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PCS 91.

GEF
english
Reg 10400/0401

Version 1/04.01
© Systeme Lauer GmbH & Co KG
Systeme Lauer GmbH & CoKG
Postfach 1465
D-72604 Nürtingen

Operator reference manual: PCS 91. GEF


Version: 10.04.01
Person responsible: Stefanie Weiß

Operating manuals, reference manuals, and software are protected by


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• We reserve the right make changes to the reference manual without


prior notice.

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on the diskette and the fault-free state of this information.

• Since diskette represent manipulatable data media, we can only


guarantee the physical completeness. The responsibility is limited to
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• At any time, we welcome suggestions for improvements and remarks


on errors.

• The agreement also applies to the special appendices to this reference


manual.

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soft Corporation in the USA and/or other countries.
SIMATIC and STEP are registered trademarks of the Siemens AG.

The remaining designations in this document can be brand names who`s


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Notes for the user

Please read the manual before beginning and keep the manual for later
use.

Target group The manual has been conceived and written for users who are
experienced in the use of PCs and automation technology.

Typographical conventions [KEY] Keys that are to be pressed by the user are given
in square brackets, e.g [CTRL] or [DEL]

Courier On-screen messages are given in the Courier font,


e.g. C:\>

Courier bold Keyboard input to be made by the user are given


in Courier bold, e.g. C:\>DIR

Italics Names of buttons to be pressed, menus or other


on-screen elements and product names are given
in italics.

Pictograms The manual uses the following pictograms to


highlight certain text passages:

Danger!
Possibly dangerous situation. Injury to persons can be the result.

Attention!
Possibly dangerous situation. Property damages can be the result.

Tips and supplementary notes

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Table of contens

Notes for the user 0-3

Table of contens 0-4

Quality and support 0-5

Safety regulations 0-6

Norms 0-7

General interference protection measures 0-8

1 First Start-Up 1-1


1.1 Delimation ............................................................................ 1-1
1.2 Equipment and accessories required .....................................1-1
1.3 To load the SNP_DIR driver in the PCS ..................................1-1
1.4 To connect the PCS to PLC .................................................... 1-2
1.5 Error elimination ...................................................................1-2

2 PCL Handling Software 2-1


2.1 Description of the handling software .................................... 2-1
2.2 To load the handling Software .............................................2-3
2.3 Communication errors ..........................................................2-4
2.4 Status .................................................................................... 2-4

3 Communication 3-1
3.1 Communication cable ...........................................................3-1
3.2 Configuration cable PCS722 ..................................................3-2
3.3 Data Transfer PCS/PLC ..........................................................3-2

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Quality and support

In our company, quality comes first. From the electronics component up


to the finished device, the quality assurance test competently and
comprehensively.
National an internation test standards (ISO, TÜV, Germanischer Lloyd)
are the basis.
Within 48 hours, every device passes a 100% check and continuous test
under worst case conditions at changing temperatures (0...50°C) and
test voltages.
A guarantee for maximum quality.

Our products not only feature a maximum economic efficiency and


reliability but also a comprehensive complete service.
You not only receive demo devices but we rather make specialists available
who support you in person with your first application.
Qualified user consultation by competent sales engineers is obvious for
us.
Our support is for you for the side with advice and deed every day.

We set up training programs and technical training for you in our mo-
dern training center or alternatively also in your house.
Request the curent training catalog.

From the consultation up to the user support, from the hotline up to the
service, from the reference manual up to the training an all covering
and individual service for the entire product line is waiting for you.

Whenever you need us, we are there for you:


dynamically, creatively and enormously efficiently. With the entire
experience of a world-wide successful enterprise.

Telephone 07022/9660 -132, -231, -230


eMail support@systeme-lauer .de
Web site www.lauer-systeme.net
Systeme Lauer Active Area
(Download of Software, driver, manuals, Forum...)

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Safety regulations

This reference manual contains the most important remarks in order to


safely operate the device.

• This operator‚s guide, particulary the safety remarks are to be noted


byall persons working with the device.

• Furtherrmore, the rules and regulations for the accident prevention


applying to the application location are to be observed.

• Use as directed. The device is deigned for the application in the


industrial area.

• The device is manufactured to the state of the art and the official
safeguarding regulations. Nevertheless, due to the application,
dangers or impairments can result to the machine or to material
assets.

• The device meets the requirement of the EMC guidelines and


harmonized European standards. Any hardware-related modification
of the system can influence the EMC behavior.

• The device may not be used without special protective measures in


the hazardous area and in plants requiring a special monitoring.

• Do not heat up the buffer batteries. Danger of explosion. Serious


burning can be the result.

• The installation and operation may only be performed by trained


personnel.

• The operating voltage of the device may only be in the specified


ranges.

• You find information on this on the type plate and in the specifications
of this reference manual.

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Norms

The device is constructed using up-to-date technologies and fulfils the


requirements of the following guidelines and norms:

• Compliant with the EMC Directive 89/336/EEC and the German law
on electro-magnetic compatibility

• Interference compliant with the generic requirements norm


EN€50081-2 and product norm EN€55022:

• Measurement of the conducted interference voltage as per EN€55022

• Measurement of the radiated radio interference field power as per


EN€55022 class A

• Interference immunity in compliance with generic requirements


norm EN 50082-2 and product norm EN 61000-6-2:

- Electro-static discharge (ESD) as per with EN 61000-4-2

- High-frequency electromagnetic fields as per EN 61000-4-3


and ENV 50204

- Fast transient interference (burst) as per EN€61000-4-4

- Surge voltages as per EN 61000-4-5

- High-frequency conducted fields as per EN 61000-4-6

- Voltage dips and short-term interruptions as per EN 61000-4-


11

The assembly and connection instructions contained in this documen-


tation must be followed.

Conformity of this equipment is confirmed by the CE logo.


The EC declaration of conformity can be requested from:

Systeme Lauer GmbH & Co KG


P-O-Box 1465
D-72604 Nürtingen

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1 First Start-Up

1.1 Delimitation
The successful parameter assignment of the PCS 090/095, as described
in section 3 (PCS 091 manual), is assumed as a precondition. This
appendix refers exclusively to the use of the PCS 090/095 together with
a controller from the 90/30 or 90/20 series supplied by GE-FANUC. This
controller is referred to in the following as the PLC (programmable logic
controller), the programming software for the PLC is referred to as
Logicmaster 90 and the driver to be loaded into the PCS as the SNP_DIR
(series 90 protocol). The driver to be loaded into the PCS 090 can be
operated with both the 90/30 and the 90/20 PLC. The GE-FANUC specific
terminology and the programming for the PLC with the Logicmaster 90
software are assumed to be known by the user. The following description
refers to the 90/30 PLC, for using the 90/20 PLC see sections 2.1 and 4.

1.2 Equipment and accessories required


To operate a PLC with a PCS 090 to which parameters have already
been assigned, the following products are required (Systeme Lauer):
1. The PCS operating console itself (to which parameters have already
been assigned)
2. The PCS 708 connection cable to connect the PCS to the PLC using
the RS 422 interface
3. This appendix
4. Diskette PCS PRO with the SNP_DIR driver
5. Diskette GE-FANUC with handling blocks SNP_DIR and SNP_DI2

In addition, the following are required (GE-FANUC):


6. A GE-FANUC 90/30 or 90/20 module
7. Programming software Logicmaster 90, version 3.02 or higher
8. An RS 422 - RS 232 converter with a 9-pole connection cable between
the PLC and the PC

1.3 To load the SNP_DIR driver in the PCS


After you have selected the SNP_DIR software in the PCS PRO
programming software you must inform the driver of the location of the
data block for the PLC. The data block of register %R1792 to %R2047 (=
256 words) is assigned as the presetting. This means that AL = 1792 and
AM = 2047. By transferring 256 words the reaction time will be longer. If
you do not use all the data words, you are recommended to select a
lower end address. This will mean that fewer data are transferred and
the reaction time will be shorter. Example: If you only use data words
below word 100, enter AL = 1792 and AM 1891. You can also move the
entire data block, but in that case you must write the synchronisation
block in the PLC. The best method of doing this is in the variables
definition by assigning a new register to the variable names. For the 90/

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1 First Start-Up

20 PLC enter AL = 100 and AM = 256, which corresponds to a data field


from word 0 - 256.

Since the baud rate and interface are fixed, DIL 5 and 6 on the rear of
the PCS 090 have a different meaning than that printed on them. DIL 5
= ON switches on the status output of the PLC (see also section 2.4 of this
manual). DIL 6 = OFF allows communication via the RS 422 programming
interface with the PCS 708 cable. If DIL 6 = ON use the RS 422 - RS 232
converter for communication via the RS 232 interface.

1.4 To connect the PCS to PLC

1. Switch DIL switches 5, 6, 8 and 9 on the rear of the PCS to "OFF", DIL
10 to "ON". DIL 7 must be set to match the programming baud rate
("OFF" = 38.5 kbaud, "ON" = 115 kbaud).
2. Connect the operating voltage (19 - 33 V) on the PCS 090. The ERR
LED at least must now be lit.
3. Load the handling software SNP_DIR or SNP_DI2 into the PLC.
4. Connect the programming interface of the PLC to the PCS using
cable PCS 708.
5. Now the ERR LED on the PCS must be extinguished. Default text 0
appear on the display of the PCS. If this is not the case, see under
point 1.5.

1.5 Error elimination


The communication between the PLC and PCS is constantly monitored
by both parties. Errors are displayed in the PLC by setting the error
output %Q97. An appropriate error text is set in the display of the PCS in
the event of communication errors and the ERR LED flashes.
The following are the most common faults which occur during the first
start-up:

1. DIL switch No. 8 is set to ON. If this is set the PCS goes into a diagnosis
routine when it is switched on, which is only needed for testing
purposes. Remedy: Switch the DIL switch to OFF and restart the PCS
(by switching off the unit briefly or pressing the RESET key above the
DIL switches).
2. The error output %Q97 (%Q1 on the 90/20 PLC) has been set in the
PLC. This is the case if data word 3 is not written by the PCS within
2.5 seconds. Is DIL 6 (interface) on the PCS set correctly? Is the
restart input %I65 (%I1 on the 90/20) on the PLC set to "ON"? Have
your used the correct cable? Is the cable defect?

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1 First Start-Up

3. Although the communication is started the following message


appears after a short time:
>>COMMUNICATION ERROR<<

In this case the connection between the PLC and the PCS is positioned in
a location where there is too much interference, the cable is too long for
the baud rate, the earthing situation is inadequate, the PLC is not set to
RUN (PLC NOT RUNNING).

Instructions for connecting the


PCS to the PLC • Place the cable screen for the communication cable on the central
earthing points of the control cabinet.

• Ensure good earth connections to the PCS 090 housing on the one
handand to the PLC board on the other. Remember that a copper
earth strapoffers considerably better HF conductivity than normal
interconnecting wires as a result of its larger surface.

• Avoid the generation of high frequency interference as far as possible


since they are very hard to damp. Although there is potential
separation between the PLC and the PCS by means of optocoupler,
it has no effect on rapid transients since even optocouplers have a
coupling capacity (albeit a very low one).

• Provide clear reference points for the supply voltages. The power
pack is potential free in order to make this easier.

• If the supply voltage carries a high level of interference you are


recommended to use a separate power pack for the PCS (24 V, 10
VA). It should have its own interference filter. 0 V can then be
connected to the PCS using the protective conductor.

• The PCS and the communication cable should be at least 200 mm.

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1 First Start-Up

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2 PCL Handling Software

2.1 Description of the handling software


In the PCSPRO software you can choose between 2 couplings for the
PCS: SNP9030 and SNP_DIR. The SNP9030 driver is a coupling which
requires a software expander in the PLC. The communication data are
formulated as jobs and exchanged in data packages. A precise description
of this driver is given in manual PCS091.8. The SNP_DIR driver (described
int his manual) exchanges the data direct in synchronised form. This
means that there are the following differences between the two drivers:

SNP9030: required a software expander in the PLC with 20-40 ms


cycle time loads and a send and receive mailbox. Access
to the data in the PLC can be made at any time. The
data quantities exchanged with the PCS are low, the
reaction time of the coupling is constant at 0.5 seconds.
SNP_DIR: Only requires a synchronisation block in the PLC with
cycle time loads of approx. 4 ms. Access to the data in
the PLC can only be made in synchronised form (i.e.
after queries). The data quantities exchanged with the
PCS are large, the reaction time of the coupler is
therefore between 0.5 and 2 seconds (depending on
the size of the data block).

For the SNP_DIR driver access to the data block in the PLC is made in
synchronised form, i.e. the PCS accesses and then the PLC software
accesses. The synchronisation is made using words 2 and 3 in the data
block. The procedure is as follows:

The PCS makes access to the data block and copies it (in the length
specified by AL and AM) into the PCS. In the PCS the data are processed
and then the data block is copied back to the PLC. As its last action the
PCS writes a job number into the low byte of data word 3 and terminates
the access. Data word 2 is now different to data word 3 in the PLC. The
PLC software can now process the data block. As its last action the job
number in word 3 is inverted and pushed into the high byte. In addition
word 3 is copied into word 2. This terminates the PLC access and the
communication cycle starts from the beginning again.

In the enclosed handling software the PLC jobs are broken down into
sub-programs for the 90/30 PLC:

The "PCS_INI" sub-program is active in the first cycle and in the event of
a communication failure. Data words 2 - 11 and 23 are set to zero, words
12 - 14 are set to the initialisation values. The sub-program is run once in
the event of a communication failure.

The sub-program "SYNC_A" is always run and checks whether the PLC
may make access. If no error output Q97 is set and word 2 is different
from word 3 then the access marker "ZUGRIFF" is set to 1. If the error
output %Q97 is set and the restart input %I65 is set and word 2 is diffe-
rent from word 3 then ZUGRIFF is set to 1. In all other cases ZUGRIFF is
set to zero. If ZUGRIFF = 1 access may be made to the data block. This
sub-program must be in the software before the first data access.

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2 PCL Handling Software

The sub-program "TEST" is only run if "ZUGRIFF" is set to 1. The content


of this program represents an example for a data access. F1 sets a setpoint
value menu 1, F2 terminates this menu. F3 sets all mes-sage bits in word
15, F4 deletes the message bits again. Keys F1 to F8 are copied into the
green LED's. Naturally this is only an idea, you must define your actual
accesses to the data here. The important thing to remember is that the
data is only accessed is "ZUGRIFF" is set to 1 and "SYNC_A" is called up
beforehand and "SYNC_E" afterwards.

The sub-program "SYNC_E" is always run and provides access to the


PCS. To do this word 3 is processed as described above and copied into
word 2. Furthermore, a timer checks whether the PCS is accessing the
data. If no access is made by the PCS over a period of 2.5 seconds error
output %Q97 is set and "PCS_INI" run in the next cycle. This sub-pro-
gram must be located after the last data access.

Several data elements are used in the sub-programs. These are all noted
in the variable definition of _MAIN. They are as follows:

VARIABLE DECLARATION TABLE

REFERENCE NICKNAME REFERENCE DESCRIPTION

%I0065 EING Input switch


%Q0097 AUSG Error output
%M0001 ZUGRIFF 1 = access allowed to data
%M0002 TIMER Timer controller
%M0003 AUSFALL Failure marker
%R1789 T-WORT 3 timer words
%R1792 DW0 Interim memory
%R1793 DW1 Timer register
%R1794 DW2 Sync word
%R1795 DW3 Sync word PCS
%R1796 DW4 Keys
%R1797 DW5 Keys
%R1798 DW6 PCS status
%R1799 DW7 PCS status
%R1800 DW8 PCS status
%R1801 DW9 PCS status
%R1802 DW10 LED's
%R1803 DW11 LED's flash
%R1804 DW12 PCS command word
%R1805 DW13 PCS command word
%R1806 DW14 Texts, menus
%R1807 DW15 Message bits
%R1815 DW23 Keys PCS 095
%R1816 DW24 LED's PCS 095
%R1817 DW25 LED's flash PCS 095

If you do not want to use the proposed data elements, simply change
the addresses in the variable declaration table. Please note that if you
move the data block DW0 to DW25 must be moved in full and that your
must tell the PCS about this move in the driver variables AL and AM.

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2 PCL Handling Software

As mentioned above the reaction time of the coupling is slowed by the


large amount of data to be transferred. It is therefore recommended
that the data block is limited to what is strictly required. This is done by
reducing the driver variable AM (see also section 1.3). The PLC software
does not need to be changed but it must be ensured that no data access
is made greater than the variable AM.

If the communication fails, error output %Q97 is set. In this case it is only
possible to restart communication if input %I65 is set to "ON". Naturally
you can replace these inputs and outputs by markers and then control
the communication yourself in the PLC. The special actions required after
a communication failure must then be defined in the sub-program
PCS_INI.

The communication connection between the PCS and PLC is a pure


point to point connection and must not be networked.

90/20 PLC The PLC software for the 90/20 PLC has a equivalent structure and is
called SNP_DI2. There are differences in the following points:
• The data block is from %R100 = DW0 to %R256 = DW156. The
remaining data words DW157 to DW255 are not available in this
PLC, please note this when addressing your variables. For your
applications the register words %R1 - %R96 are available %I1, %R97
- %R99, %M1 - %M3 and %Q1 are assigned. DW3 (sync word) is at
address %R103.
• The average cycle time use is 6 ms.
• Of the 2048 program bytes available, approx. 600 are assigned.
Design your program accordingly.
• Since there are no sub-programs for the 90/20 PLC all program
parts must be included in _MAIN.

2.2 To load the handling Software


1. Connect the PLC to the PC using the RS 232 - RS 422 adapter.
2. Call the Logicmaster 90 software up on the PC (min. 560 kbyte free
memory required).
3. Switch the PLC to ONLINE.
4. Load the folder SNP_DIR or SNP_DI2.
5. Transfer the program to the PLC.
6. Switch the PLC to RUN.

You can now connect the PCS as described in section 1.4. The program
_MAIN can be used as a basis for your PLC program.

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2 PCL Handling Software

2.3 Communication errors


In the communication between the PCS and the PLC, the PCS assumes
the function of master. This means that it is the job of the PCS 090 to
establish and monitor the communication. There are three criteria to
monitor: is the communication running, is the communication processing
running in the PLC and is the PLC in the RUN mode.

Timeout Both in the PCS and in the PLC there is a time monitoring system for the
serial data exchange and for processing the sync word. The timeout
time in the PCS is 2.5 seconds. After this an error message is displayed in
the PCS and the ERROR LED is lit. In the background, however, the PCS
attempts to re-establish the communication. If it manages to do so the
error message will be deleted.

===== COMMUNICATION ERROR =====


TiMEOUT!

Too many repetitions The data exchange is made in data blocks and each block is checked for
length, content and block check. If an error is discovered the block is
requested again. The number of repetitions per 100 write/read cycles
may be called up in the internal variable @ZX. After three consecutive
repetitions the communication is aborted and the following error message
is displayed:

===== COMMUNICATION ERROR =====


TOO MANY REPETITIONS

PLC not running For communication it is essential that the jobs are processed in the PLC.
Therefore a communication error message is output is the PLC is not in
RUN mode.

===== COMMUNICATION ERROR =====


PLC NOT RUNNING

2.4 Status
To check the communication your can have the status of the PLC displayed
in the PCS. To do this you must switch DIL 5 to ON. A display is only made
if the communication is running perfectly.

STATUS PLC : PRIV LEVEL= 11


PLC= 2222, SWEEP=33, 44 X 100 µS, 55555555

Explanation of display contents:


11 = values from 1 to 4. The PRIV LEVEL (Privilege Level) is the access
authorisation of the master to the slave. The value must be 2 or greater.

2222 = RUN or STOP. Must be set to RUN, i.e. the PLC must be running.

33, 44 = values in hexadecimal form. SWEEP is the last cycle time of the

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2 PCL Handling Software

PLC time 100 µS. 33 is the high byte, 44 is the low byte. Example: 01.A3
corresponds to 419 times 100 µs = 41 ms. Since the maximum allowed
cycle time is 200 ms, the largest value is 07, D0.

55555555 = NO FAULT or FAULT. If the FAULT (error) table of the PLC


has an error entry "FAULT !" is displayed, if no error is
entered "NO FAULT !" is displayed. An entered error does
not impair the communica-tion.

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2 PCL Handling Software

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3 Communication

3.1 Communication cable


PCS 708: connection between PCS and the PLC via RS 422

DIL 6 on the PCS 090 must be set to "OFF" if communication is through


RS 422 (if you change first perform a reset).

Connection between PLC and


PCS 090 using the RS 232
interface The RS 422 - RS 232 converter HE693SNP232 must be used on the PLC
side. On the PCS 090 DIL 6 must be set to "ON" if your are communicating
using the RS 232 (if you change first perform a reset).

• Screening the communication cable


The screen should be connected on both sides to a metallised plug
casing. If non-metallised plug casings are used the screen may also
be connected to Pin 1; however, this is not recommended as
interference may result since the data lines should be covered in full
if at all possible by the screen. However, with the double-sided
earthing it must be noted that in certain circumstances (as a result
of earth potential shifts) an equipotential bonding cable of at least

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3 Communication

10 times potential bonding cable of at least 10 times the cross section of


the screen is necessary (reason: bonding currents should not pass through
the screen if at all possible), particularly if the PCS and PLC are not
connected to the same earth point. This is the case, for example if the
PCS and PLC are not located in the same control cabinet.

3.2 Configuration cable PCS722


Connection between PC and PCS090

3.3 Data Transfer PCS/PLC


The data transfer with the controller is made in packages. Each package
has a check sum and its content is checked by both the PLC operating
system and the PCS for possible errors. In addition each read/write cycle
is given a serial number in word 3. Any limit on the data exchange using
word 13 has no effect since the entire defined data block is always
exchanged. A clear improvement in the reaction speed can only be
produced by reducing the size of the data block used (-> section 1.3).

The PCS is the master for the communication process. It is responsible


for establishing the communication and sending jobs to the PLC. The
PCS and PLC communicate via the RS 422 interface with the following
settings: 19200 baud, 8 bit, ODD parity, 1 stop bit. In this manual only
the exchange of packages is described. The structure of the packages is
shown in the "Series 90 PLC, SNP_DIR Communications, Reference Ma-
nual" supplied by GE FANUC.

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3 Communication

The initialisation of the communication is as follows:


PCS PLC
----------------------------------------------------

Attach message ---> Attach respond


message
<---
Initial request --->
MS message (Set priv.
level)
<--- Complement
ACK MB message

PCS PLC
----------------------------------------------------

Attach message ---> Attach respond message


<---
Initial request --->
MS message (Set priv.
level)
<--- Complement ACK MB message

When the initialisation of the communication has been completed the


further communication is as follows: read cycle word 3 - AM, write cycle
word 4 - AM, write cycle word 3. These cycles are repeated continuously.
The packages specified as "data" below represent the actual content of
the communication. These data are written direct into the registration
field of the PLC (write cycle) and read from it (read cycle). The validity of
a job is checked by a job number in data word 3.

Structure of the read cycle

PCS PLC
----------------------------------------------------

Initial request --->


MS message (Give
read job)
<--- ACK
<--- Complement ACK MB
message with text buffer
ACK --->
<--- Response text buffer message
(data)
ACK --->

© Systeme Lauer GmbH & Co KG • Kelterstr.59 • 72669 Unterensingen • Tel. (07022) 96 60-0 • Fax (07022) 96 60-103 3-3
3 Communication

Structure of the write cycle

PCS PLC
----------------------------------------------------

Initial request --->


MS message (Give
write job)
<--- ACK
Request text buffer <---
with message (data)
<--- ACK
<--- Completion ACK MB message
ACK --->

3-4 © Systeme Lauer GmbH & Co KG • Kelterstr.59 • 72669 Unterensingen • Tel. (07022) 96 60-0 • Fax (07022) 96 60-103

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