Input/Output Communications Control Module (I/O CCM) July 1989 IC600BF948 General Description The Input/Output Communications Control Module (I/O CCM) provides a serial data link between the CPU of a Series S i x programmable controller and many other devices. Some devices which can be connected are: - CCM2, CCM3, or I/O CCM in a Series Six PLC. - Data Communications Unit (DCU) in a Series O n e , or Series One Plus or Series O n e Junior PLC. - Data Communications Module (DCM) in a Series Thr e e PLC. VuMaster and Factorymastersoftware running on the Workmaster computer. - Intelligent devices such as a host computer. - Process Control Systems. The I/O CCM contains two independently configurable serial ports. Both ports support RS-232 and RS-422 serial interfaces, with Port 1 also supporting active/passive 20 mA current loop. Both ports support asynchronous serial communications with data rates of up to 19.2 Kbps. The user may select any of the following options using DIP switches. Data rate: 110 to 19.2 Kbps. Maximum data rate is limited to 4800 Kbps for current loop operation on Port 1. Protocol type: For CCM mode -- master, slave, or peer. For Remote Terminal Unit (RTU) mode -- RTU slave. Parity: even odd, none Turn-around delay: 0 or 500 ms, Port 2 only. The features and benefits of the I/O CCM are given in Table 1. Table 1. Features and Benefits FEATURES Contains two programmable communications interfaces. Multiple modules per Series Six PLC. Redundant communications. BENEFITS Permits a data link between the Series Six PLC and a host computer, programmable terminals, and other intelligent devices. Permits communication ports as required. Permits duplication of communication hardware and separate data paths by using two I/O CCM modules for each Series Six CPU. Interfaces to process control systems. Allows the Series Six PLC to be used with process control systems. Ability within the user logic program to initiate a data transfer or request to a host computer or another intelligent device. On-board diagnostics and board fault indicator lights. Allows the Series Six PLC to act as a master or peer in its relationship with other PLC s, host computers, or smart terminals. Simplifies troubleshooting and indicates correct data transfer. 2 Input/Output Communications Control Module (I/O CCM) The I/O CCM can be used in communications systems using: Multidrop modem based links Multidrop RS-422 links Radio links (port 2 only) Six Light-Emitting Diodes (LEDs) show port activity and module status. If the on-board power-up diagnostics detect a failure, the BOARD OK LED will remain OFF and the lower five LEDs will provide an error code to specify the error. (See Table 5 for the specific power-up error codes). NOTE The CPU COMM LED blinks to indicate communications between the I/O CCM module and the Series Six CPU. As a master device port 1 or port 2 can be used in multidrop configuration; As a slave device The remaining four LEDs show port activity of the only port 2 can be used in multidrop transmitters and receivers on both ports. They will configurations. BLINK when a port is communicating and will be OFF when an error occurs on a particular port. The module provides isolation of the serial port receivers and transmitters and also provides 1500 volts of isolation protection from port to port and from the ports to the rest of the Series Six PLC system. The I/O CCM may be inserted in a high-capacity I/O rack or a Series Six CPU rack I/O slot. GEK-90824D Table 2, RS-232C/RS-422 Cable Specifications Length, Maximum - 50 feet (15 meters) for RS-232C; 4000 feet (1.2Km) for RS-422; 1,000 feet (305 meters) for current loop. Overall Shield Recommended 24 AWG Minimum Mating connector to Port 1 or Port 2 is a D-Subminiature Type. Cannon DB25P (Solder Pot) with DB11096B-3 Hood or Equivalent. (Standard RS-232C male connector.) The following cables provide acceptable operation at data rates up to 19.2 Kbps and distances up to 4000 feet. Belden - 9184 Belden - 9302 NEC - 222PlSLCBT At shorter distances, almost any twisted pair or shielded twisted pair cable will work. It should be noted that RS-422 requires that the transmitter and receiver ground be within a few millivolts of each other or damage to the transmitter and receiver may result. It is also noted that the twisted pairs should be matched so that both transmit signals make up one twisted pair and both receive signals make up the other twisted pair. If this is ignored, then cross-talk can result from the mis-matching which may affect the performance of the communication system. COMM. Board has passed self-diagnostics and is operating properly. Invalid slave ID when either port is configured as a slave. Board has failed self-diagnostics (see Table 5). Board is communicating with the Series Six CPU properly. The rate of blink indicates the frequency of CPU communication windows. No communication between the Series Six CPU and the board. (Check DPREQ in ladder diagram and backplane DIP switches for Code Description Code Description 1 Processor test failed 5 EPROM test failed 2 Timer 0 test failed 6 RAM test failed (E000-1-1-1-1); board location, U20 3 Timer 1 test failed 7 RAM test failed (C000-D1-14F); board location, U19 4 Timer 2 test failed Installation To install and operate the I/O CCM you must complete the following steps. 1. Calculate the power requirements for the rack which will contain the I/O CCM. 2. Set the I/O CCM address using the backplane DIP switches. (Reference Figure 3, Table 6) Refer to a later section, \"Running at the DPU Executive Window\", to set the I/O CCM module to run at the DPU address. 3. Configure the communications port using the on-board DIP switches. (Tables 7, 8, 9) 4. Check the RS-232/RS-422 DIP pack for desired orientation - Port 2 only. (Reference Figure 2) 5. Insert I/O CCM in the rack. 6. If not running at the DPU executive window, program the [DPREQ] or [WINDOW] instruction to establish windows between the I/O CCM and the CPU. The [WINDOW] instruction is valid for CPU microcode Version 130 and thereafter. 7. Program the registers containing the communications command and parameters for the required transfer of data if the I/O CCM is to initiate communications. 8. Set up valid CPU ID number through the CPU scratch pad. 9. Construct and install cable. (Reference Figures 5, 6, 7, and 8) Power Requirements for the I/O CCM The I/O CCM may be installed in a Series Six CPU rack I/O slot, the Series Six High-Capacity I/O rack, or a Series Six Plus CPU rack. The Series Six CPU rack can support a maximum of 300 units of load. Consequently, four I/O CCMs can be powered by the Series Six CPU rack, and when no other loading exists for +12 Vdc, five I/O CCM modules may be installed. A maximum of five I/O CCM modules can be powered by a high capacity I/O rack. In this case there are 140 units of load remaining for I/O modules with +5v power only. When other types of I/O modules are to be placed in the same rack as an I/O CCM, calculate the power requirements of all the modules to ensure that the maximum power of the rack is not exceeded. Refer to the power requirements of the I/O CCM in Table 13, and to the appropriate manual or data sheet for other modules. 6 Input/Output Communications Control Module (I/O CCM) Positioning the RS-422/RS-232 Hybrid Dip Package The RS-422/RS-232 hybrid DIP package affects the operation of port 2 only. Verify the position of the configuration hybrid DIP package located between ports Jl and J2, It is marked 232 on one end and 422 on the other end and is mounted on a zero insertion force socket. Use a small screwdriver to turn the screw which releases the configuration hybrid DIP package from tie socket. Position the package with the desired interface type (RS-232 or RS-422) closest to port Jl. See Figure 2 for proper orientation. a42442 RS-232-C SELECTED 422 RS-422 SELECTED GEK-90824D Setting the Module Address Before installing the module, set the Dual-In-Line Package (DIP) switches adjacent to the card slot on the rack backplane to establish which group of eight consecutive input points in the CPU I/O tables will be used by the module being installed. Figure 3 illustrates a typical I/O DIP switch set for address 673-680 and Table 6 shows switch settings for all possible module addresses. Refer to a later section Running at the DPU Executive Window\' , to set the I/O CCM module to run at the DPU address. a4244 1 Figure 2. RS-232/RS-422 Hybrid DIP Package (for Port 2) Figure 3. Typical I/O Backplane DIP Switch Input/Output Communications Control Module (I/O CCM) 7 GEK-90824D Table 6. Setting the Backplane DIP Switch to Address the I/O CCM b40478 0 ms* 500 ms Parity Selection No Parity Odd Parity* Module Operation Execute I/O CCM operational software* Execute factory test software Reset Switch open* closed * Factory-set default position. I/O CCM module is enabled* I/O CCM module is reset 10 Input/Output Communications Control Module (I/O CCM) GEK-90824D Table 9. Configuration Switches for Port 1 (Bank C) SWITCH 1 open * closed FUNCTION RS-232 Operation Disconnects Pins 15, 16 for Port 1 RS-232 Connects Pins 15 and 16 for Port RS-232 operation (use external jumper if desired across pins 15-16). * Factory-set default position, Inserting the I/O CCM in its SIot Use the extraction/insertion tool to remove or install the module in the Series Six CPU rack, I/O slot, or Series Sk Plus rack. programs initiate serial data transfers to another device by loading a command into the I/O CCM command registers. Guide the faceplate over the circuit board so that proper contact is made. Then secure the faceplate to the rack using the thumbscrews at the top and the bottom of the faceplate. Program the DPREQ or WINDOW instruction to establish windows between the I/O CCM and the CPU. The WINDOW instruction is valid for CPU microcode Version 130 or thereafter. Power may now be applied to the module and other external devices may be connected to either of the ports. After power up diagnostics, the indicator lights should all turn ON. Program the registers containing the communications command and parameters for the required transfer of data if the I/O CCM is to initiate communications. Establishing I/O CCM to CPU Communications Windows Programming the I/O CCM There are two methods of generating window communications between the I/O CCM and the CPU. DPREQ Windows DPU Executive Windows The CPU provides a window to the I/O CCM using the DPREQ instruction (or WINDOW instruction) as shown below. When properly entered, the CPU COMM LED will start blinking to indicate that windows are occurring. NOTE Example ladder logic rung for programming the DPREQ instruction. The DPU Executive Window method of communication may be used with the following versions (or later) Series Six Logic Control Function cards : IC6OOCB525 for Advanced, IC6OOCB526 for Expanded, and IC600CB515 Expanded II. oxxxx Rnnnn OYYYY -1 p-- EDP=Ql -------------------( ) HHHB Earlier Logic Control Function cards (CB502 for Advanced, CB512 for Expanded) require that a DPREQ be programmed to communicate with the I/O CCM, and the CPU must be set to RUN mode. In this program, the I/O CCM will receive a CPU communications window if output Oxxxx is on. The contents of register Rnnnn must correspond to the first I/O point address of the I/O CCM plus 1000 decimal. If the I/O CCM address is for inputs 1-8, then HHHH equals 03E9H (decimal 1001). When the I/O CCM services the CPU communications window without fault, output Oyyyy will remain off. If a fault occurs during the CPU communication Programming the DPREQ window, Oyyyy will turn on. The ladder logic program grants communication win- The I/O CCM does not process serial transfers until dows to the I/O CCM through the programmed the first window is received after the module has DPREQ or WINDOW instruction. The ladder logic powered up. The module needs the first window to Input/Output Communications Control Module (I/O CCM) 1 1 GEK-90824D determine the CPU ID number and the CPU register and user logic size. The CPU COMM LED blink rate will show the frequency of DPREQ windows. The LED blinking means that the module detects that the window opened and closed successfully. (The module may or may not transfer data during that window). The frequency of DPREQ windows to the I/O CCM module affects the performance (time to complete a message) of the serial links. Therefore, the user should guarantee that the module receives windows on a regular basis. For the fastest response times on the serial link, the module can be given a window once per scan or even multiple windows per scan. The I/O CCM has a 5-second timeout on waiting for a window to transfer data to or from the Series Six CPU. If the timeout occurs, the I/O CCM will abort the serial link (sends EOT or an error response). Running at the DPU Executive Window With the enhanced I/O CCM (Version 203 Hex, or thereafter), it is possible to get windows with the CPU without having a DPREQ in the ladder logic. This feature allows windows to continue while the CPU is stopped. NOTE You must have CPU microcode version V107 Advanced, VI18 Expanded, V130 Expanded II (or later versions) for windows to continue while the CPU is stopped. The following stops are required to set-up the I/O CCM to run at the DPU address. - Power-down the unit. Set the backplane DIP switch for Inputs 1009-1016 to be addressed (7E hexadecimal). Refer to Figure 4 for switch configuration (Switch 1 CLOSED, all other switches OPEN). Connect the I/O terminator plug. Refer to Tables 10 and 11, for the I/O Terminator Plug wiring. - Power-up the unit. a42720 Figure 4. Backplane Switch Setting for Running at DPU Window I/O Terminator Plug (DPU) A special I/O terminator plug may be required when operating the I/O CCM module at the DPU Executive Window. The I/O Terminator Plug requirement is dependent upon: whether the I/O CCM is placed in a CPU rack or an I/O rack, and whether the I/O Controller card installed in the CPU rack is type I014 or IOI5. Installing the I/O CCM in a CPU Rack: When the I/O CCM is installed in a CPU rack (e.g., Series Six Plus or Series 60 PLC) along with the 1014 card, the I/O terminator plug (wired as Table 10) must be used. Table 10. I/O Terminator Wiring (CPU Rack) 1 PIN 1 SIGNAL 1 JUMPER I 3 7 3311 3 4 3 6 FFIINN++ DPE+ GND FIN- +5v DPEPiinnss:: 3300,, 3355,, 3377 Pins: 31, 34, 3 6 Position the 37-pin, male connector plug on the I/O port of the I/O Controller (1014) card in the Series Six CPU -- Slot 1. InstalIing the I/O CCM in an I/O Rack: When the I/O CCM is installed in an I/O rack along with the IOI4 card in the CPU rack, the I/O cable must be modified at the connector going to the CPU rack. 12 Input/Output Communications Control Module (I/O CCM) Verify that the CPU connector end of the I/O cable is wired as shown in Table 11. Also, a jumper setting for the 1014 card is required -- Locate Jumper ABC in A-B position. Table 11. Connector Modification (I/O Rack) PIN SIGNAL JUMPER ;: +5v Pins: 34, 36 DPE- ;; DPE+ Pins: 35, 37 L GND Installing the I/O CCM with I/O Controller (IO15): When the I/O CCM is installed in either a CPU rack or I/O rack along with the I/O Controller (IOI5) card, the I/O terminator plug is NOT required. Position the 1015 card jumper (Jumper ABCK) in A-K position. Programming the Communications Command and Parameter Registers Each I/O CCM has an associated communications command register. This register is monitored by the I/O CCM for communication commands which the user program wants to initiate. The command register corresponds to the first input point of the address of the module. -1 E-- Command Register ROOOl xxxx nnnn VW CONST -[ A MOVE 01001 GEK-90824D For example, if the I/O CCM is addressed (using the backplane DIP switches) at inputs 9-16, then the communications command register in the Series Six CPU is register 9. The format of these commands and the command parameters is the same as for the CCM2 and CCM3. The main difference is that for the I/O CCM, the command register reference must always correspond to the module address. Therefore, the reference for the DPREQ register must not be the same as the command register reference. When the user sets up one of these commands for execution, the I/O CCM will read the communications command number and the command parameters. It will then zero the communications command register to notify the user that the command was read by the I/O CCM. The I/O CCM status byte indicates when the command is in progress and when the command has completed. The module is addressed for I/O points l-8 (01001 dec or 03E9 hex). The CPU communications window is opened once each scan. The example below shows the logic necessary to initiate a serial request using the BLOCK MOVE function in the Series Six CPU. Refer to GEK-25364, Series Six PLC Data Communications Manual for definitions of the command and parameter registers, and for programming examples.