SOP Converting PLC Communications to Ethernet

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Standard Operating Procedure
Subject:
SOP Converting PLC Communications to Ethernet
Author:
Troy Humphrey
Approved by:
UNAPPROVED

Contents

Objective

The objective of the SOP is to give the user step by step guidelines on what is required when a Ethernet ready PLC (SLC 5/05) is used to replace a SLC 5/03.

Scope

The scope of this procedure is focused on the communications between Allen Bradley devices. Communications between the platform (M4 or Multimon) and the PLC is briefly touched on but is not the focus of this SOP. For help with those types of communications please refer to the following SOP: SOP PLC Message Instructions

Responsibilities

The PSCMF Kennewick staff is responsible for converting communications to Ethernet when M4 is installed at a site.

Procedure

Modify the current RSLogix500 file

  1. Open the RSLogix500 file for the site you are converting communications for.
  2. Save the file under a different name to preserve the original file.
    • This will also save the same processor name which is critical for communications. Typically the processor name is SGATE.

Convert the Processor Type

  1. In the project window(left window) double click on Controller Properties.
  2. Change the Processor Type to 1747-L551B/C 5/05 CPU - 16K Mem. 0S501 Series C.
  3. Click Apply.
  4. The program will ask you to confirm the processor type change. Make sure the 're size the data table' check box is checked.
  5. You will receive a rung error.(A information window will pop up on the bottom of the screen)
  6. Click OK to close the Controller Properties window and navigate to the rung error via the information window at the bottom of the screen.
  7. You should now be at the Message Instruction rung. If not find the Message Instruction rung.
  8. Drop a new Message Instruction on the rung and use the following graphics to set up the Message Instruction.
    • You will have to change the Read/Write parameter from Read to Write.
    • You will have to change the Target Device from 500CPU to 485CIF.
    • You will have to enter the same address for the Control Block as that of the old Message Instruction.
  9. Double click on the Setup Screen at the bottom of the Message Instruction.
    • You will have to enter in the Data Table Address (Currently N7:1).
    • You will have to enter in the Size in Elements (Currently 6).
    • You will have to change the Channel from 0 to 1.
    • Currently the Message Timeout is unknown.
    • Currently the Data Table Offset is unknown.
    • You will have to enter in the IP address of the M4 machine that you want the messages sent to.
  10. Delete the old message instruction and verify the program.


Message Instruction Multimon to PLC via RS232
Message Instruction - M4 to PLC via Ethernet




Message Instruction Setup Multimon to PLC via RS232
Message Instruction Setup - M4 to PLC via Ethernet



Setup the Channel Configuration

Setting up the Channel Configuration is a two part process. First you have to ensure that you have a way to initially communicate with the 5/05. This is typically done via DF1 on CH0.

Channel Configuration Chan. 0 - System Tab
  1. Channel 0 is 9 pin channel
  2. From the project window on the left hand side double click on Channel Configurations under the Controller folder.
  3. Click on the Chan. 0 - System tab
  4. Ensure that the the parameters match the following graphic.
    • You can adjust the 'Max Node Address:' up to 31 but the lower the number the less nodes the PLC has to poll.



Channel Configuration Chan. O - System Tab DF1 Communications
Channel Configuration Chan. O - System Tab DF1 Communications

NOTE: This will be changed to DH485 later in this SOP. It must remain DF1 Full Duplex (RS232) until you are able to switch to a Ethernet driver for communications.

Channel Configurations Chan. 1 - System Tab

The following graphic shows the Chan. 1 - System Tab prior to configuration.

image:Channel 1 Ethernet No Config.jpg
SLC 5/05 Channel 1 prior to configuration

  1. You will have to enter in the site allocated IP address of the PLC.
  2. You will have to enter in the site Subnet Mask.
  3. You will have to enter in the site Gateway Address.
  4. You will have to un-check the Bootp Enable box.
  5. Click Apply then OK.



Download the Program to a 5/05

  1. Install a SLC 5/05 into a lab chassis configured exactly the same way as the chassis that is at the site you are configuring the 5/05 for.
  2. Turn power on to the chassis.
  3. Hook up a RS232 cable from the PC to CH0.
  4. Hook up a Ethernet cable from your PC to CH1.
    • If you use a hub a normal Ethernet cable will work. If you go directly from the Ethernet jack on your PC to the CH1 of the PLC you will need a cross over Ethernet cable.
  5. Ensure RSLinx has a configured DF1 driver.
    • If not create one.
  6. Ensure RSLinx sees the 5/05 on the DF1 driver.
  7. Double click on Controller Properties under the Controller folder in the left hand Project window.
  8. Click on the Controller Communications Tab.
  9. Under the Driver parameter, select DF1.
  10. Click OK
  11. Download the program.
  12. You will be warned that the communications is changing and will be asked to click Apply if you want to continue. Click Apply.
  13. You may receive a message stating A change was detected with the SNMP, HTTP, or Auto Negotiate configurations. In order for the change to take effect, a power cycle is required.
  14. Click OK.
  15. Cycle the power on the SLC 5/05.

Switch the Communication Driver

  1. Ensure that you are off line.
  2. Change the IP address of the PC to one that would work at the site you are configuring the SLC 5/05 for.
  3. Open DOS Command prompt and make sure you can ping the SLC 5/05.
    • If you cannot ping the PLC RSLinx will not establish communications.
    • Resolve any communications problems prior to proceeding.
  4. Open RSLinx.
  5. Right click on the AB_ETH-1 driver (or whatever the name of your Ethernet driver is) and select Configure Driver.
  6. Add the IP address of the SLC 5/05 to the list of IP address.
  7. Click on Add New or Apply, then OK.
  8. Ensure that the Ethernet driver in RSLinx sees the SLC 5/05 and that it has the same processor name as the 5/03 it is replacing had.
  9. From RSLogix500 double click on Controller Properties under the Controller folder in the left hand Project window.
  10. Click on the Controller Communications Tab.
  11. Under the Driver parameter, select the AB_ETH-1 driver (or whatever the name of your Ethernet driver is).
  12. Click apply or OK.
  13. Go online with processor via Ethernet.
  14. If you get no response from the processor try the following.
    • Click on Comm from the top toolbar.
    • Select Sytem Comms... .
    • Click on the IP address of the SLC 5/05 under the AB_ETH-1 driver (or whatever the name of your Ethernet driver is).
    • Click on Online on the right hand tool bar.
    • If you are asked if you want to save changes to the program select Yes.
    • If you receive a message stating no matching file found then browse to where you saved the file and select that file.
    • Click on Upload Use File.
  15. Change the program from REMOTE PROG to RUN.



Set up the Channel Configuration General Tab

  1. From the project window on the left hand side double click on Channel Configuration under the Controller folder.
    • The General Tap will appear on top.
    • Verify that the Passthru Link ID (dec) parameters match for each channel.
    • Typically set to 1 for each channel.


Channel Configuration General Tab
Channel Configuration General Tab


Change the CH0 Configuration

  1. Channel 0 is 9 pin channel.
  2. From the project window on the left hand side double click on Channel Configurations under the Controller folder.
  3. Click on the Chan. 0 - System tab.
  4. Ensure that the the parameters match the following graphic.
    • You can adjust the 'Max Node Address:' up to 31 but the lower the number the less nodes the PLC has to poll.
  5. Click on Apply.
  6. You may receive a warning stating Loss of communication on OTHER channel (SH0) WILL occur.
  7. Select Apply.
  8. You may receive a pop up window asking if you want to switch the processor to remote PROG mode.
  9. Select Yes.
  10. Change back to Run Mode.


Channel Configuration Chan. O - System Tab DH485 Communications
Channel Configuration Chan. O - System Tab DH485 Communications

NOTE: It is very important that the processor name of the 5/05 matches the 5/03 that it replaced. The HMIs will not communicate properly is the processor name is wrong.

Install in the field

The following steps assume the reader of this SOP is intending to use CH0 to communicate with the 'legacy' DH485 devices currently installed in the field.

THIS PART OF THE PROCEDURE WILL LIMIT A SITES ABILITY TO DIVERT FISH AND RUN SAMPLES. THIS PROCEDURE SHOULD BE DONE IN COORDINATION WITH THE COE BIOLOGIST AND PREFERABLY DURING THE OFF SEASON.

  1. Note the Sample Rate on Openings Per Hour.
  2. Note the Slide Gate times.
  3. Note the sensor times if the site has slide gate sensors.
  4. Remove power from the SLC 5/03 in the field.
  5. Remove the processor and replace with the SLC 5/05 you configured in the lab.
  6. Remove the AIC card typically installed to the left of the processor/chassis power supply.
    • Note the wiring configuration of the DH485 jack and ensure that it matches the data highway drawing.
  7. Install a AIC+ card and wire 24VDC to it.
  8. Hook up the DH485 network cables to the AIC+ card.
  9. Install a crossover RS232 cable between CH0 of the processor and the 9 pin jack on the AIC+ card.
  10. Install a CAT5 cable between the platform and the PLC.
  11. Restore power to the chassis.
  12. Ensure you have Ethernet communications from the platform to the PLC.

Test the DH485 Network

  1. Enter in the the Sample Rate and Openings Per Hour from the appropriate HMI.
  2. Enter in the Slide Gate times from the appropriate HMI.
  3. Enter in the sensor times from the appropriate HMI is the site has slide gate sensors.
  4. Go online with the processor and ensure that the times you just entered via the HMIs were properly received by the PLC.
  5. If you have problems establishing communications between the PLC and the HMIs.
    • Ensure that the processor name of the SLC 5/05 matches that of the SLC 5/03 that it replaced.
    • Cycle power on each HMI.
    • Make sure there isn't a NODE # conflict.
    • Make sure the data highway connections are solid.

References


Contact PSMFC at (509) 735-2773

Name Extension
Don Warf 1
Scott Livingston 2
Darren Chase 3
Alan Brower 4
Troy Humphrey 5
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