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AB PLC Configuration (Demo)

게시자: Sundew Shin, 2011. 4. 20. 오전 9:57   [ 2011. 4. 20. 오전 10:09에 업데이트됨 ]

Before Start Anything

  • Upgrade the development software toolkit to the latest or a reasonable revision, or there is possibility you meet people(engineer) claim the problem caused by your 'outdated' software tool.
    • RSLogix 5000 Standard, Eng (v17.01.02)
    • RSNetworx for Controlnet (v9.00.00)
    • RSNetworx for DeviceNet (v9.00.00)
    • RSLinx (v)
    • BOOTP/DHCP Server Utility (v2.3)
    • FactoryLink (v7.5)

[AB ControlLogix]

Network Initialization

  • Set the pre-defined IP address using the BOOTP utility bundled with the RSLogix5K
    • Record the MAC address from the module and identify each module at BOOTP.
    • Set the predetermined IP for the both EN2T module, and disable the BOOTP service one by one, or you will loose the setting at the next power cycle.
    • The firmware version has been decided and optimized after a timely experiment, so you wouldn't need to re-flash it.

Synchronizing CPU

  • Match the revision level of the project & CPU module
    • Firmware version 16.50 or above is required for redundancy functionality.
      • In our case, the factory set firmware version was 16.20, which was not able to recognize for redundancy
    • Install the ControlFlash 8.00.017 or above.
      • You would need other(lower) versions of this S/W to upgrade/downgrade certain modules' firmware.
    • Upgraded to 16.80, and we could synced each CPU.
      • Refer to the chapter, 'Upgrade Firmware,' for the methodology.
  • Match and get ready EN2T, RM, CN2R modules for sync.
    • RM needed to be revised to 2.5 to recognize each other.
    • The both CN2R's node address should be same, and you should allocate a space one higher.
      • e.g. If you set the both as node# '1', the next available node# for other modules should be started from '3', not '2'
    • Applied the same rule of above to EN2T for IP address.
      • If you messed up something, factory reset the module and try again.
        • For resetting, set the setting knots to all '8' and insert it back; wait few secs and you will see the message it's been restored. Go back to '999' and do the BOOTP thing again.
      • Make sure you 'Disable BOOTP' once you could be able to setup the IP, unless, the setting will be erased on the next power cycle.
    • Reference: http://samplecode.rockwellautomation.com/idc/groups/literature/documents/um/1756-um523_-en-p.pdf
  • Once you get one 'PRIM' and the other 'SYNC', move on to configure the rest of ControlNet nodes using the 'RSNetworx for ControlNet'

Preparing ControlNet

  • Requires RSNetworx for ControlNet and the license
  • First, upload from the network and see the currently available modules/connections.
  • Download to Network (not sure yet what does it in effect)
    • I do have a feeling, however, the configuration is being downloaded to each controlnet module..
  • The indication of Media Redundancy set properly is the LED lighting on a ControlNet module. e.g., The both A & B LED indication should be on.
    • Make sure you select the 'Media Redundancy', 'A/B' for activating both A and B channels.

Upgrade Firmware

  • I decided the firmware revision-level as below for the demo system.
  • Visit the ControlFlash download site, and you need an account.
    • http://support.rockwellautomation.com/ControlFlash/
  • Make sure you try first with all the default levels and upgrade each with specific purpose.
  • I made a spreadsheet with all the revision level record in. Please update it if you've changed anything.

Preparing DeviceNet

  • DNB Module (Scanner) Dip Switch Manual Setting: Data Rate=0(125K) Node=00
    • I discourage '9' for the programmatic setting option.
  • EDS file matching
    • Online search and detect by the Internet is the most safer/standardized/convenient option.
    • Consider the UDT impact from your existing PLC project. If things have changed, make the required modifications.
  • Troubleshoot the entire network to recognize all nodes.
    • Confirm each module has an unique node number
    • Match the communication speed for all nodes (Demo, 125K Baud)
    • Check the physical integrity of network. e.g. shield connection between two ends (panel-MCC)
    • Opinions:
      • AB's IntelliCENTER has equipped with a decent DeviceNet sub-network so you can trust 80% from the beginning.
      • Each network node's insertion sequence also matters when the network is not fully stabilized.
      • I highly recommend an official commission for assurance by vendor (Rockwell Automation) to identify any hidden troubles.
      • Adding/relocating the terminal resisters would be considered as the final resort. Keep the solid priority and don't let the theologists jump around and make everyone get confused. 
  • Once you have got all nodes online, even though there are still inconsistency ('missing'), you are ready for input/output mapping.
    • Map the input and output based on the program specification
  • Open the RSNetworx for Devicenet and scan w/ 'Continuous Browse'
    • Confirm all nodes are up and stable w/o any 'missing'
DeviceNet Scanner Characteristics
  • Initially, the DNB module will run in monitor mode and
    • only detect the following error situations:
      • Node duplication
      • Baud rate miss configuration
    • and will not check:
      • Node missing
  • Once you add each module into the scanlist, the scanner will start checking any node missing.
    • For any node missing, it will display E#078.
  • After IO mapping, if you delete any nodes in the list, you lose the module's mapping information & the module will also be removed from the scanlist.
    • This means the scanner will not manage the module.