapter. Use the following procedure to construct a long cable segment: Step 1.
  • Page 41 Module Installation The following sections describe how to install the Remote I/O module, the Shark Interface module, Remote I/O Head, and Remote Drive Interface Head. To reduce the possibility of electrical noise interfering with the proper operation of the control system, exercise care when installing the wiring from the system to the external devices.
  • Page 42 encountered, an error code will be displayed on the seven segment LED. If the green status light is off and no seven segment error code is displayed, a local watchdog failure has occurred. If diagnostic fault codes 0 through 9 or b are displayed, the Remote I/O module must be replaced.
  • Page 43 3.5.2 Installing the Shark Interface Module Use the following procedure to install the Shark Interface module: Step 1. Stop any application tasks that may be running. DANGER THIS EQUIPMENT IS AT LINE VOLTAGE WHEN A C POWER IS CONNECTED. DISCONNECT AND LOCK OUT ALL UNGROUNDED CONDUCTORS OF THE A C POWER LINE.
  • Page 44 Step 10. To connect the module to a fiber optic network, refer to figure K2.2 in Appendix K and connect the drop cable to the transceiver. Continue to step 11. Step 11. Check the status of the master Remote I/O module's green OK LED.

  • Page 45: Figure 3.17 Mounting Dimensions

    5.50 (140) .25 (6) 5.00 (127) 1.00 (25) .22 x .36 9.00 SLOT (229) 7.00 (178) 5.50 (140) MOUNTING DETAILS TOP VIEW 9.40 (239) 7.55 (192) FRONT VIEW SIDE VIEW DIMENSIONS IN INCHES (MM) Figure 3.17 Mounting Dimensions 3 19...

  • Page 46: Figure 3.18 Mounting Examples

    Step 2. Mount the Remote I/O Head on the panel and attach it securely with #10 (M5) bolts or studs. Examples of attaching the Remote I/O Head to the mounting surface are shown in figure 3.18. MOUNTING SURFACE É MOUNTING FLANGE É...

  • Page 47: Figure 3.19 Grounding Stud Location

    GROUNDING STUD REMOTE HEAD RAIL GROUNDING STUD Figure 3.19 Grounding Stud Location Step 4. Connect a green wire from earth ground to either stud on the Remote I/O Head housing. For proper termination, a lug should be used. A star washer (toothed lock washer) should be used under the lug to ensure effective grounding to the Remote I/O Head.

  • Page 48: Figure 3.20 Grounding The Remote Head

    REMOTE HEAD RAIL EARTH GROUND RAIL Figure 3.20 Grounding the Remote Head DANGER THE OPEN FACEPLATE TERMINALS CAN POSE A SHOCK HAZARD IF TOUCHED WHEN POWER IS APPLIED. THE GUARD COVERING THE TERMINAL STRIP MUST BE REINSTALLED AFTER TERMINATIONS ARE MADE. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

  • Page 49: Figure 3.21 120 Vac Or 240 Vac Input Power Connections

    Step 5. Refer to figure 3.21 and use the following procedure to connect input power to the Remote I/O Head: M/N 57C328, M/N 57C329, and M/N 57C330 120 VAC INPUT POWER 240 VAC INPUT POWER Figure 3.21 120 VAC or 240 VAC Input Power Connections a.) Using a screwdriver, remove one of the screws from the plastic guard covering the terminal strip and slide the guard to the left to expose the terminals.

  • Page 50: Figure 3.22 Connecting The Remote I/O Head To The Fiber

    The Remote I/O Head can be used only as a slave drop (drop numbers 1 7, inclusive). Switch settings 0, 8 and 9 are invalid. If the thumbwheel switch is set to an invalid drop number, error code A" will be displayed on the seven segment LED on the Remote I/O Head's faceplate after power up.
  • Page 51 3.5.4 Installing the Remote Drive Interface Head (M/N 57C329) Use the following procedure to install the Remote Drive Interface Head: Step 1. Refer to the mounting dimensions in figure 3.17. The Remote Drive Interface Head is designed to be mounted vertically (either in an enclosure or on a mounting surface to ensure proper air flow for cooling).

  • Page 52: Figure 3.23 Connecting The Remote Drive Interface Head To The Fiber Optic Network

    wires that will be used to provide 120 VAC or 240 VAC input power. c.) Using 14 AWG wire, connect the input power wires to terminals L1 and L2. d.) Connect the jumper wire to the corresponding terminal, either 120 or 240 volts. e.) Slide the guard back to cover the terminal strip and replace the screw.
  • Page 53 Step 10. Connect the rail ports using a Rail I/O Interconnect Cable (M/N 45C5), which is provided with the Rail Interface module (1SC4000). If you are using the Ready Relay, see section 3.5.5 for connection information. Step 11. Turn on power to the Remote Drive Interface Head. Step 12.

  • Page 54: Figure 3.24 Ready Relay

    READY 240 VAC Figure 3.24 Ready Relay 120 VAC EMERGENCY RESET READY STOP LINE Figure 3.25 Typical E Stop Circuit Using Ready Contacts Module Replacement The following sections provide instructions on how to replace a Remote I/O module, a Shark Interface module, a Remote I/O Head, and a Remote Drive Interface Head.
  • Page 55 Step 2. Turn off power to the rack. Step 3. Disconnect the drop cable from the module faceplate. Step 4. Use a screwdriver to loosen the screws that hold the module in the rack. Take the module out of the slot in the rack.
  • Page 56 Step 9. Turn on power to the rack. The module automatically executes its power up diagnostics. If no errors are detected, the green CPU OK LED will turn on. If the LED is off, refer to chapter 6 for troubleshooting information. Step 10.
  • Page 57 3.6.4 Replacing the Remote Drive Interface Head (M/N 57C329) Use the following procedure to replace the Remote Drive Interface Head: Step 1. Stop any application tasks that may be running. Step 2. Disconnect the BNC Tee Adapter that connects the Remote Drive Interface Head to the Remote I/O network.
  • Page 58 3,000 feet as defined in the network cable specifications in Appendix F. If it exceeds 3,000 feet, consult with Reliance Electric before going on to the next step. Step 3.

  • Page 59: Figure 3.26 Adding A New Rack Drop To The End Of The Remote I/O Network (Coax)

    NEW DROP DROP CABLE PASSIVE NEW CABLE SEGMENT 75 OHM TERMINATING BNC CONNECTOR LOAD Figure 3.26 Adding a New Rack Drop to the End of the Remote I/O Network (Coax) Step 6. If a new drop is to be added along the cable route, use the following procedure: a.) Cut the remote I/O cable at the point where the new drop is to be added.

  • Page 60: Figure 3.27 Adding An Intermediate Rack Drop To The Remote I/O Network (Coax)

    NEW DROP DROP CABLE PASSIVE BNC CONNECTORS SPLICING ADAPTER Figure 3.27 Adding an Intermediate Rack Drop to the Remote I/O Network (Coax) Disconnecting a Slave Drop from the Remote I/O Network CAUTION: Powering down a drop may result in a loss of communication on a coaxial cable network.

  • Page 61: Figure 3.28 Disconnecting An End Rack Drop From The Remote I/O Network (Coax)

    DISCONNECTED DROP DROP CABLE PASSIVE BNC CONNECTOR 75 OHM TERMINATING LOAD Figure 3.28 Disconnecting an End Rack Drop from the Remote I/O Network (Coax) Step 3. To disconnect a drop along the cable route, refer to figure 3.29 and use the following procedure: a.) Disconnect both Remote I/O network cable segments from the tap or BNC Tee Adapter.
  • Page 62 Remote I/O Network Coaxial Cable Maintenance Over time, Remote I/O network operating efficiency may suffer from gradual degradation of the network cabling components or changes in the environmental conditions along the cable paths. In order to prevent this from occurring, some preventive maintenance should be performed on the network.
  • Page 63 4.0 PROGRAMMING This section describes how the data is organized in the Remote I/O module, Remote I/O Head, Remote Drive Interface Head, and Shark Interface module, and provides examples of how the module is accessed by the application software. For more detailed information on programming, refer to the AutoMax Programming Reference Binder.

  • Page 64: Figure 4.1 Drop 0 Status Register Assignments

    Remote Drive Interface Head. Non Reliance Multibus I/O modules (modules not manufactured by Reliance Electric) that are Write Only will be Read/Write in the master drop dual port memory. Non Reliance modules used in slave drops are subject to the following limitations: D The module base address must begin on a 64K boundary.
  • Page 65 D The module must be memory mapped, not I/O mapped. D The module must support 16 bit data transfers. D Interrupts will be ignored. D Input and output registers must be located at separate addresses. Modules that do not have separate addresses will be considered output modules.
  • Page 66 For an M/N 57C330 Remote I/O Head slave drop, DROP_TIME = [1.9 + (X x 0.08) + (Y x 0.036)] milliseconds where: X = Total number of output registers being transferred to the slave drop Total number of input registers being transferred from the slave drop For an M/N 57C328 Remote I/O Head drop, DROP_TIME=[1.7 + R  0.036] milliseconds...

  • Page 67: Figure 4.2 Shark I/O Module Configuration Word

    Programming Executive software, use a Generic I/O card in the Rack Configurator. If a feature of the module is not supported in your version of the Programming Executive software or you need more information, contact Reliance Electric. 4.6.1 Shark Configuration...
  • Page 68 diagnostics, and then communicate the new rail configuration to the Remote I/O master. WARNING REMOVING OR INSERTING A MODULE OR I/O INTERCONNECT CABLE WITH POWER APPLIED MAY RESULT IN UNEXPECTED MACHINE MOTION OR LOSS OF PROCESS CONTROL. STOP THE MACHINE OR PROCESS IN AN ORDERLY FASHION AND DISCONNECT THE POWER TO THE SYSTEM BEFORE YOU REMOVE OR INSERT A MODULE OR I/O INTERCONNECT CABLE.
  • Page 69 access to registers defined as INPUT. All other registers (those without rails connected) will have no access allowed. Whenever the rail configuration is to be physically changed (i.e., rails added or removed), the drop should first be disconnected from the network (disconnect the BNC Tee Adapter from the Remote I/O Head).
  • Page 70 Application Programming The variable names assigned to registers and bits during configuration are referred to as common variables. These are made available to BASIC and Control Block application tasks through the COMMON statement. Ladder Logic/PC tasks can access these variables simply by referencing them in their sequences. The remainder of this section provides application task examples.

  • Page 71: Figure 4.3 Sample Coaxial Cable Remote I/O Network With Multibus Rack And Remote I/O Head Drops

    4.7.1 Multibus and Remote I/O Programming Examples The sample programs that follow reference the physical points illustrated in figure 4.3. Figure 4.3 Sample Coaxial Cable Remote I/O Network With Multibus Rack and Remote I/O Head Drops...
  • Page 72 4.7.1.1 Configuration Task Example The following is an example of a configuration task for the master Remote rack in figure 4.3. Note that a configuration task is required only if you are using AutoMax Version 2.1 or earlier. If you are using AutoMax Version 3.0 or later, you use the AutoMax Programming Executive Software to assign symbolic names to the same physical I/O points.
  • Page 73 4.7.1.3 BASIC Task Example The following is an example of a BASIC task for the Remote I/O network in figure 4.3. This task reads a speed reference value and writes it to a speed indicator. 1000 COMMON SPD_REF% 1010 COMMON SPD_IND% 1020 COMMON RUN@ 1030...

  • Page 74: Figure 4.4 Sample Coaxial Cable Remote I/O Network With Shark Rack Drops

    4.7.2 Shark Programming Examples The sample programs that follow reference the physical points illustrated in figure 4.4. Figure 4.4 Sample Coaxial Cable Remote I/O Network With Shark Rack Drops 4 12...
  • Page 75 4.7.2.1 Configuration Task Example The following is an example of a configuration task for the Remote I/O network in figure 4.4. The two variables, DO_CFG% and DO2_CFG_RDY@, are used to configure drop 2. It is not necessary to configure drop 4 since it is an all digital rack as specified by the setting of the Shark Interface module's rotary switch to the C"...
  • Page 76 RIONET_OK should be included in the READY sequence. It is set by the BASIC task shown in 4.7.2.3. Note that the trailing at" symbol (@) is not used for Boolean variables in ladder logic tasks. 4.7.2.3 BASIC Task Example The following is an example of a BASIC task for the Remote I/O network in figure 4.4.
  • Page 77 5.0 PROGRAMMING TERMINAL COMMUNICATIONS Local monitoring of a Remote I/O module, Remote I/O Head, or Remote Drive Interface Head is performed with an ASCII terminal or a personal computer running terminal emulation software connected to the RS 232 port on the faceplate of the module. Note that the Shark Interface module does not support the programming terminal functions.
  • Page 78 Therefore, if application tasks running on a Processor module in the master rack access variables on this Remote I/O module, you should stop the application tasks before doing the self test to avoid shutting down the system with a bus error. 5.1.2 Status (S) Entering S"...
  • Page 79 seconds, there is a problem with integrity. Refer to chapter 6 for the troubleshooting procedure. In addition to the above status information, the Status command will display the I/O configuration of the local rack for slave drops. The following column header will be displayed: SLOT REGISTER I/O where: SLOT...
  • Page 80 BIN: (Binary) Enter a leading B, then any valid combination of 1s and 0s. The data is right justified if less than 16 bits are entered. The WRITE function will then display the current values of all registers located at the specified slot with the following headers: REGISTER HEX DEC BIN Remote Heads (M/N 57C328, M/N 57C329, and M/N 57C330)
  • Page 81 OVERRUN ERRORS is the total number of message overrun errors that have occurred since the last reset of the drop. This number should ideally remain equal to zero. ABORT ERRORS is the total number of message abort errors that have occurred since the last reset of the drop. This number should ideally remain equal to zero.
  • Page 82 where: PORT REGISTER = No rail exists `unknown' Rail exists but it has not been determined whether it is INPUT or OUTPUT (M/N 57C330 only) `INPUT' Rail exists and contains INPUT modules `OUTPUT' Rail exists and contains OUTPUT modules `INPUT/ OUTPUT' Rail exists (M/N 57C328 only) 5.2.3...
  • Page 83 If the entered rail location exists but has not yet been defined as INPUT or OUTPUT, the following prompt will be displayed (M/N 57C330 only): This register has not been defined as INPUT or OUTPUT. If you continue and write data to this register, it will be defined as an output.
  • Page 84 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 85 6.0 DIAGNOSTICS AND TROUBLESHOOTING This section describes how to troubleshoot the Remote I/O module, Remote I/O Head, Remote Drive Interface Head, the Shark Interface module, and the Remote I/O network. See Appendix D for a list of the error codes that can be displayed by the Remote I/O module or Remote Heads.
  • Page 86 If the Processor in the master rack fails or issues a BOARD RESET command (clears all outputs in the rack), the entire image in the master's dual port memory will be cleared. All Remote I/O slave drops will detect that the master has failed. Their response to this will be to clear all AutoMax module outputs in remote drops.
  • Page 87 switches, you must cycle power to the rack (or reset the module using the self test function) in order for the new settings to be recorded in register 12. Note: Use steps 2 through 8 if you have a coaxial cable network.
  • Page 88 All LEDs on the Remote I/O Head or Remote Drive Interface Head are Off Problem: All LEDs on the Remote I/O Head (or Remote Drive Interface Head) are off. This problem indicates that the Head is not receiving 120 VAC (or 240 VAC) power within the specified ranges, the fuse has blown, or that the Head is malfunctioning.
  • Page 89 Error Code A is on the Remote I/O Head or Remote Drive Interface Head 7 Segment Display Problem: Error Code A appears on the seven segment display of the Remote I/O Head (or Remote Drive Interface Head) at power up. This error code indicates an invalid drop number.
  • Page 90 Error Code 31 is on the Processor Module's LED Display Problem: Error code 31" appears on a Processor module's LED display. This error indicates the system has a problem accessing the module though the backplane bus. A bus error may be caused by removal of an I/O module, an I/O module failure, a rack backplane failure, attempting to access an invalid address, or incorrect cabling (45C8, 45C5).
  • Page 91 Appendix A Hardware Technical Specifications Remote I/O Communications Module M/N 57C416 Ambient Conditions D Storage Temperature: to 185 to 85 D Operating Temperature (at the module): 32 to 140 to 60 D Humidity: 5 to 95%, non condensing D Altitude: 1000 meters (3300 feet) without derating Dimensions D Height: 29.845 cm (11.75 inches) D Width: 3.175 cm (1.25 inches)
  • Page 92 Appendix A (Continued) AutoMax Remote I/O Shark Interface Module M/N 57C554 Ambient Conditions D Storage Temperature: to 158 to 70 D Operating Temperature (at the module): 32 to 131 to 55 D Humidity: 30 to 90%, non condensing D Altitude: 1000 meters (3300 feet) without derating Dimensions D Height: 15.2 cm (6 inches) D Width: 3.5 cm (1.4 inches)
  • Page 93 Appendix A (Continued) AutoMax Remote I/O Head M/N 57C328 and M/N 57C330 Ambient Conditions D Storage Temperature: -40_C to 85_C -40_F to 185_F D Operating Temperature: 0_C to 60_C 32_F to 140_F D Humidity: 5 to 95%, non condensing D Altitude: 1000 meters (3300 feet) without derating Dimensions Without Cables With Cables Attached...
  • Page 94 Appendix A AutoMax Remote Drive Interface Head M/N 57C329 Ambient Conditions D Storage Temperature: -40_C to 85_C -40_F to 185_F D Operating Temperature: 0_C to 60_C 32_F to 140_F D Humidity: 5 to 95%, non condensing D Altitude:1000 meter (3300 feet) without derating Dimensions Without Cables With Cables Attached...
  • Page 95 Appendix A (Continued) Stand Alone Fiber Optic Transceiver M/N 57C365 Dimensions D Height: 1.3 in (3.3 cm) D Width: 5.19 in (13.18 cm) D Depth: 2.35 in (5.96 cm) Ambient Conditions D Operating temperature: 0_C to +60_C D Storage temperature: -40_C to +95_C D Humidity: 5 to 95%, non condensing D Maximum altitude: 3300 feet (1000 meters), without derating Fiber Optic Interface...
  • Page 96 Appendix A (Continued) Fiber Optic Rack with Power Supply M/N 57C368 Dimensions D Height: 5.23 in (13.28 cm) D Width: 19.00 in (48.26 cm) D Depth: 9.72 in (24.68 cm) Power Supply Input Power D 115/230 VAC, -15% to +20% Power Supply Fuse D 1.25 amp Ambient Conditions...
  • Page 97 Appendix B Block Diagrams Remote I/O Communications Module M/N 57C416 LOCAL MEMORY FAULT CODE DUAL PORT MEMORY WATCHDOG DROP NUMBER LOGIC COMMON LOGIC COMMON CHAN 1489 RECV XMIT 1200 BAUD 1488 XMIT CHAN MANCHESTER ENCODER/ DECODER 875 KBITS 875 KHz TRANSCEIVER NOTE DROP NUMBER SHOWN = 03...
  • Page 98 Appendix B (Continued) AutoMax Remote I/O Shark Interface Module M/N 57C554 LOCAL MEMORY CPU OK WATCHDOG COM OK SHARK RACK INTER FACE DROP NUMBER SERIAL CONTROLLER XMIT MANCHESTER ENCODER/ DECODER 875 KHz TRANSCEIVER...
  • Page 99 Appendix B Remote I/O Head M/N 57C328 and M/N 57C330 DROP NUMBER FAULT CODE WATCHDOG POWER LOCAL MEMORY CPU READY FAULT MS B FAULT LS B RAIL FAULT LOGIC COMMON POWER SUPPLY BOARD PORT PORT INTERFACE PORT PORT LOGIC COMMON CHAN 1489 RECV...
  • Page 100 Appendix B Remote Drive Interface Head M/N 57C329 DROP NUMBER FAULT CODE LOCAL WATCHDOG MEMORY POWER CPU READY POWER SUPPLY BOARD LOGIC COMMON PORT PORT INTERFACE PORT PORT LOGIC COMMON CHAN 1489 RECV 1200 BAUD XMIT 1488 XMIT CHAN MANCHESTER ENCODER/ DECODER 875 KBITS...
  • Page 101 Appendix C RS 232 Port Pinout PIN 13 PIN 1 PIN 25 PIN 14 PIN # SIGNAL XMIT RECV The RS 232 port is used for programming terminal communications with the Remote I/O module, Remote I/O Head, or Remote Drive Interface Head. The programming terminal is connected to this port using an Interface cable (M/N 61C127).
  • Page 102 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 103 Appendix D Remote I/O Error Codes Remote I/O Module Remote I/O Head Remote Drive Interface Head CPU failed power up diagnostic EPROM failed power up diagnostic RAM failed power up diagnostic CTC failed power up diagnostic .3 CTC runtime failure SIO port failed power up diagnostic DMA failed power up diagnostic .5 DMA runtime failure;...
  • Page 104 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...

  • Page 105: Figure 3.2 Communications Passive Tap

    Appendix E Schematics Communications Passive Tap M/N 57C380 TO NETWORK I/O COMMUNICATIONS MODULE 9 Pin D" Shell Network Drop Cable 9 Pin D" Shell T 1:1 BNC 2 BNC 1 TO COAXIAL CABLE...
  • Page 106 Appendix E (Continued) Fiber Optic Rack Power Supply M/N 57C368 FUSE POWER PIN A 14/18 VAC OUTPUT TO MODULE CONNECTOR 115/230 V SWITCH PIN D...
  • Page 107 Appendix F Network Cable Specifications Belden 9259 RG 59/U Type Coaxial Cable Nominal Impedance D 75 ohms Nominal Velocity of Propagation D 78% Nominal Capacitance D 17.3 picofarad/foot Nominal Attenuation at 1 MHz D 0.3 decibels/100 feet Outer Jacket D PVC Nominal Outer Diameter D 0.242 inches Shield...
  • Page 108 Appendix F (Continued) Minimum Bending Radius D 2.5 inches Maximum Standard Length D 1000 feet Belden 225362 62.5 Micron Fiber Optic Cable Cable Size D 62.5 micron core, 125 micron cladding, 900 micron buffer Recommended Manufacturer D Belden Belden Part Number D 225362 breakout cable Number of Fibers per Cable Outside Diameter...
  • Page 109 Appendix F (Continued) Maximum Attenuation D 3.5 dB per km Nominal Operating Frequency D 820 nanometers Fiber Optic Connector Recommended Fiber Optic Connector D Hot Melt Connector, ST compatible Manufacturer D 3M 3M Part Number D 6100 Ferrule D Ceramic Maximum Attentuation D -0.6 dB per mated pair Recommended Connector Termination Kit...
  • Page 110 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 111 Appendix G Cable System Component List Coaxial Cable Network Reliance Recommended Component Part No. Manufacturer Part No. Drop Cable M/N 57C381 Passive Tap M/N 57C380 Terminating Load M/N 45C71 Amphenol 46650 75 RG 59/U Coaxial Cable Belden 9259 Dual Crimp Plug Connector For Belden M/N 45C72 227079 7...
  • Page 112 Appendix G (Continued) Fiber Optic Network Reliance Recommended Component Part No. Manufacturer Part No. Fiber Optic Connector 3M 6100 Connector 3M 6150A Termination Kit Drop Cable M/N 57C366 Stand Alone Math Associates M/N 57C365 Transceiver EN 19418C Rack with Power Math Associates M/N 57C368 Supply...
  • Page 113 Appendix H Remote I/O Network Specifications Using Using Coaxial Cable Fiber Optic Cable Specification Topology Active Star Cable Options Cable Options 62.5 micron 62.5 micron RG 59U (Belden 9259) RG 59U (Belden 9259) (Belden 225362) Maximum Cable Length RG 59U: 3000 ft (1000 m) 6,000 ft (2000 m)* Organization Master Slave...
  • Page 114 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 115 Appendix J Glossary of Terms attenuation: signal reduction inherent in a transmission line or cable over a given distance. The amount of loss is usually stated in decibels per kilometer at a specific wavelength. bend loss: increased attenuation caused by bending a fiber cable at a radius smaller than the recommended bend radius.
  • Page 116 Appendix J (Continued) impedance match: a condition whereby an impedance of a particular circuit, cable or component is the same as the impedance of the circuit, cable or device to which it is connected. jack: a connecting device into which a plug can be inserted to make circuit connections.
  • Page 117 Appendix K Fiber Optic Remote I/O Network Installation Guidelines Table of Contents K1.0 Introduction ..........K1.1 Fiber Optic Remote I/O Network Overview .
  • Page 118 List of Figures Figure K1.1 Fiber Optic Remote I/O Network ......Figure K1.2 Stand Alone Transceiver ....... Figure K1.3 Fiber Optic Rack and Power Supply .

  • Page 119: K1.0 Introduction

    K1.0 INTRODUCTION This appendix provides an overview of fiber optic networks, a description of the hardware components that comprise the AutoMax fiber optic Remote I/O network, and guidelines for installing the components and fiber optic cable. Refer to sections 3.5 and 3.6 in this manual for module installation and replacement procedures.
  • Page 120 Remote I/O Communications Module Master AutoMax Rack Drop Cable (M/N 57C366) Twisted Pair Wire Hub (Rack/Power Supply M/N 57C368 9 10 P/S containing 10 transceivers M/N 57C367) Fiber Optic Cable Stand Alone Transceiver (M/N 57C365) Twisted Pair Wire Drop Cable Balun (M/N 57C366) Tee Adapter...

  • Page 121: K1.2 Fiber Optic Remote I/O Network System Components

    K1.2 Fiber Optic Remote I/O Network System Components The AutoMax fiber optic Remote I/O network system consists of the following components: D Drop Cable (M/N 57C366) used only with the Remote I/O Communications module or the Shark Interface module. D BNC Tee Adapter (M/N 45C70), BNC Terminating Load (M/N 45C71), and Balun used only with the Remote I/O Head, the Remote Drive Interface Head, or a personal computer contianing a PC Link module.

  • Page 122: K1.2.4 Fiber Optic Rack With Power Supply

    fiber optic link with the transceiver hub. The transceiver is shipped with dust caps covering the fiber optic ports. The dust caps should not be removed until the fiber optic cables are installed, and should be replaced if the cables are disconnected, to prevent dust accumulation and the resulting loss of signal integrity.

  • Page 123: K1.2.5 Rack Mounted Transceiver

    The rack is a 19 inch clear anodized aluminum enclosure with a transparent plastic front panel. The rack contains a 115/230VAC power supply and 10 slots for transceivers. Each transceiver receives operating power through plug connections at the bottom of each slot in the rack.

  • Page 124: K1.2.6 Fiber Optic Cable

    LEDs on either side each connector indicate the status of the receiver and transmitter and will flicker as data is received and transmitted by the transceiver. WARNING TURN OFF AND LOCKOUT OR TAG POWER TO BOTH THE MASTER OR SLAVE DROP AND THE CORRESPONDING RACK MOUNTED OR STAND ALONE TRANSCEIVER BEFORE...

  • Page 125: K2.0 Installation

    K2.0 INSTALLATION This section describes how to install and replace the individual components that make up a fiber optic link. It also provides network installation and cable handling guidelines. Refer to section 3.6 in the manual for module installation and replacement procedures. DANGER THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND INTERNATIONAL CODES.

  • Page 126: K2.2 Installing The Stand Alone Transceiver

    Step 7. Note that the maximum link length is 2000 meters without splicing. Step 8. Document the fiber optic cable system layout. This document should be maintained for the life of the installation. Step 9. Determine the number of fiber optic cable components that are needed.

  • Page 127: K2.3 Installing The Rack/Power Supply And Rack Mounted Transceivers

    Step 2. Secure the transceiver to the mounting surface using #8 screws. Step 3. Verify that the external power supply is turned off. Make the drop cable and input power connections to the transceiver terminal block as shown in figure K2.2. TRANSCEIVER TERMINAL CONNECTION...
  • Page 128 TOP VIEW 17.53 9.72 REF. 8.98 Cover FRONT VIEW 19.00 18.18 1.49 5.23 2.25 .250 (4) PL. Figure K2.3 Fiber Optic Rack Mounting Dimensions Step 3. Plug each transceiver into any empty slots in the rack. Verify that on the transceivers at the extreme ends of the rack, a jumper has been connected between terminals 3 and 4 on the six screw terminal block.

  • Page 129: K2.4 Installing The Fiber Optic Cable

    Improper handling may result in damage to the cable. Unless you have in house expertise with fiber optic cable assemblies and installation, Reliance Electric recommends that you contact an experienced contractor for making up and installing fiber optic cables. Use the following general guidelines to protect the cable: D Visually inspect the cable before the installation.

  • Page 130: K2.4.1 Attaching The Fiber Optic Connectors

    D Route the fiber optic cable to protect it from abrasion, vibration, moving parts, and personnel traffic. Be sure the cable does not touch abrasive surfaces such as concrete which could wear through and damage the cable's outer jacket. D Locate the fiber optic cable away from temperatures greater than 80_C (176_F).
  • Page 131 CAUTION: Do not damage the ends of the fiber optic cable connectors by touching them or dropping them. Do not use factory compressed air to clean the fiber optic ports or connectors because the air may contain impurities that could scratch them. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

  • Page 132: K2.6 Replacing The Stand Alone Transceiver

    Transceiver Pins Connector LEDs Slot Figure K2.6 Fiber Optic Ports and Connectors K2.6 Replacing the Stand Alone Transceiver Use the following procedure to replace a Stand Alone Transceiver. Step 1. Remove power from the external power supply that is supplying power to this transceiver. Step 2.

  • Page 133: L2.8 Replacing The Fiber Optic Rack And Power Supply

    Step 4. Disconnect the twisted pair cable from the transceiver's four screw terminal block. Step 5. Loosen the captive screws on the transceiver's faceplate and remove it from the rack. Step 6. If the new transceiver is to be located at an extreme end of the rack, connect the jumper between terminals 3 and 4 on the transceiver's six screw terminal block.

  • Page 134: K2.9 Adding A Network Drop

    Calculate the new link length. Ensure the new total cable length does not exceed the maximum cable length defined in Appendix H. If it exceeds the maximum specified cable length, consult with Reliance Electric before taking any further steps. Step 3.

  • Page 135: K2.11.3 Cable System Inspection

    these changes have on the performance of the network. If necessary, take corrective action such as re routing certain fiber optic cables. K2.11.3 Cable System Inspection Inspect the fiber optic cable system periodically. Use the optical time domain reflectometer (OTDR) or power meter for the cable inspection.

  • Page 136: K3.0 Diagnostics And Troubleshooting

    K3.0 DIAGNOSTICS AND TROUBLESHOOTING This section describes how to troubleshoot the fiber optic Remote I/O network and its components. Refer to section 6.0 of this manual for troubleshooting procedures for the Remote I/O module, the Remote I/O Head, Remote Drive Interface Head, and the Shark Interface module.

  • Page 137: K3.2 Power Supply Status Indicator Is Off

    a.) Using a voltmeter, verify that the power supply voltage is within normal limits. (This step assumes that the Power Supply in the the Fiber Optic Rack is functional; refer to section K3.2). The power status indicator on the faceplate should be on. If it is off, unscrew the captive screws on the faceplate and remove the transceiver from the rack.
  • Page 138 Step 3. The received signal duty cycle should be 50%. If it is not, then use the potentiometer on the transceiver to adjust it. The potentiometer is located between the two fiber optic connectors as shown in figure K3.1. Remove the snap in button to access and adjust the potentiometer.
  • Page 139 Numbers remote drive interface head, 4 7 Shark interface, 4 5 Products Contents M/N 57C328, remote I/O head, 2 4, 2 9, table of, 1 CPU READY, see Status LEDs M/N 57C329, remote drive interface CRC ERRORS, see Programming terminal head, 2 7, 2 10, A 4 communications, remote I/O module, M/N 57C330, remote I/O head, 2 5,...
  • Page 140 Emergency stop considerations, remote electrical isolation, 3 8 I/O network, 3 27 physical isolation, 3 9 Error code 31, 6 6 disconnecting a slave drop from the remote l/O network, 3 34 Error code A, 6 5 installation planning procedure, 3 7 Error codes, D I module installation, 3 15 Example...
  • Page 141 remote I/O head (M/N 57328), 2 4 register organization, 4 1 remote I/O head (M/N 57C330), 2 5 Programming terminal communications, remote I/O module (M/N 57C416), 2 1 Shark interface module (M/N 57C554), remote heads (M/N 57C328, M/N 57C329, and M/N 57C330), MESSAGES RECEIVED, see Programming clear (C), 5 6 terminal communications, remote I/O...
  • Page 142 Watchdog timer, 2 7 Index 4...
  • Page 143 afadfdfdasfdsfdsdsdfdsfdsfdsfsdfdsa fdfdsfdsfdfdsfdsfsadfda sfdfaddfdd...
  • Page 144 For additional information 1 Allen-Bradley Drive Mayfield Heights, Ohio 44124 USA Tel: (800) 241-2886 or (440) 646-3599 http://www.reliance.com/automax Publication J-3606-4 - July 1996 Copyright © 2002 Rockwell Automation, Inc.. All rights reserved. Printed in U.S.A.

This manual is also suitable for:

Automax 57c329Automax 57c330Automax 57c416Automax 57c554

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