Hardware Manual Version 13.0 Giddings Lewis Controls, Measur
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PiC900
Hardware Manual
Version 13.0
Giddings Lewis Controls, Measurement Sensing
NOTE
Progress ongoing commitment Giddings Lewis. continually strive offer most advanced products industry; therefore, information this document subject change without notice. illustrations specifications binding detail. Giddings Lewis shall liable technical editorial omissions occurring this document, consequential incidental damages resulting from this document. ATTEMPT Giddings Lewis product until such product completely understood. responsibility user make certain proper operation practices understood. Giddings Lewis products should used only qualified personnel express purpose which said products were designed. Should information covered this document required, contact Customer Service Department, Giddings Lewis, South Military Road, P.O. 1658, Fond Lac, 54936-1658. Giddings Lewis reached telephone (920) 921-7100.
Release 2002
1990-2002 Giddings Lewis, Controls, Measurement, Sensing, Company Thyssen Krupp Technologies
Belden® registered trademark Cooper Industries, Inc. registered trademark International Business Machines Corp. Microsoft® MS-DOS® registered trademarks Microsoft Corporation. trademark Contemporary Control Systems, Inc. ARCNET® registered trademark Datapoint Corporation. trademark AT&T Bell Labs. Temposonicsis trademark MTS® Systems Corporation. DeviceNetis trademark Open DeviceNetVendor Association, Inc. PiC900, PiC90, PiCPro, MMC, PiCServoPro, PiCTune, PiCProfile, PiCMicroTerm, Programming Pendant registered trademarks Giddings Lewis.
Table Contents: PiC900 Hardware Manual
CHAPTER PiC900 Hardware Setup General Precautions System Safety. Overview PiC900 system. System Rack. Dimensions Racks System rack power environment requirements General Requirements Control Cabinet Specifications Power Distribution Diagrams Grounding System Controlling Heat Within System Hardware Modules Types Modules Installing Module Rack Wiring System Application Making Wiring Worksheet Making Connections Preventing Electrical Noise Data Lines Starting Operation Troubleshooting Power-On Diagnostics Run-Time Diagnostics 1-10 1-10 1-13 1-13 1-13 1-13 1-15 1-16 1-17 1-19 1-20 1-22 1-22 1-22 1-24 1-27 1-27 1-28 1-30
Appendix Control Modules
A.1-PiC900 CSM/RSM Central Service Module/Remote Service Module Introduction. Connections. Theory Operation. Time-of-Day Clock LEDs Replacing Battery Specification Table A.2-PiC900 (Document 108-31043-00) -CPU (Document 108-31044-00) -PiC90 CSM/CPU (Document 108-31045-00) A1-1 A1-2 A1-2 A1-3 A1-3 A1-4 A1-6
TOC-1
-RSM Remote Service Module Driver Introduction. Connections LEDs Theory Operation. Specification Table -CPU Central Processing Unit Module Turbo Introduction. Connections Serial Ports ARCNET Expansion LEDs Theory Operation. EPROM PiC94X PiC900 Memory Organization. Procedure Installing EPROM into Socket -PiC9011/9012 CSM/CPU (Document 108-31046-00) -PiC904X- CSM/CPU Central Service Module/Central Processing Unit Introduction. Connections. Serial Ports Peer-to-Peer (ARCNET) Block Expansion (Optional) LEDs Status LEDs Communication LEDs CSM/CPU Time-of-Day Clock. Theory Operation. Application Flash. Replacing Battery CSM/CPU Specification Table A8-1 A8-2 A8-2 A8-3 A8-5 A8-5 A8-6 A8-7 A8-7 A8-8 A8-8 A8-10 A5-1 A5-2 A5-3 A5-5 A5-5 A6-1 A6-2 A6-2 A6-2 A6-5 A6-6 A6-6 A6-7 A6-9
Appendix Communication Modules
Driver Module Introduction. Connections. LEDs Specification Table -Serial Communications Module channel) Introduction. Connections. Theory operation. Specification Table B1-1 B1-2 B1-3 B1-4 B2-1 B2-2 B2-7 B2-8
TOC-2
-DeviceNetModule Introduction. Connections. DeviceNet Port Configuration (RS232) Port LEDs Theory operation. Specification Table -ETHERNET- TCP/IP Module Introduction. Connections. Ethernet Ports RS232 COMM Ports LEDs Theory operation. Specification Table Useful Internet Links -Profibus Module Introduction. Connections. Profibus Port Configuration (RS232) Port LEDs Theory operation. Specification Table B3-1 B3-2 B3-2 B3-3 B3-3 B3-4 B3-5 B4-1 B4-2 B4-5 B4-6 B4-6 B4-7 B4-8 B4-9 B5-1 B5-2 B5-2 B5-3 B5-3 B5-4 B5-5
Appendix Discrete Modules
-Output Source Module points) Introduction. Connections. Theory Operation. Protecting from Inductive Load External Zener Diode Point Module Replacing fuse. Specification Table -Input Module points) Introduction. Connections. Theory Operation. Specification Table C1-3 C1-4 C1-7 C1-7 C1-8 C1-9 C1-11 C2-1 C2-2 C2-6 C2-8
TOC-3
-Output 120/240V Module point) Introduction. Connections. Theory Operation. Protecting from Inductive Load Replacing Fuse Specification Table -Input 120V Module points) Introduction. Connections. Theory Operation. Specification Table -Output Sink Module point) Introduction. Connections. Theory Operation. Protecting from Inductive Load Replacing Fuse Specification Table -Output Relay Module points) Introduction. Connections. Theory Operation. Specification Table -Input/Output (24/8 pts) Introduction. Connections. Theory Operation. Specification Table -Input Module points) Introduction. Connections. Theory Operation. Specification Table -24V Input/Output Sink Module (16/8 points) Introduction. Connections. Theory Operation. Protecting from Inductive Load Replacing Fuse Specification Table C3-1 C3-2 C3-5 C3-5 C3-7 C3-9 C4-1 C4-2 C4-4 C4-6 C5-1 C5-2 C5-5 C5-6 C5-7 C5-9 C6-1 C6-2 C6-4 C6-5 C7-1 C7-2 C7-6 C7-7 C8-1 C8-2 C8-5 C8-5 C9-1 C9-2 C9-6 C9-9 C9-10 C9-12
TOC-4
C.10 -24V Input/Output Source Module (16/8 points) Introduction. Connections. Theory Operation. Replacing fuse. Specification Table C.11 -Input Switch Module switches) Introduction. Theory Operation. Specification Table C10-1 C10-2 C10-5 C10-8 C10-11 C11-1 C11-1 C11-2
Appendix Servo/Feedback Modules
-Input Encoder Module High-Speed channel) Introduction. Connections. Encoder Drivers Theory Operation. Specification table. -Input Resolver Module channel) Introduction. Connections. Resolvers. Theory Operation. Specification Table -Input Multi-Channel Resolver Module channel) Introduction. Connections. Resolvers. Theory Operation. Specification Table -Servo Module Encoder with Analog Input Introduction. Connections. Analog Output Connections. Analog Input Connections Encoder Connections Encoder Drivers Analog Output Theory Operation. Analog Input Theory Operation Encoder Theory Operation Specification Table D1-1 D1-2 D1-4 D1-7 D1-9 D2-1 D2-2 D2-4 D2-5 D2-6 D3-1 D3-3 D3-6 D3-6 D3-7 D4-1 D4-2 D4-4 D4-5 D4-9 D4-9 D4-13 D4-13 D4-14 D4-15
TOC-5
-Servo Module Encoder Introduction. Connections. Analog Output Connections. Encoder Connections Encoder Drivers Analog Output Theory Operation. Encoder Theory Operation Specification Table -Output Stepper Module channel) Introduction. Connections. Connecting SMCM Stepper Drives Theory Operation. Specification Table -Slider Driver Module Introduction. Connections. Theory Operation. Specification Table -SERCOS Module Introduction. Connections. Theory Operation. Specification Table Specification Table Fiber Optic Cable -Output Stepper Axis Module channel) Introduction. Connections. Connecting Stepper Drives. Theory Operation. Specification Table D5-1 D5-2 D5-4 D5-4 D5-5 D5-8 D5-9 D5-10 D6-1 D6-2 D6-5 D6-10 D6-11 D7-1 D7-2 D7-6 D7-7 D8-1 D8-2 D8-3 D8-4 D8-6 D9-1 D9-2 D9-5 D9-10 D9-11
Appendix Analog Modules
-Input Analog Module channel) Introduction. Connections. Theory Operation. Specification Table E1-1 E1-2 E1-7 E1-8
TOC-6
-Input Thermocouple Module channel) Introduction. Connections. Theory Operation. Thermocouple Precautions. Specification Table -Input Module channel) Introduction. Connections. Theory Operation. Precautions. Specification Table -Output ±10V Module channel) Introduction. Connections. Analog Output Receiving Devices. Theory Operation. Specification Table -Output 4-20mA Module channel) Introduction. Connections. Theory Operation. Specification Table -Analog Input\±10V Output Channel) Introduction. Connections. Analog Output Connections. Analog Input Connections Analog Output Theory Operation. Analog Input Theory Operation Specification Table E2-1 E2-2 E2-6 E2-6 E2-7 E3-1 E3-2 E3-4 E3-5 E3-5 E4-1 E4-2 E4-3 E4-3 E4-4 E5-1 E5-2 E5-4 E5-5 E6-1 E6-2 E6-4 E6-4 E6-7 E6-7 E6-8
Appendix Barrier Module
Barrier Module Barrier Module Empty Slot
Appendix Wiring Worksheets
TOC-7
-Wiring Worksheets Output Wiring Worksheet Output Wiring Worksheet Input Wiring Worksheet Input Wiring Worksheet Output 120/240V Wiring Worksheet Output 120/240V Wiring Worksheet Input 120V Wiring Worksheet Output ±10V Wiring Worksheet Output ±10V Wiring Worksheet Input Encoder Wiring Worksheet Input Encoder Wiring Worksheet Input Resolver Wiring Worksheet Input Resolver Wiring Worksheet Input Analog Wiring Worksheet Thermocouple TEMP Wiring Worksheet Output Sink diode protected) Wiring Worksheet Output Sink diode protected) Wiring Worksheet Input Wiring Worksheet Serial Communications (2,4 Wiring Worksheet Output 4-20mA Wiring Worksheet Output Stepper Wiring Worksheet Output Relay Wiring Worksheet Input Resolver Wiring Worksheet Input/Output (24/8 pts) Wiring Worksheet Input Wiring Worksheet Input/Output (16/8 sink Wiring Worksheet Input/Output (16/8 source Wiring Worksheet Servo Encoder Analog input Analog output Servo Encoder Analog output Wiring Worksheet Analog input ch)/Analog output Wiring Worksheet Slider/Driver Wiring Worksheet Block Output Source Wiring Worksheet Block Input Module Wiring Worksheet Block Input Analog Wiring Worksheet Block Output 4-20 Wiring Worksheet Block in/8 Wiring Worksheet Input Resolver Wiring Worksheet Output Stepper/Input Encoder/Input Wiring Worksheet Output Analog ±10V Wiring Worksheet H-10 H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26 H-27 H-28 H-29 H-30 H-31 H-32 H-33 H-34 H-35 H-36 H-37 H-38 H-39 H-40 H-41
TOC-8
Appendix Wiring
Wiring Making Using
Appendix Power-on Circuitry
-Power-on Circuitry Wiring Axis Power-On Circuitry
Appendix Math Coprocessor Installation
-Math Coprocessor Installation (Document 108-31047-00) Description Archived Document
Appendix Flash Memory Installation
-Flash Memory Installation Installation Flash Memory Board
Appendix Diagnostic Error Codes
-Diagnostic Error Codes Error Codes
Appendix Communication Connections
-Peer-to-Peer Communication Connections Establishing Communications Communication Topologies. Topology Star Topology Distributed Star Topology Distributed Star/Bus Topology Connecting PiCs feet Topology Expanding with Active Hubs Connectors -I/O Expansion Connections Expansion Racks. Local Expansion Remote Expansion. Fiber Optic Cables Peer-to-Peer Remote Expansion Specification Table Fiber Optic Cable Block Expansion. LEDs N1-2 N1-3 N1-3 N1-3 N1-4 N1-4 N1-5 N1-8 N1-8 N2-1 N2-2 N2-5 N2-6 N2-9 N2-11 N2-12 N2-13
TOC-9
Appendix Guidelines
Guidelines Background (Electromagnetic Compatibility) Compliance. Background Voltage Compliance Emission Immunity Classes Operating Environments Conformance with Directive Conformance with Voltage Directive Changes Products Changes Affecting User Using CE/EMC Non-CE/EMC Modules Index O-10
TOC-10
Part Number List
502-03510-XX 502-03512-XX 502-03518-XX 502-03548-XX 502-03549-XX 502-03550-XX 502-03551-XX 502-03552-XX 502-03605-XX 502-03638-XX 502-03640-XX 502-03641-XX 502-03642-XX 502-03643-XX 502-03644-XX 502-03651-XX 502-03657-XX 502-03658-XX 502-03673-XX 502-03674-XX 502-03676-XX 502-03677-XX 502-03679-XX 502-03680-XX 502-03681-XX 502-03722-XX 502-03732-XX 502-03782-XX 502-03786-XX 502-03794-00 502-03809-XX 502-03810-XX 502-03813-XX 502-03814-XX 502-03817-XX "PiC900 (Document 108-31043-00)" page A.2-1. "PiC900 CSM/RSM Central Service Module/Remote Service Module" page A.1-1. "Output ±10V Module channel)" page "Input Module points)" page "Output Source Module points)" page "Input 120V Module points)" page "Output 120/240V Module point)" page "Input Resolver Module channel)" page "Input Module points)" page "PiC900 (Document 108-31043-00)" page A.2-1. "Output Source Module points)" page "Output 120/240V Module point)" page "Input Analog Module channel)" page "Input Module points)" page "Output Relay Module points)" page "Input Switch Module switches)" page C.11 "I/O Driver Module" page "Input Thermocouple Module channel)" page "Barrier Module" page "Output Sink Module point)" page "Serial Communications Module channel)" page "Output Stepper Module channel)" page "Input Module channel)" page "PiC900 (Document 108-31043-00)" page A.2-1. "Output 4-20mA Module channel)" page "Input Multi-Channel Resolver Module channel)" page "PiC900 CSM/RSM Central Service Module/Remote Service Module" page A.1-1. "Input Encoder Module High-Speed channel)" page "PiC900 (Document 108-31043-00)" page A.2-1. "Input Thermocouple Module channel)" page "Input/Output (24/8 pts)" page "PiC900 CSM/RSM Central Service Module/Remote Service Module" page A.1-1. "PiC900 (Document 108-31043-00)" page A.2-1. "PiC900 CSM/RSM Central Service Module/Remote Service Module" page A.1-1.
TOC-11
502-03839-XX 502-03840-XX 502-03842-XX 502-03843-XX 502-03846-XX 502-03853-XX 502-03876-XX 502-03907-XX 502-03941-XX 502-03944-XX 502-03947-XX 502-03956-XX 502-03963-XX 502-03973-XX 502-03994-XX 502-04011-XX 502-04050-XX 502-04071-XX 502-04073-XX 502-04080-XX 502-04081-XX 502-04077-XX 502-04104-XX 502-04110-XX 502-04111-XX 502-04112-00 502-04125-XX 502-04126-XX 502-04157-XX 502-04317-XX 503-25906-XX 503-25907-XX 503-25908-XX 503-25909-XX 503-25910-XX 503-25986-XX 503-25987-XX 503-25988-XX
"Servo Module Encoder with Analog Input" page "Servo Module Encoder" page "24V Input/Output Source Module (16/8 points)" page C.10 "24V Input/Output Sink Module (16/8 points)" page "PiC90 CSM/CPU (Document 108-31045-00)" page "RSM Remote Service Module Driver" page "Analog Input\±10V Output Channel)" page "CPU (Document 108-31044-00)" page "SERCOS Module" page D.8-1. "Input Encoder Module High-Speed channel)" page "Slider Driver Module" page "CPU (Document 108-31044-00)" page "PiC900 CSM/RSM Central Service Module/Remote Service Module" page A.1-1. "CPU Central Processing Unit Module Turbo" page "CPU Central Processing Unit Module Turbo" page "Input Analog Module channel)" page "PiC9011/9012 CSM/CPU (Document 108-31046-00)" page
"Output Stepper Axis Module channel)" page "PiC904X- CSM/CPU Central Service Module/Central Processing Unit" page "CPU Central Processing Unit Module Turbo" page "PiC904X- CSM/CPU Central Service Module/Central Processing Unit" page "DeviceNetModule" page "ETHERNET- TCP/IP Module" page "Block In/8 Module" page C.14 "Block Input Module points)" page C.13 "Block Output Source Module points)" page C.12 "Block Input Analog Module channel)" page "Block Output 4-20mA Module channel)" page E.8-1. "Block Input Resolver Module channel)" page D.10 "Block Output ±10V Module channel)" page "Block Output Stepper/Input Encoder/Input Module (2/2/2 Ch)" page D.11
TOC-12
CHAPTER
PiC900 Hardware Setup
Generally throughout this manual, PiC900 refers PiC900 family programmable industrial computers includes PiC90.
General Precautions
READ UNDERSTAND THIS SECTION ENTIRETY BEFORE UNDERTAKING INSTALLATION ADJUSTMENT CONTROL EQUIPMENT
advice contained this section will help users operate maintain equipment safe manner times.
PLEASE REMEMBER THAT SAFETY EVERYONE'S RESPONSIBILITY
Chapter PiC900 Hardware Setup
System Safety
basic rules safety forth this section intended guide safe operation equipment. This general safety information, along with explicit service, maintenance operational materials, make complete instruction set. personnel operate, service involved with this equipment should become totally familiar with this information prior operating.
User Responsibility
responsibility buyer ensure that procedures forth here followed and, should major deviation change from original specifications required, appropriate procedures should established continued safe operation system. strongly recommended that contact your ensure that system safely converted continue operate safe manner.
Safety Instructions
operate your equipment with safety devices bypassed doors removed. Only qualified personnel should operate equipment. Never perform service maintenance while automatic control sequences operation. avoid shock serious injury, only qualified personnel should perform maintenance system. ATTENTION DANGER LIFE touch main power supply fuses components internal power modules while main power supply switch Note that when main power switch OFF, incoming supply cable live. GROUNDING (Protective Earth) equipment must grounded (connected protective earth connection) according recommendations latest local regulations electrical safety. grounding (protective earth) conductor must interrupted inside outside equipment enclosures. wire used equipment grounding (connection protective earth) should green with yellow stripe. there doubt safety equipment, should main power switch contact your advice.
Chapter PiC900 Hardware Setup
Safety Signs
purpose system safety signs draw attention objects situations which could affect personal plant safety. should noted that safety signs does replace need appropriate accident prevention measures. Always read follow instructions based upon level hazard potential danger.
Warning Labels
Danger Electric Shock Risk
Hazard warning. When this safety sign system, gives warning hazard possibility hazard existing. type warning given pictorial representation sign plus text used. safety color black yellow background with black symbol. ignore such caution could lead severe injury death arising from unsafe practice. voltage levels included text they must indicate maximum level hazard normal fault condition. Danger, Warning, Caution warning. Symbol plus DANGER, WARNING CAUTION: These notices provide information intended prevent potential personal injury equipment damage. Surface warning
Surface
Safety First
Giddings Lewis equipment designed manufactured with consideration care generally accepted safety standards. However, proper safe performance equipment depends upon sound prudent operating, maintenance servicing procedures trained personnel under adequate supervision. your protection, protection others, learn always follow these safety rules. Observe warnings machines accordingly. Form safe work-
Chapter PiC900 Hardware Setup
habits reading rules abiding them. Keep these safety rules handy review them from time time refresh your understanding them.
Safety Inspection Before Starting Operations
Ensure that guards safety devices installed operative doors which carry warning labels closed locked. Ensure that personnel clear those areas indicated potentially hazardous. Remove (from operating zone) materials, tools other objects that could cause injury personnel damage system. Make sure that control system operational condition. Make certain that indicating lights, horns, pressure gauges other safety devices indicators working order.
After Shutdown
Make certain controlled equipment plant safe associated electrical, pneumatic hydraulic power turned off. permissible control equipment contained enclosures remain energized provided this does conflict with safety instructions found this section.
Chapter PiC900 Hardware Setup
Operating Safely operate control system until read understand operating
instructions become thoroughly familiar with system controls. Never operate control system while safety device guard removed disconnected Where access control system permitted manual operation, only those doors which provide that access should unlocked. They should locked immediately after particular operation completed. Never remove warnings that displayed equipment. Torn worn labels should replaced. start control system until personnel area have been warned. Never stand anything that might cause fall onto control equipment peripheral equipment. Horseplay around control system associated equipment dangerous should prohibited. Know emergency stop procedure system. maximum protection when carrying major servicing requiring system powered down, power source should locked using lock which only have key. This prevents anyone from accidentally turning power while servicing equipment. Never operate equipment outside specification limits. Keep alert observe indicator lights, system messages warnings that displayed system. operate faulty damaged equipment. Make certain proper service maintenance procedures have been performed.
Chapter PiC900 Hardware Setup
Electrical Service Maintenance Safety
ELECTRICAL ELECTRONIC MAINTENANCE SERVICE SHOULD PERFORMED TRAINED AUTHORIZED PERSONNEL ONLY. should assumed times that POWER conditions treated live. This practice assures cautious approach which prevent accident injury. remove power: LOCK MAIN SWITCH OPEN POSITION. LOCK WHICH ONLY HAVE KEY. Make sure circuit safe using proper test equipment. Check test equipment regularly Capacitors take time discharge. Care should taken manual discharging capacitors There circumstances where troubleshooting live equipment required. Under such conditions, special precautions must taken: Make sure your tools body clear areas equipment which live. Extra safety measures should taken damp areas. alert avoid outside distractions. Make certain another qualified person attendance. Before applying power equipment, make certain that personnel clear associated equipment. Control panel doors should unlocked only when checking electrical equipment wiring. completion, close lock panel doors. covers junction panels should fastened closed before leaving job. Never operate controls while others performing maintenance system. bypass safety device. Always proper tool job. Replace main supply fuses only when electrical power (locked out).
Chapter PiC900 Hardware Setup
Cleaning Safely Manual cleaning Procedure
toxic flammable solvents clean control system hardware. Turn electrical power (lock out) before cleaning control system assemblies. Keep electrical panel covers closed power when cleaning enclosure. Always clean spills around equipment immediately after they occur. Never attempt clean control system while operating. Never water clean control equipment unless certain that equipment been certified sealed against water ingress. Water very good conductor electricity single largest cause death electrocution.
Chapter PiC900 Hardware Setup
Overview PiC900 system
PiC(Programmable industrial Computer) system combination hardware software that allows control application your specifications. Central Processing Unit (CPU) integrates hardware software elements. Hardware consists system rack, hardware modules, connections application. hardware modular. This makes PiC900 hardware easy configure. PiC900 designed interact with computer workstation and/or operator interface device. However, application programmed execute without either device.
Figure PiC900 system hardware
AA101-0890
NOTE: modules combined into physical module PiC90 system. This combination module referred CSM/CPU module this manual. Software covered Software manual. consists software module (application program) created using PiCPro. designed control specific application. PiCServoPro development tools installed your computer workstation. tools include PiCPro, ServoSetup, SERCOS setup.
Chapter PiC900 Hardware Setup
Figure Diagram PiC900 system operation
Computer Workstation using PiCPro PiCServoPro Application programs (optional)
INPUT OUTPUT ENCODER OUTPUT RESOLVER
PiC900
Operator Interface Devices (optional)
Motor Drive
(POSITION LOOP)
Machine Inputs/Outputs
Machine Servos/ Feedback Devices
AA102-1890
combination hardware software application. Hardware input modules accept data from application. Data processed specified software application program. Commands generated program instructions sent application hardware output modules. Data sent workstation allows operator monitor modify application using PiCPro commands.
Chapter PiC900 Hardware Setup
System Rack
system rack four functions: provides physical support bottom each hardware module.
passes power from CSM/CPU)to each other modules. contains data bus, address control lines. These lines allow data pass between CSM/CPU) module each other modules. 64-pin female connector each slot position which allows communication between modules. Dimensions Racks
PiC900 system racks differ only length number hardware modules they contain. dimensional diagram each rack shown following pages.
Number actual slots Number modules PiC900 Depth (with modules) Part Number
Length
Height
CSM, CPU, CSM, CPU, CSM, CPU, CSM/CPU, CSM/CPU,
21.6" 16.8" 12.0" 8.8" 5.6"
14.0" 14.0" 14.0" 14.0" 14.0"
9.0" 9.0" 9.0" 9.0" 9.0"
503-18011-03 503-18010-03 503-18009-03 503-19184-02 503-19185-02
PiC90
*The PiC90 retaining labels CSM/CPU module slot 1/2, leaving slots available modules. Figure 1-3, racks with slots shown with modules inserted. racks same height have same profile. other rack sizes shown empty (Figures 1-5).
1-10
Chapter PiC900 Hardware Setup
Figure System racks with modules installed
PiC90 Slots available hardware modules
.365"/9.3 2.8"
PiC90 Slots available .365"/9.3 hardware modules
CSM/CPU
CSM/CPU
Servo Servo
13.375"/340mm
14.0"/355mm
2.3" .265"/6.7mm
58.4
13.375"/340mm
14.0"/355mm
6"/152mm .265"/6.7mm
1.4"/35.6
5.6"/142mm
1.4"/35.6
8.8"/224mm
.365"/9.3
PiC900 Slots available hardware modules
13.375"/340mm
14.0" 355mm
Side View racks
9.2" 234mm
.265"/6.7mm
9.0" 229mm
1.4"/35.6
12.0" 305mm
Chapter PiC900 Hardware Setup
1-11
Figure 10-slot system rack
.365"/9.3
13.375"/340mm
14.0" 355mm
7.0" 178mm
.265"/6.7mm
1.4"/35.6
14.0" 356mm 16.8" 427mm
Figure 13-slot system rack
.365"/9.3
13.375"/340mm
14.0" 355mm
9.4" 239mm
.265"/6.7mm
18.8" 478mm 21.6" 549mm
1.4"/35.6
1-12
Chapter PiC900 Hardware Setup
System rack power environment requirements
General Requirements
required install system rack control cabinet. However cabinet protects system from dust mechanical damage recommended. methods power distribution shown. Figure works most situations. installations where electrical noise severe, Figure illustrates setup with filtered power. both cases, Install system rack away from sources strong electromagnetic noise. Such noise interfere with PiC900 operation. Protect PiC900 system away from following:
conductive fluids particles corrosive atmosphere explosive atmosphere diagrams recommendations modified necessary wiring conforms current standards government regulations. NOTE: modules presently rated operation between 55°C. PiC900/90 suitable operation pollution degree environment (i.e., normally, only non-conductive pollution occurs).
Control Cabinet Specifications
control cabinet PiC900 should have NEMA-12 rating better. cabinet
with this rating protects contents from dust mechanical damage. must large enough provide adequate circulation system rack, drives, other components. must have least free space within cabinet sides system rack. must have rigid vertical surface mount rack door should open fully easy access.
IMPORTANT Post warnings according National, State, local codes voltage present control cabinet.
Power Distribution Diagrams
PiC900 system requires power source system rack modules more and/or sources connections devices. Figures show ways provide necessary power setup.
Chapter PiC900 Hardware Setup
1-13
Figure Example 115V basic power distribution PiC900 system
PiC900 module CUSTOMER'S POWER SUPPLY
LINE LINE GRND
115V
Line1 (HOT) Line2 (COMMON) ground (protective earthing connection) PLANT GROUND
MAIN DISCONNECT
(Grounds from other devices)
outlet
SINGLE-POINT GROUND (SPG) COMPUTER WORKSTATION other DEVICE CHASSIS GROUND from another PiC900 GROUND CONTROL CABINET
power source connected PiC900 system through 3-pin female connector. plugs into power connector CSM/CPU). ground from power source "GRND" (protective earthing ground) from CSM/CPU) module must connected Single-Point Ground (SPG). Devices connected hardware modules must have their power sources input data output control signals. Both versions power distribution setup provide properly grounded sources that used such devices. other wiring setups, provided that each correct voltage current levels module device. connected same Single-Point Ground that system rack uses.
recommended that same main disconnect switch used PiC900 system devices application. NOTE: This main (primary) disconnect switch must have minimum contact separation poles meet requirements Voltage directive (73/23/EEC). IMPORTANT matter system installed, before replace module connect application, make sure that power system rack devices modules wired
1-14 Chapter PiC900 Hardware Setup
basic power distribution modified power source subject severe voltage spikes surges. many installations, control transformer rated minimum noise filter such Islatrol model I-115/U have been installed series with power source. Even though this model worked successfully past, approved. meet requirement Voltage Directive (73/23/EEC), approved filter must used. Control Concepts "Elite" series Islatrol filters that have this approval. Filtered power distribution recommended most applications. will prolong life control. should always used when using communication and/or analog hardware.
Figure Example 115V filtered power distribution PiC900 system
PiC900 module CUSTOMER'S POWER SUPPLY
LINE LINE GRND
115V
Line1 (HOT) Line2 (COMMON) Ground PLANT GROUND
MAIN DISCONNECT
TRANSFORMER
ISLATROL FILTER
(Grounds from other devices)
outlet
SINGLE-POINT GROUND (SPG) maximum GROUND from another PiC900 CONTROL CABINET CHASSIS GROUND WORKSTATION other DEVICE
AA105-1093
Grounding System
ground PiC900 system power source must connected directly Single Point Ground (SPG) block. block should made brass copper, bolted brazed control cabinet. block bolted rather than brazed, scrape away paint grease point contact. star washers between block cabinet ensure good electrical contact. Metal enclosures power supplies, drives, etc., should also have good electrical contact with SPG.
Chapter PiC900 Hardware Setup
1-15
CAUTION Single Point Ground should only common point ground lines. not, ground loops cause current flow between components system which interfere with proper operation PiC900.
Devices connected directly Single Point Ground include:
Plant safety ground. Ground (GRND protective earthing connection) from CSM: green/yellow wire. "Common" lines from power supplies that provide external power modules devices which they connected. Chassis grounds from devices themselves, such device drivers, machinery, operator interface devices. common line from noise filter, any. ground power source computer workstation, any, from which monitor system operation. outlet control cabinet recommended. Figure 1-7. Single point grounds from other control cabinets, any, PiC900 system. Shielded wires. Shielded wiring recommended with analog output, encoder interface, resolver interface modules.
Controlling Heat Within System
hardware module cases system rack designed promote circulation dissipate heat. rack must mounted vertically take advantage this design. Normally fans conditioners needed. However, environment outside control cabinet humid, need fan, heat exchanger, dehumidifier conditioner provide correct operating environment. Table 1-1. Operating Limits System Rack Temperature Relative humidity 131° 95%, non-condensing
Make sure that components installed cabinet with rack raise temperature above system limits that spots exceed specifications. instance, when heat-generating components such transformers, drives motor controls installed, separate them from system following:
1-16 Chapter PiC900 Hardware Setup
Place them near control cabinet their heat output rises away from PiC900 system. them another control cabinet above side cabinet with system rack. This protects PiC900 system from both heat electrical noise.
PiC900 system itself source heat, though most installations heat dissipates without harmful effects. System heat generated from power dissipated power supply logic side components each hardware module installed system field side input/output components each module need calculate total heat generated particular setup, refer Appendixes specifications each hardware module have installed.
CAUTION PiC900 system operated outside recommended limits, rack modules installed damaged. This will void warranty.
Hardware Modules
modules except CSM/CPU have identical dimensions they physically placed slot system rack. CSM/CPU 2.4" wide instead 1.6", length depth, rack connector back, same other modules.
IMPORTANT CSM/CPU must placed first slot left system rack. PiC900, module must second slot. modules assigned application program other slot.
face each hardware module segments. upper segment identifies type module gives status information. Every module DIAG which discussed this section. LEDs that give status specific modules explained Appendixes.
Chapter PiC900 Hardware Setup 1-17
lower segment contains screw terminal connector that allows wire inputs outputs PiC900 specific parts application. door swings shut protect these connections. bosses vents side allow free circulation within system (Figure 1-8).
Figure Front Right Side Module
LATCH
OUTPUT DIAG
VENTS
DOOR MALE CONNECTOR
9.5" 241mm
12.0" 305mm
VENTS FOOT 1.6" 41mm 8.4" 213mm
AA112-0890
Handling Module
module's case protects internal circuitry against mechanical damage shipping handling. However, like electronics device, circuitry destroyed
temperatures over (131° moisture condensing inside module static discharge exposure magnetic field strong enough induce current circuitry freezing temperatures, vibration, other hazards
1-18
Chapter PiC900 Hardware Setup
Normally there need open module case. Occasionally must replace battery fuse. Modules with replaceable components have diagram detailed anti-static precautions appendixes. IMPORTANT good practice keep module system rack antistatic times.
Types Modules
Each module name printed front face, separated colorcoded bands from rest upper segment. colors identify which four main categories module belongs silver CSM, CPU, CSM/CPU, driver, relay output modules blue green servo/analog Power comes through input plug. then converted power. There internal battery back-up. diagrams specifications appendixes. other modules powered from CSM/CPU) which sends specific voltages through system rack. PiC900, module contains Central Processing Unit several kinds memory. uses power from control application, integrating hardware software components PiC900 system. diagrams specifications Appendixes. module always second slot, next CSM. PiC90, these modules combined into CSM/CPU. Several models PiC9X have capability communicate between PiC900s and/or perform expansion. With PiC90, there optional peer-to-peer communications port CSM/CPU. Driver Module connecting expansion racks master rack covered Appendix Several types modules available. Refer Table Contents complete listing modules available. input module accepts signals that convey status information. output module sends commands application. module either screw terminal connections. Each screw terminal assigned specific function. This illustrated wiring diagram each module write-up appendixes. Some connections used external power supply, others data signals. Modules that differential signals have paired terminals data other terminals assigned shield commons.
Chapter PiC900 Hardware Setup 1-19
Installing Module Rack
CAUTION ALWAYS turn power main disconnect switch before installing, removing wiring module. install module system rack (Figure 1-9), follow these steps: Loosen thumbscrews metal retaining rack. foot module J-Clip near bottom rack rotate module until latch snaps into slot near system rack (2). connection between male 64-pin connector module female system rack complete. Tighten thumbscrews retaining hold modules securely place (4).
1-20
Chapter PiC900 Hardware Setup
Figure Steps procedure
RETAINING with thumbscrew
MODULE
MODULE
SYSTEM RACK
SYSTEM RACK
AA113-0890
IMPORTANT Always loosen thumbscrews retaining before attempting install remove modules from system rack. Tighten thumbscrews firmly after modules installed.
Chapter PiC900 Hardware Setup
1-21
Wiring System Application
screw terminal connectors each module allow connect PiC900 system with application. need kinds information about terminal assignments order wire module correctly: screw assignment diagram that module, found appendixes
inputs outputs assigned this specific application supplied software application program
Each signal from module takes form voltage which powered external sources (that from system rack). Figures illustrated power distribution.
Making Wiring Worksheet
make wiring worksheets each application program. Appendix wiring worksheet each module. Make copy appropriate worksheet each slot system rack. Copy input output connection wire numbers signal names that came with software program onto worksheets. Check each carefully. Note: power supply signals daisy-chained. label supplied inside module door which enter wire name each screw terminal. Copy wire name onto worksheet future reference.
Making Connections
acceptable range wire sizes mm2) mm2) gauge. copper wire. shield wire insulated. leave bare wire exposed. Protect bare wiring with following:
spaghetti tubing tape shrink tubing NOTE: wires/cables connected must mechanically secured against undue stress must suitably rated approved voltage conditions use. Install modules system rack before start wiring. Make sure wires correct length. When wiring complete connectors should stressed. find that wiring makes easier; instructions making given Appendix Strip 0.2" (5.1 insulation from wire.
1-22
Chapter PiC900 Hardware Setup
Start wiring bottom left screw terminal. Work left (inner) column. Then continue with lowest terminal column right, work (See Figure 1-10.)
Figure Wire Screw Terminal
Screw terminal connector (front)
Retention Screw*
Screw terminal connections (left side)
Retention Screw*
overtighten retention screws screw terminal connectors.
AA114-1093
Chapter PiC900 Hardware Setup
1-23
IMPORTANT Make sure screws tight when adding wires when probing unwired terminals. screw head fully tightened, there electrical connection between screw head circuitry module.
Preventing Electrical Noise Data Lines
PiC900 system relies electrical signals report what going application send commands addition, signals constantly being exchanged within system. PiC900 designed industrial environments, there limits much noise tolerate. Some suggestions given below reduce electrical noise. Keep electrically noisy devices away from PiC900.
Reduce noise generated application itself. Protect data signals from noise. differential devices analog encoder signals.
CAUTION Errors data transmission PiC900 system cause malfunctions application. device wire that generates uses electricity create electrical noise nearby circuits devices. 'Nearby' relative term: welder create noise problems many feet directions including room above. When device's currents affect another device, they said coupled. Coupling between pair wires running parallel each other directly proportional length parallel portion inversely proportional distance between them.
Keep Noisy Devices Away from PiC900.
Make sure that welding equipment, heavy duty motors, other devices that large amounts current their power lines least feet away from PiC900 devices connected
1-24
Chapter PiC900 Hardware Setup
Shield cables that carry heavy current near system, using continuous foil wrap conduit grounded both ends. Such cables include power leads highfrequency welders pulse-width-modulation motor drives.
Reduce Noise Generated Application Itself.
Equip inductive devices that directly connected PiC900 modules with suppression circuits. These devices include contactors, solenoids motors. Wires system which carry high current should routed away from data lines that sensitive noise. communications, analog cables must bundled together inside outside control cabinet. Figure 1-11.
Protect Data Wires from Noise
Install system rack close application can. Short communications lines less affected noise than long ones. Make connections Single-Point Ground short possible, gauge larger wire these connections. Route data lines more away from power lines them through separate conduit. Communications lines, example those that RS232, RS422 biphase transformer mode signals, should also shielded. Figure 1-11 communications data lines encoder/resolver/analog data lines each separate conduit, grounded SPG.
Figure Power signal cables from system
COMMUNICATIONS
PiC900 SYSTEM MODULES
ENCODER, ANALOG INPUT/OUTPUT INPUT/OUTPUT
INPUT POWER SINGLE-POINT GROUND
POWER SUPPLY
AA107-0890
Chapter PiC900 Hardware Setup
1-25
Differential Devices Analog Encoder Signals
differential device receives sends signal over wires (typically shielded twisted pair). input/output voltage second terminal inverse first. Information received/sent difference between voltages. single-ended device effectively receives sends data over only line. Information received/sent difference between signal voltage device's ground potential.
Figure Differential Single-Ended Digital Pulse Train
SIGNAL INVERTED SIGNAL
SIGNAL INPUT TIED
DIFFERENTIAL
SINGLE-ENDED
advantages using differential signals are: differential signal less susceptible electromagnetic noise. Static other interference affects both twisted-pair wires equally, difference between normal inverted voltage remains unchanged. differential signal transmitted over much longer distance much noisier environment than single-ended one. single-ended device's signal affected noise while ground which compared not. receiver cannot tell difference between pulse from sending device that carries information pulse created noise line. PiC900 hardware circuitry detect signal loss from encoder signal differential, single-ended. application program shut down application such error detected.
IMPORTANT differential drivers differential inputs possible. singleended devices must used, keep distance between device PiC900 less than feet.
1-26
Chapter PiC900 Hardware Setup
Starting Operation
Good procedure suggests that system should tested each time application powered Each module PiC900 rack tested automatically every time power applied. DIAG each module should indicating that module passed diagnostic tests.
Installing Testing Hardware Modules
Insert CSM/CPU) into first slot left system rack. With PiC900, insert module into second slot next CSM. Turn main disconnect switch plug connector into power connector. Turn input power power switch (see power distribution diagrams). DIAG turns then turns when module passes diagnostic tests. With PiC900, DIAG module repeats these steps. Turn power switch main disconnect switch. Slide modules into appropriate slots designated software program.
Connecting PiC900 System Application
Turn main disconnect switch control cabinet. some devices powered from control cabinet, turn them also. Connect screw terminal connectors according your diagrams. Turn power system power switch. light goes stays DIAG light each module goes then goes turn. Turn clockwise. SCAN light goes application starts work under control system. application program system memory, Software manual describes number procedures that used there.
Troubleshooting
Table summarizes proceed when performing certain maintenance and/ setup functions.
Chapter PiC900 Hardware Setup
1-27
Table 1-2. Summary order Turn entire application. Turn main disconnect input line (which should also turn external power supplies application), power switch; unplug power. Turn main disconnect input line power switch; unplug power. Turn main disconnect input line. Turn main disconnect input line.
Wire modules application.
Replace module rack. Change fuse output module. Change battery.
Connect/disconnect PiC900 with Turn power switch. computer workstation through PiCPro port. Connect/disconnect PiC900 with operator interface through User port. Turn power switch.
Download application program into Make sure power (check module memory. LED). Stop scan. From workstation PiCPro commands. From PiC900 turn RUN/STOP switch.
This section covers types diagnostics; power-on run-time.
Power-On Diagnostics
When system powered tests itself reports results tests form signals. Power light does goes during operation system, check that power still connected CSM/CPU). turn main disconnect switch replace CSM/CPU) Scan SCAN does Check that light Check that DIAG lights modules OFF. Check that switch position.
1-28
Chapter PiC900 Hardware Setup
application program RAM, turn key, download program again from workstation, turn key. program EPROM, make sure correctly installed. Appendix PiC900 PiC90.
Diagnostic LEDs Each module marked DIAG which lights briefly while diagnostic tests running then goes off. DIAG module remains module failed tests. Follow these steps: Turn power system application. wiring connected, remove screw terminal connector from module, leave wiring attached. Pull defective module from rack. Insert replacement module same type rack. Replace screw terminal connector module. Turn power check diagnostics again.
NOTE Diagnostics only when system powered possible that module might fail during operation. DIAG light remains off. suspect that module might defective, cycle power diagnostics again. diagnostic LEDs remain more modules, there something wrong with module CSM/CPU). Follow these steps tracing problem: Turn main disconnect switch control cabinet other power application. Remove modules except CSM/CPU). Turn power diagnostics again. With PiC900, both LEDs stay lit, turn power, replace either module turn power. LEDs remain lit, original module back replace other module. With PiC90, replace CSM/CPU module. problem CSM/CPU) module, turn power, replace modules, turn power diagnostics. Repeat until find defective module.
Chapter PiC900 Hardware Setup
1-29
problem traced module, check wiring devices system connected There short other problem outside system rack.
Run-Time Diagnostics
While PiC900 running, other tests performed regular basis with their results also reported through LEDs. BATT CSM/CPU starts flashing, battery must replaced. Appendix PiC900 PiC90. output modules goes fuse must replaced. section specific module Appendixes details. PiC900 running, DIAG CSM/CPU will flash three digit code signal there error. example, there long pause, code 123. errors described Appendix
1-30
Chapter PiC900 Hardware Setup
Appendix Control Modules
A.1- PiC900 CSM/RSM Central Service Module/Remote Service Module
Introduction
Central Service Module (CSM) Remote Service Module (RSM) convert incoming power regulated power. Through bus, supplies this power modules master rack supplies this power modules expansion rack. following additional features: Scan control which includes switch run/stop scan when power lithium battery back such items non-volatile module time-of-day clock module when power turned off. internal clock provide time date when needed software.
must always located first slot left master rack expansion rack respectively.
Figure A1-1. CSM/RSM Remote Service Module Central Service Module
(for master rack) (for expansion rack)
Name modu
DIAG SCAN BATT
Name module
DIAG SCAN
LEDs
LEDs
Stop GIDDINGS LEWIS
Programmable industrial Controlle
slot
Stop
(Key slot used)
Door
Door
Power switch
Power switch
LINE1 LINE2 GRND
LINE1
Power connec
LINE2 GRND
Power connector
AA21-489
AA1092-4892
A.1-1
PiC900 CSM/RSM Central Service Module/Remote Service Module
Connections
modules receive power through 3-pin power connector. Figure A1-2 illustrates connections listed below.
Module Power Source 110VAC Power Source 220VAC Power Source 24VDC
LINE
Line1 Line2 Single Point Ground
+24V -24V Single Point Ground
LINE Common GRND Single Point Ground
Figure A1-2. Power System
CSM/RSM Module
LINE LINE GRND
Power Source
110V 220V Line +24V COMMON Line -24V GROUND GROUND GROUND
(protective earthing connection)
Theory Operation
(RSM) module converts incoming input power into power voltages supplies them logic side modules rack. External power supplies used field side modules. Such supplies routed through (RSM), they should have same power cut-off switch PiC900. power distribution diagrams Chapter CAUTION on/off rocker switch face (RSM) does control power supplies. Always shut power main disconnect switch before replace module system rack. With CSM, supplied protect system from unauthorized start-ups. PiC900 hardware, power diagnostic tests, even load software application program without system key. However, application program will scanned until turn Run/Stop position.
A.1-2
PiC900 CSM/RSM Central Service Module/Remote Service Module
Time-of-Day Clock
internal clock maintains current date time. power system, battery maintains clock. application program PiCPro access this clock. Details given Software Manual.
LEDs
DIAG, diagnostic
DIAG should turn briefly whenever power turned system. processor module automatically runs diagnostic tests modules power This goes during testing, then turns when module passes tests.
Status LEDs
four LEDs indicate status. During normal operation DIAG BATT LEDs should off, SCAN LEDs should three LEDs indicate status. During normal operation DIAG should off, SCAN LEDs should
PWR, power
light should time that power system. indicates that supply within tolerance. specification sheet section.
SCAN, scan
SCAN light indicates that processor executing application program. scan loss occurs light will there orderly shutdown procedure.
BATT, battery
BATT light should turn briefly while battery checked power-on. After battery passes test, goes off. BATT starts flashing either start-up during system operation, lithium battery must replaced. Each module that uses battery back data circuitry that maintain data approximately hours system rack. Power must least five minutes ensure that modules that require backup power will retain their data while system rack.
A.1-3
PiC900 CSM/RSM Central Service Module/Remote Service Module
Replacing Battery
Follow procedure below replace battery.
After power been applied least five minutes, turn power control cabinet main disconnect switch power switch. Unplug input power connector from CSM. Remove module from rack pressing down latch pulling out. static-free work surface possible. Ground yourself using properly grounded wrist strap before open case. These standard precautions before handling electronics component. work surface with label side Press plastic tabs bottom module case toward each other lift side off.
WARNING touch capacitors. touch pins ICs; even with precautions against static destroy circuitry.
Figure A1-3 locate battery. Note oriented.
A.1-4
PiC900 CSM/RSM Central Service Module/Remote Service Module
Figure A1-3. Battery Location Module
DIAG SCAN BATT
BATTERY
Battery Clip
POWER
SUPPLY
insulated screwdriver battery clip. Remove clip. Lift battery out. Replace with 2/3A lithium battery. (See specification sheet this section.) Replace clip ensuring that latched. Close case insert rack. Connect power cable. Turn power check LEDs.
A.1-5
PiC900 CSM/RSM Central Service Module/Remote Service Module
Specification Table
Characteristic
CSM/RSM specifications
Functions power source Part numbers power source Part number Input connector
Supplies regulated power hardware modules installed rack 110-230 VAC, 47-63 502-03512-03 CSM-50 502-03732-03 RSM-50 VDC, 502-03973-00 CSM-50 (24VDC) 3-terminal plug connector, meets specifications touch safety accordance with 0470 part CSM/RSM-50 @4.0 V@2.0 @0.5 CSM/RSM-60 V@8.5 +15V@1.5 -15V@1.5 24VDC +15V -15V 502-03813-03 CSM-60 502-03817-03 RSM-60
Power output, total Individual outputs
Battery (CSM only)
CAUTION Lithium Batteries
2/3A lithium battery 401-52446-00
Danger explosion battery incorrectly replaced. Replace only with same equivalent type recommended manufacturer. Dispose used batterries according manufacturers instructions. supply monitor Trip points .5%: 4.725 4.775V 5.225 5.275 goes PiC900 shuts down Trip points 13.5 14.1 15.9 16.5 Access PiCPro application program. second Over temperature, voltage aging variation, +2/-12 seconds +15V -15V
supply monitor Time-of-day clock (CSM only) Clock tolerance (CSM only)
Logic side power requirements (typical)
(from battery during power down CSM)
Operating temperature range
(45° 131°
A.1-6
PiC900 CSM/RSM Central Service Module/Remote Service Module
Storage temperature range Humidity Marked
-40° (-40° 185° 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 31/EEC, 93/68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information.
C/UL Listed (CSM/RSM-50) Physical size
File E126417 NRAQ Programmable Controllers
2.4" wide high 8.4" deep (including latch)
Vibration (per 68-2-6) Shock (per 68-2-27)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
A.1-7
PiC900 CSM/RSM Central Service Module/Remote Service Module
NOTES
A.1-8
A.2- PiC900 (Document 108-31043-00)
(This document archived available from Giddings Lewis requesting part number 108-31043-00.)
A.2-1
PiC900 (Document 108-31043-00)
NOTE
A.2-2
(Document 108-31044-00)
(This document archived available from Giddings Lewis requesting part number 108-31044-00.)
(Document 108-31044-00)
NOTE
PiC90 CSM/CPU (Document 108-31045-00)
(This document archived available from Giddings Lewis requesting part number 108-31045-00.)
PiC90 CSM/CPU (Document 108-31045-00)
NOTE
Remote Service Module Driver
Introduction
When PiC90 slot rack used remote local expansion rack PiC900 master rack, driver module required slot PiC90 rack. (Each PiC90 used expansion rack must have module.) driver module converts power regulated power. Through bus, supplies this power modules expansion rack. Refer Appendix information expansion connections. DIAG turns briefly while diagnostic tests running.
Figure A5-1. Remote Service Module Driver (for Slot PiC90 Expansion Rack)
Name module
DIAG PWR/SCAN CONFIG DATA IN/OUT
LEDs
Stop
(Key slot used)
Power switch
LINE1 LINE2 GRND
Power connector
local expansion twisted pair local expansion twisted pair Twisted pair shield
Door
Fiber optic connections
Remote Service Module Driver
Connections
driver module receives power through 3-pin power connector. Figure A5-2 illustrates connections listed below.
Module Power Source
LINE LINE GRND
Common Single Point Ground
Figure A5-2. power system
CSM/RSM/RSM Modules
LINE LINE GRND
Power Source
Line (HOT) Line (COMMON) GROUND
AA22-4892
pinout 6-pin driver connector shown Figure A5-3. This connector used local expansion using twisted pair wire. connections expansion twisted pair out. next expansion twisted pair fifth connection shield used with twisted pair wire. sixth connection used. Remote expansion uses fiber optic cable connected fiber optic connectors shown Figure A5-1. NOTE: possible combine local remote expansion racks same system. twisted pair wiring connect racks that feet apart fiber optic cable connect racks that 2000 feet apart.
NOTE ensure compliance, fiber optic cables only. some applications using only local expansion racks, possible comply standards when using shielded twisted pair wires. Verification would have done system system basis.
Remote Service Module Driver
Figure A5-3. Pinout driver twisted pair connector
expansion twisted pair expansion twisted pair
Shield Used with twisted pair wire Used
CAUTION system polarity dependent. Always connect positive output module positive input next negative negative (-), etc. Always connect positive input module positive output next negative negative (-), etc.
LEDs
driver module LEDs indicate status. They shown Figure A5-4.
Figure A5-3. driver LEDs
Diagnostic Power Scan This rack configured expansion line activity expansion line activity
DIAG PWR/SCAN CONFIG DATA IN/OUT
Remote Service Module Driver
DIAG
Diagnostic
DIAG goes when power testing performed master rack. NOTE: processor module automatically runs diagnostic tests modules expansion loop power turns when module passes tests. During normal operation DIAG should off. light should whenever power indicates that supply within tolerance. specification sheet section. During normal operation should power SCAN light indicates that application program being executed. During normal operation SCAN should scan loss occurs light will there orderly shutdown procedure. Communication established with this expansion rack connected expansion loop. Communication established
Power
SCAN Scan
CONFIG This rack configured DATA
expansion line Dull Indicates line receiving active. activity glow activity
DATA
expansion line Dull Indicates line transmitting active. activity glow activity
NOTE: diagnostic module flashes certain error codes connected with expansion. These codes listed Appendix
Remote Service Module Driver
Theory Operation
driver module converts input power into power voltages supplies them logic side modules rack. External power supplies used field side modules. Such supplies routed through driver module, they should have same power cut-off switch PiC900. power distribution diagrams Hardware chapter.
CAUTION on/off rocker switch face driver module does control power supplies. Always shut power main disconnect switch before replace module system rack.
Specification Table Characteristic driver specifications
Functions
Supplies regulated power hardware modules installed rack Allows additional racks modules connected PiC900 master rack 502-03876-02 110-230 VAC, 47-63 3-terminal plug connector, meets specifications touch safety accordance with 0470 part Trip points .5%: 4.725 4.775V 5.225 5.275 goes PiC900 shuts down Communication capabilities master rack
Part number power source Input connector
Power output, total Individual outputs
supply monitor
PiC9XX module Logic side power requirements (typical)
Remote Service Module Driver
Operating temperature range Storage temperature range Humidity Marked
(45° 131° -40° (-40° 185° 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 31/EEC, 93/68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information.
C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
File E126417 NRAQ Programmable Controllers 2.4" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
Central Processing Unit Module Turbo
Introduction
PiC94X Turbo module controls PiC900 system executes application program. contains:
processor providing overall control math coprocessor Eight LEDs shown Figure A6-1 (EPROM optional) memory application program RAMDISK memory data storage system runs FLASH memory system software RS232 ports communicate with computer workstation with serial interface device Optional communication (ARCNET expansion) capability Optional flash memory system (FMS) storing things like application source modules
module must always second slot from left system rack.
Figure A6-1. PiC94X Turbo Module
Name module Diagnostic expansion LEDs ARCNET LEDs User Port LEDs
TURBO PiC900
ARCNET, local, block expansion
RS232 port, computer workstation
RS232 User Port, serial interface device
Fiber Optic Connections Remote expansion
Central Processing Unit Module Turbo
Connections
Serial Ports
PiCPro Port (9-pin connector) communicates with workstation serial port User Port (10-pin screw terminal connector) communicates with optional serial interface device.
Figure A6-2. Pinouts RS232 Communications Ports
User Port max.) max.) max.) Data terminal ready Request send Connected Clear send ground Receive data Transmit data
(output) Transmit Data (output) Receive Data (input) (output) max.)
max.) (output) Connected (output) (output) max.)
Outputs
Inputs Output
AA27-1390
PiCPro Port
PiCPro Port allows PiC900 communicate with workstation. This port used when downloading application program from workstation into memory. also used exchange data between workstation PiC900 system while PiC900 system running. pinout PiCPro Port cable shown below.
PiCPro Cable Pinout 9-pin female 9-pin female PiCPro Port)
NOTE: Other pins connected cable recieved from Giddings Lewis, only pins used. User Port used communicate with touch-screen, hand-held controller, other serial interface device.
ARCNET Expansion
ARCNET Expansion available some PiC94X Turbo CPUs. specification table this appendix lists modules that have this communication capability board. 7-pin screw terminal connector used ARCNET communications local block expansion. fiber optic connectors used remote
Central Processing Unit Module Turbo
expansion. NOTE: choose only type expansion time: local block remote. pins used peer-to-peer (ARCNET) communication connections using twisted pair wire*. next four pins used local feet segment] expansion seven expansion racks) block expansion using twisted pair wire*. bottom shield connection. When using shielded wire, connect shields *Use shielded cables when necessary meet standards. recommended wire characteristic impedance.
Figure A6-3. Pinout ARCNET, Local Expansion Block Expansion Port
Peer-to-peer solid twisted pair wire) Local block expansion stranded twisted pair wire) Local block expansion stranded twisted pair wire) Shield
CAUTION network polarity dependent. peer-to-peer communications, always connect positive twisted pair interface first positive twisted pair interface second negative negative (-), etc. expansion systems, connect positive twisted pair module positive twisted pair next module negative negative (-), etc. Connect positive twisted pair module positive twisted pair next module negative negative (-), etc.
Central Processing Unit Module Turbo
Remote Expansion
remote expansion [from feet (1.2 2,000 feet (610 m)/segment], fiber optic cable connected bottom connectors module shown Figure A6-4.
Figure A6-4. Location Fiber Optic Connections Remote Expansion
TURBO PiC900
Fiber Optic Connections
Appendix Peer-to-Peer Communication Connections information connecting PiCs network. Appendix Expansion Connections more information local remote expansion block expansion.
Central Processing Unit Module Turbo
LEDs
There seven communication LEDs this module addition DIAG LED. They located directly under DIAG shown Figure A6-5.
Figure A6-5. Communication LEDs
DIAG CONFIG
Diagnostic expansion LEDs ARCNET LEDs User Port LEDs
DATA
ARCNET
RS232
Below list LEDs what they mean.
DIAG
Flashing
briefly during startup. Flashes error codes under certain conditions. These codes listed Appendix Normal operation Communication established with this expansion rack connected expansion loop. Communication established
CONFIG
expansion rack configured
DATA
Dull glow Indicates line receiving active. activity
expansion line activity
DATA
Dull glow Indicates line transmitting active. activity
expansion line activity
ARCNET
ARCNET transmit status ARCNET ARCNET active status
RS232
Normal network activity Blinking Network reconfiguration active part network Flash/On Data being transferred to/from ARCNET interface data transfer Data being received user port data being received user port Data being transmitted from user port data being transmitted user port
User Port data
RS232
User Port data
Central Processing Unit Module Turbo
Theory Operation
module performs following tasks:
runs diagnostic tests, checks battery CSM, performs other routine maintenance tasks. executes application program, communicating with modules. maintains communication with workstation through PiCPro port. This port dedicated communication functions PiCPro/PiCServoPro. maintains communication with user interface device through User port. Details this communication depend partly type interface device. Refer manual that comes with device. ARCNET expansion communications board, supports peerto-peer, ARCNET expansion communication capability.
Diagnostics
runs diagnostic tests each module system rack whenever power turned PiC94X. tested first, then module, then modules turn. module's DIAG while being tested, goes when internal circuitry checks out. DIAG does after diagnostic tests, fault been detected. Troubleshooting section Hardware chapter.
EPROM PiC94X
PiC94X socket Mbyte EPROM. recommended EPROM
Atmel AT27C080-20DC
This EPROM three memory areas:
Application RAMDISK System
software manual gives directions creating file format suitable EPROM programmer. This file loaded from workstation into EPROM using number commercially available EPROM Programmers. application file originates address zero and, therefore, requires offset. file uses 16-bit word format. With PiC94X processor, when programming EPROM with RAMDISK information, necessary locate RAMDISK information EPROM memory follows:
Central Processing Unit Module Turbo
default 256/512 memory configuration, RAMDISK located 80000. optional 384/384 memory configuration, RAMDISK located 60000. When version system software issued Giddings Lewis, also loaded EPROM programmer. will check time/date stamp system EPROM compare with system FLASH. system EPROM newer than system FLASH, will reprogram FLASH with system.
PiC900 Memory Organization
module contains Megabyte memory. This memory divided into four groups. groups are:
System Memory which used executive data, memory, user variables. Specific areas memory reserved each these functions. RAMDISK which used provide extra memory program data storage. access data RAMDISK, special commands covered software manual. loaded from EPROM which data been programmed. Application Memory which where application program stored. loaded from EPROM which application been programmed. System FLASH which contains executive code system, diagnostics, etc. updated from loaded from EPROM which system been programmed.
Figure A6-6 shows location EPROM PiC94X.
Central Processing Unit Module Turbo
Figure A6-6. Position EPROM PiC94X
DIAG Configure Communication LEDs (Not components shown)
System FLASH
Socket EPROM
Communication Port
EPROM
PiCPro Port
User Port
Fiber Optic Connections
Central Processing Unit Module Turbo
Procedure Installing EPROM into Socket
Turn power main disconnect switch. installed rack, remove module static-free surface, cover side Ground yourself using properly grounded wrist strap before open module. These standard precautions before handling electronic components Press plastic tabs bottom module toward each other lift module cover. CAUTION touch pins EPROM. EPROM circuitry easily damaged. Broken bent pins prevent EPROM from functioning properly. Figure A6-6 where EPROM should placed. EPROM occupies socket already, removal tool remove insertion tool position EPROM over socket being sure match notches. CAUTION Make sure EPROM oriented correctly. installed backwards, destroyed when power turned system. Line pins push place.
Replace module cover. Insert module rack next CSM. Turn power main disconnect switch check LEDs.
Central Processing Unit Module Turbo
Specification Table Characteristics module specifications
Function
Executes application program. Executes Diagnostics system modules. Communicates through RS232 port external devices. provide ARCNET expansion from module Number servo axes available update rates**
Part Number Speed 512K 512K 512K 512K 512K 512K User 256K 256K 256K 256K 256K 256K 256K 256K 24/12 24/12 12/6 12/6 24/12 24/12 12/6 12/6 24/12 24/12 12/6 12/6
CPUs
Model
80486DX2 502-04111-01
Turbo2 80486DX2 502-04111-11* 80486DX2 502-04011-01
Turbo2 80486DX2 502-04011-11* 80486DX2 502-03994-01
Turbo3 80486DX2 502-03994-11*
80486DX4 502-04112-01 100MHz 512K
24/12 12/6 24/12 12/6
Turbo3 80486DX4 502-04112-11* 100MHz 512K
*ARCNET expansion communications standard these modules. When numbers listed (H/L), High number typical when running things like RATIO_GR, RATIOCAM, VEL_STRT, POSITION, DISTANCE move types, etc. number typical when running time axes, servo tasks, RATIO_RL, M_LINCIR, M_SCRVLC move types, etc. latter place heavier burden time than former. Consult Giddings Lewis assistance want exceed number axes this chart. Flash memory system board (optional) Memory PiCPro Port workstation) User Port serial interface device) Megabyte Board 502-03882-00 Megabyte Board 502-03882-20 Megabyte max. RS232 serial port, secured protocol Software selectable baud rate 115.2K RS232 serial port Supports RTS/CTS hardware handshaking Software selectable baud rate 19.2K
Central Processing Unit Module Turbo
Logic side power requirements (typical)
Part Number
502-04111-01 502-04011-01 502-03994-01 502-04112-01 502-04111-11* 502-04011-11* 502-03994-11* 502-04112-11*
1200 1000 1100 1400
CPUs draw from battery during power down. Operating temperature range Storage temperature range Humidity Marked 55°C (45°F 131°F) -40°C 85°C (-40°F 185°F) 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 92/31/ EEC, 93/68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information. C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
File E126417 NRAQ Programmable Controllers 1.6" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
Central Processing Unit Module Turbo
NOTES
PiC9011/9012 CSM/CPU (Document 108-31046-00)
(This document archived available from Giddings Lewis requesting part number 108-31046-00.)
PiC9011/9012 CSM/CPU (Document 108-31046-00)
NOTE
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Introduction
PiC904X CSM/CPU module occupies slot rack. CSM/CPU converts power regulated power. supplies this power modules rack through bus. PiC904X CSM/CPU controls system executes application program.
Figure A8-1. PiC904X CSM/CPU Module
CSM/CPU
SCAN/BAT/PWR/DIAG PROG/USER PORTS ARCNET CONFIG BLOCK
Name module
LEDs
slot
Stop
PiC90
GIDDINGS LEWIS®
Programmable industrial Controller
Power switch
LINE1 LINE2 GRND
Power connector
PiCPro
RS232 port connector computer workstation) Communications port peer-to-peer block (optional) RS232 port connector user serial interface) Door
User Block Port
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Connections
CSM/CPU module receives power through 3-pin power connector. Figure A8-2 illustrates connections listed below.
Module Power Source 110VAC Power Source 220VAC Power Source 24VDC
LINE
Line1 Line2 Single Point Ground
+24V Common Single Point Ground
LINE Common GRND Single Point Ground
Figure A8-2. Power System
CSM/CPU Module
LINE LINE GRND
Power Source
110V 220V Line +24V COMMON Line COMMON GROUND GROUND GROUND
Serial Ports
PiCPro Port (9-pin connector) communicates with workstation serial port User Port (10-pin screw terminal connector) communicates with optional serial interface device.
Figure A8-3. Pinouts RS232 Communications Ports
User Port max.) max.) max.) Data terminal ready Request send Connected Clear send ground Receive data Transmit data
(output) Transmit Data (output) Receive Data (input) (output) max.)
max.) (output) Connected (output) (output) max.)
Outputs
Inputs Output
AA27-1390
PiCPro Port
PiCPro Port allows PiC904X communicate with workstation. This port used when downloading application program from workstation into memory. also used exchange data between workstation PiC904X system while PiC904X system running.
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
pinout PiCPro Port cable shown below.
PiCPro Cable Pinout 9-pin female 9-pin female PiCPro Port)
NOTE: Other pins connected cable received from Giddings Lewis, only pins used. User Port used communicate with touch-screen, hand-held controller, other serial interface device.
Peer-to-Peer (ARCNET) Block Expansion (Optional)
Peer-to-peer block expansion optional PiC904X. PiC90s with this communication capability have communications port with 10-pin screw terminal connector left user port. (See Figure 7-1.) pins used peer-to-peer communication connections using twisted pair wire*. next four pins used block expansion block modules) where maximum distance between block modules feet using shielded twisted pair wire*. shield connection. When using shielded wire, connect shields *Use shielded cables when necessary meet standards. recommended wire characteristic impedance.
Figure A8-4. Pinout ARCNET Block Expansion Port
Peer-to-peer twisted pair interface Block
Shield
Peer-to-Peer(ARCNET)/ Block communications port
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
CAUTION network polarity dependent. peer-to-peer communications, always connect positive twisted pair interface first positive twisted pair interface second negative negative (-), etc. block expansion systems, connect positive twisted pair module positive twisted pair next block module negative negative (-), etc. Connect positive twisted pair module positive twisted pair next block module negative negative (-), etc. Appendix Peer-to-Peer Communication Connections information connecting PiCs network. Appendix Expansion Connections more information block expansion.
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
LEDs
There LEDs PiC904X CSM/CPU shown Figure A8-5 below. This section describes these LEDs.
Figure A8-5. LEDs SCAN/BAT/PWR/DIAG PROG/USER PORTS ARCNET CONFIG BLOCK
Status LEDs
CSM/CPU module four LEDs indicate status shown Figure A8-5 above. They described below. NOTE: During normal operation DIAG BATT LEDs should off, SCAN LEDs should
Scan (SCAN)
processor executing application program. Scan lost there orderly shut down procedure followed.
Battery (BAT)
Goes briefly while battery checked power-on. Battery passed power test.
Flashing Replace lithium battery. replacement procedure that follows. Power (PWR)
Power system. indicates that supply within tolerance. specification sheet. power system
Diagnostic (DIAG)
briefly during startup diagnostics. remains module failed startup diagnostics. Normal operation These codes listed Appendix
Flashing Flashes error codes under certain conditions.
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Communication LEDs
There seven communication LEDs shown Figure A8-5: RS232 communication, ARCNET communication, three Block communication. They described below.
PiCPro Programming Port Data (IN)
Data being received programming port data being received programming port
PiCPro Programming Port Data (OUT)
Data being transmitted from programming port data being transmitted from programming port
RS232 User Port Data (IN)
Data being received user port data being received user port
RS232 User Port Data (OUT)
Data being transmitted from user port data being transmitted from user port
ARCNET Transmit Status (TX)
Blinking
Normal network activity active part network Network reconfiguration
ARCNET Active Status (ACT)
Flash/ON
Data being transferred to/from ARCNET interface data transfer
BLOCK Module Configuration (CONFIG)
Communication established with block modules Communication established with block modules
BLOCK Data (IN)
Indicates receiving data from block modules Indicates receiving data from block modules
BLOCK Data (OUT)
Indicates transmitting data block modules Indicates transmitting data block modules
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
CSM/CPU Time-of-Day Clock
internal clock maintains current date time. power system, battery maintains clock. application program PiCPro access this clock. Details given Software manual.
Theory Operation
CSM/CPU module converts input power into power voltages +5V, supplies them logic side modules rack. External power supplies used field side modules. Such supplies routed through CSM/CPU, they should have same power cut-off switch PiC9041. CAUTION on/off rocker switch face CSM/CPU does control power supplies. Always shut power main disconnect switch before replace module system rack. With CSM/CPU module, supplied protect system from unauthorized start-ups. PiC9041 hardware, power diagnostic tests, even load software application program without system key. However, application program will scanned until turn Run/Stop CSM/CPU position. CSM/CPU module does following:
Performs diagnostic tests. Checks battery. Performs routine maintenance tasks. Executes application program. Communicates with modules. Maintains communication with workstation through PiCPro port. Maintains communication with user interface device through user port. (Details this communication depend partly type interface device. Refer manual that comes with device.) Provides peer-to-peer (ARCNET) communication block expansion capability (optional).
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Application Flash
904X flash chip board that allows load application program into This standard 904X same optional Flash Memory System (FMS) that add. Having application standard flash chip ensures that will lose application battery fails. power application transferred from flash chip when directly downloaded from PiCPro. place application flash:
Compile application into file PiCPro. SENDHEX utility (refer PiCPro Utilities Manual) download application into flash.
Even though have placed application flash, still download differenct application from PiCPro. However, when cycle power PiC, application flash will always placed into RAM. want remove application from FLASH that placed into when cycle power, SENDHEX utility send CLRFLASH.HEX file PiC.
Replacing Battery CSM/CPU
Follow procedure below replace battery.
After power been applied CSM/CPU least five minutes, turn power control cabinet main disconnect switch CSM/CPU power switch. Unplug connectors from CSM/CPU. Remove CSM/CPU module from rack pressing down latch pulling out. static-free work surface possible. Ground yourself using properly grounded wrist strap before open case. These standard precautions before handling electronics component. CSM/CPU work surface with label side Press plastic tabs bottom module case toward each other lift side cover WARNING touch capacitors. touch pins ICs; even with precautions against static destroy circuitry. Figure A8-6 locate battery. Note oriented.
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Figure A8-6. Inside CSM/CPU Module: Position Battery
LEDs
Power Supply
BATTERY
Battery Clip
insulated screwdriver battery clip. Remove clip. Lift battery out. Replace with 2/3A lithium battery. (See specification sheet this section.) Replace clip ensuring that latched. Close case insert CSM/CPU rack. Reconnect cables. Turn power check LEDs.
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Specification Table
Characteristic
CSM/CPU specifications
Functions
Supplies regulated power hardware modules installed rack. Executes application program. Executes Diagnostics system modules. Communicates through RS232 ports external devices. Peer-to-peer communication with PiC900 family controls (optional)
Number servo axes available update rates*
Models available
PiC90 Model (for with Power Source) 256K 256K 256K 256K 128K 128K 128K 128K
Part Number Speed 502-04104-01 502-04104-11 502-04125-01 502-04125-11
User
9041 Standard comm 9041 Standard comm 9043 Turbo comm 9043 Turbo comm
PiC90 Model (for with Power Source)
9041 Standard comm 9041 Standard comm 9043 Turbo comm 9043 Turbo comm
502-04110-00 502-04110-10 502-04126-00 502-04126-10
256K 256K 256K 256K
128K 128K 128K 128K
*The number axes listed typical RATIO_GR, RATIOCAM, VEL_STRT, POSITION DISTANCE move types. Applications which time axes, servo tasks, RATIO_RL, M_LINCIR M_SCRVLC moves require more time. Consult Giddings Lewis assistance want exceed number axes this chart.
power source power source Input connector
110-230 VAC, 47-63 -30V 3-terminal plug connector, meets specifications touch safety accordance with 0470 part
CSM/CPU (for power source) (for power source)
Power output, total
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Individual outputs Battery
Power Source
Power Source
2/3A lithium battery
CAUTION Lithium Batteries
Danger explosion battery incorrectly replaced. Replace only with same equivalent type recommended manufacturer. Dispose used batterries according manufacturers instructions. supply monitor trip point 4.50V 4.75V High trip point 5.50V 5.94V goes PiC9041 shuts down Megabyte Board 502-03882-00 Megabyte Board 502-03882-20 Used connect work station RS232 serial port, secured protocol Software selectable baud rate (300 57600 baud) Used connect serial interface device RS232 serial port Supports RTS/CTS hardware handshaking Baud rates 19.2 Allows communication between PiC90s and/or PiC900s 255) dedicated network controller supports peer-to-peer communications. Provides twisted pair wire interface that transformer isolated. Data transferred serially rate megabits second. Block expansion (optional) Allows communication between PiC90 block modules maximum distance between modules feet using shielded twisted pair wire Time-of-day clock Clock tolerance Access PiCPro application program. second Over temperature, voltage aging variation, +2/-12 seconds
Flash memory system board (optional) PiCPro port
User port
Peer-to-peer communications (optional)
PiC904X- CSM/CPU Central Service Module/Central Processing Unit
Logic side power requirements (typical)
@+15 -15V
-15V
502-04104-00, 502-04110-00 502-04104-10, 502-04110-10 502-04125-00, 502-04126-00 502-04125-10, 502-04126-10 502-04104-00, 502-04110-00, 502-04125-00, 502-04126-00 502-04104-10, 502-04110-10 502-04125-10, 502-04126-10 (all) From battery during power down
Operating temperature range
(45° 131°
Storage temperature range -40° (-40° 185° Humidity Marked 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 92/31/EEC, 68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information. C/UL Listed Physical size File E126417 NRAQ Programmable Controllers 2.4" wide high 8.4" deep (including latch)
Vibration (per 68-2-6) 10-57 (constant amplitude 2000 (acceleration Shock (per 68-2-27) Four shocks axis (15g/11 msec)
Appendix Communication Modules
Driver Module
Introduction
PiC900 system include expansion racks containing modules. driver module must installed each expansion rack. PiC900 module with daughter board PiC9XX module with communication capability must installed master rack. driver module must always second slot from left each expansion rack. Refer Appendix information expansion connections. DIAG turns briefly while diagnostic tests running.
Figure B1-1. DRIVER Module
Driver
Name module Diagnostic
DIAG CONFIG DATA DATA
driver LEDs
6-pin driver twisted pair connector
(located behind
Fiber Optic connectors
Driver Module
Connections
pinout 6-pin driver connector shown Figure B1-2. This connector used local expansion using twisted pair wire. connections expansion twisted pair out. next expansion twisted pair fifth connection shield used with twisted pair wire. sixth connection used. Remote expansion uses fiber optic cable connected fiber optic connectors shown Figure B1-1. NOTE: possible combine local remote expansion racks same system. twisted pair wiring connect racks that feet apart fiber optic cable connect racks that 2000 feet apart. NOTE ensure compliance, fiber optic cables only. some applications using only local expansion racks, possible comply standards when using shielded twisted pair wires. Verification would have done system system basis.
Figure B1-2. Pinout driver twisted pair connector
expansion twisted pair expansion twisted pair Shield used
CAUTION system polarity dependent. Always connect positive output module positive input next negative negative (-), etc. Always connect positive input module positive output next negative negative (-), etc.
Driver Module
LEDs
There three LEDs driver module addition DIAG LED. They located directly under DIAG shown Figure B1-3.
Figure B1-3. Driver LEDs
Diagnostic This rack configured driver LEDs expansion line activity expansion line activity
AA823-0791
NOTE: diagnostic module flashes certain error codes connected with expansion. These codes listed Appendix
This rack configured expansion line activity Communication established with this expansion rack connected expansion loop. Communication established
Dull glow Indicates line transmitting active. activity
expansion line activity
Dull glow Indicates line receiving active. activity
Driver Module
Specification Table
Characteristics
driver module specifications
Function Part number
Allows additional racks modules connected PiC900 master rack 502-03657-03
PiC9XX module with communication capabilities master rack Logic side power requirements (typical) Operating temperature range Storage temperature range Humidity Compliant Emissions Noise immunity Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) IEC1000-4-2 electromagnetic fields 1000-4-3 Electrical fast transients 1000-4-4 incoming power lines Refer Guidelines more information. C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
(45° 131° -40° (-40° 185° 95%, non-condensing
File E126417 NRAQ Programmable Controllers 1.6" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
Serial Communications Module channel)
Introduction
serial communications module provides four channels used asynchronous serial communication with external devices such computers, operator interface devices, etc. each channel, RS232 electrical interface provided data control lines; RS422/485 electrical interface provided data lines. DIAG goes briefly while diagnostic tests running.
Figure B2-1. Serial Communications Module
COMMUNICATIONS
Name module Diagnostic
DIAG
Screw terminal connector
Door
AA890-3391
Serial Communications Module channel)
Connections
screw terminal connection provided each input output shown Figure B2-2. RS232 RS422/485 interface available four channels. This table defines inputs outputs available each channel module using RS232 interface.
Label Definition Input/Output
RDx_232 TDx_232 CTSx_232 RTSx_232 DTRx
Receive data Transmit data Clear send (handshaking) Request send (handshaking)
Input Output Input Output
Data terminal ready (pullup 12V) Output
This table defines inputs outputs available each channel module using RS422/485 interface.
Label Definition Input/Output
RDx_DIF+ RDx_DIFTDx_DIF+ TDx_DIF-
Receive data
Input Input
Transmit data
Output Output
Serial Communications Module channel)
Figure B2-2. Screw Terminal Connection Assignments
SCREW TERMINALS CONNECTION
TD1_232 RTS1_232
CONNECTION
RD1_232
CTS1 _232
_DIF+
RS232 RS422/485
Channel
(Pins
TD1_DIF+
_DIF-
TD1_DIF-
COMMON
DTR_A
SHIELD
Available channels
(Pins
CTS2 _232
RD2_232
RTS2_232
TD2_232
RS232 RS422/485
TD2_DIF+
_DIF+
Channel
(Pins
TD2_DIF-
_DIF-
CTS3_232
RD3_232
RTS3_232
TD3_232
RS232 RS422/485
TD3_DIF+
RD3_DIF+
Channel
(Pins
TD3_DIF-
RD3_DIF-
DTR_B
COMMON
SHIELD
RD4_232
Available channels
(Pins
CTS4_232
TD4_232
RTS4_232
RD4_DIF+
RS232 RS422/485
Channel
(Pins
TD4_DIF+
RD4_DIF-
TD4_DIF-
(Future Use)
(Future Use)
AA891-3391
Serial Communications Module channel)
Figure B2-3 illustrates connect RS232 device channel Maximum cable length RS232 devices feet.
Figure B2-3. Connections RS232 Device
External RS232 Communication Device
Connections RD1_232 CTS1_232 TD1_232 RTS1_232
Screw Terminals
Common DTR_A
AA892-4491
Serial Communications Module channel)
Figure B2-4 illustrates connect RS422/485 device channel NOTE: RS422 refers earlier standard that applied only single drop connections. RS485 refers multidrop connections. Figure B2-5. Since interface used both RS422 RS485, terminating resistors required proper operation.
Figure B2-4. Connections RS422/485 Device
Screw Terminals
terminating resistors
External RS422/485 Communication Device Connections RD1_DIF+ TD1_DIF+ RD1_DIFTD1_DIF-
Note: Shield pins connected internally SPG.
Serial Communications Module channel)
With RS485, multidrop connections possible shown Figure B2-5. serial communications module acts master, sending control sequences activate/deactivate external devices such hand-held terminals, touch control screens, etc. devices connected channel. Maximum cable length 4000 feet. terminating resistor (100 installed each system shown.
Figure B2-5. Multidrop Connections
Serial Communications Module
Screw Terminals
terminating resistors
RD1_DIF+ TD1_DIF+ RD1_DIFTD1_DIF-
Note:
Shield pins connected internally SPG.
terminating resistors External communication devices-Hand-held pendants devices connected)
Serial Communications Module channel)
Theory operation
Serial communication accomplished through DUARTs (Dual Universal Asynchronous Receiver/Transmitter). External serial devices connected given channel DUART through either RS232 interface RS422/485 interface. There dedicated processor with FIFO buffers module which services DUARTs. This saves main from time-consuming task directly polling each DUART. processor supports data transfers with rates 19.2 Kbaud each channel. rates above 9600 baud, hardware handshaking should used. FIFO buffers provide main means data transfer between main DUARTs. input data output data buffered given time each channel. Communication handled through PiCPro software.
Serial Communications Module channel)
Specification Table
Characteristics
Communications Module Specifications
Function Part number Dedicated processor Ports
Provides asynchronous serial communication channels used with serial interface devices channel- 502-03676-23 channel- 502-03676-03 80C186, MHz, EPROM, RS232 RS422/485 electrical interface Supports RTS/CTS hardware handshaking Baud rates 19.2 Kbps +15V -15V
Logic side power requirements (typical)
terminated RS422/485 channel active RS232 channel +15V active RS232 channel -15V Operating temperature range Storage temperature range Humidity Marked (45° 131° -40° (-40° 185° 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 31/EEC, 93/68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information.
Serial Communications Module channel)
C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
File E126417 NRAQ Programmable Controllers 1.6" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
Serial Communications Module channel)
DeviceNetModule
Introduction
DeviceNetscanner module interface between DeviceNet network. module contains on-board processor, DeviceNet compliant interface, firmware that makes master other nodes network. Prior initial operation, file generated with specific configuration software external This file must downloaded RS232 configuration port DeviceNet module prior initial operation. indicator LEDs (IN/OUT) connected this configuration port. Directly above DeviceNet port LEDs that provide operation information; Network Status DeviceNet Scanner Status. DIAG goes briefly while diagnostic tests running.
Figure B3-1. DeviceNet Module
DeviceNetDIAG CNFG PORT
Name module Diagnostic Configuration Port LEDs
Network Status DeviceNet Port Phoenix 5-pin
DeviceNet Scanner Status
Door
Configuration Port RS232 Port 9-pin
DeviceNetModule
Connections
DeviceNet connections illustrated Figure B3-2. DeviceNet Nodes attached DeviceNet scanner module.
Figure B3-2. DeviceNet Connections
DEVIC
connected RS232 port downloading file generated with Giddings Lewis configuration software
DeviceNet Node
DeviceNet Trunk
DeviceNet Port
DeviceNet port front module near center shown Figure B3-1. pinout DeviceNet port shown below:
Signal Name Standard Wire Colors
DeviceNet Node
VCAN_L Shield (drain) CAN_H
DeviceNet Node
DeviceNet Trunk
black blue bare white
DeviceNetModule
Configuration (RS232) Port
There RS232 port lower front module shown Figure B3-1. This used connect order download file representing your DeviceNet network.
Signal Name In/Out
LEDs
Receive Data Transmit Data Ground
In/Out
configuration port LEDs DeviceNet port LEDs described below.
Port Network status Color State Definition
DeviceNet
Green
Flashing
Off-line On-line connected least node On-line connected least node Unrecoverable Fault (dupicate check failed, critical fault, etc.) connections timed-out state other Recoverable Fault power else reset asserted Scanner active Scanner active Hardware software error Recoverable configuration error (invalid data downloaded) Configuration (download) mode Data being passed module data module Data being passed from module data from module
Flashing
Scanner status
Green
Flashing
Flashing
Orange
Configuration
Flickering
Flickering
DeviceNetModule
Theory operation
DeviceNet scanner module provides memory image nodes (slaves) connected DeviceNet network. this memory image that controlled your created PiCPro. module's on-board processor continually transfers data between this memory image actual DeviceNet nodes. Communication between DeviceNet module nodes Kbaud, Kbaud, Kbaud. baud rate, relationship between memory image specific data each node, other parameters established with configuration software external This configuration software generates files. file downloaded DeviceNet module through RS232 serial port. other file used PiCPro establish relationship between memory image declared variables LDO. ensure that given location memory image connected variable corresponding data DeviceNet node, same name label must used. example, when running configuration software, PROX_SW1 could used name boolean representing DeviceNet proximity switch's logic state. name PROX_SW1 must also used corresponding variable your LDO.
NOTE DeviceNet configuration software (G&L Part M.1017.4267) required configure DeviceNet scanner (within DeviceNet module) devices associated network.
IMPORTANT Additional information about DeviceNet obtained from www.odva.org.
DeviceNetModule
Specification Table
Characteristics
DeviceNet Module Specifications
Function Part number DeviceNet Port Configuration Port Logic side power requirements (typical) Operating temperature range Storage temperature range Humidity Marked
Interfaces DeviceNet network with other nodes 1016.9720 (old 502-04157-98) Phoenix style 5-pin male connector RS232 interface (45° 131° -40° (-40° 185° 95%, non-condensing Conforms Directives 73/23/EEC, 89/336/EEC, 31/EEC, 93/68/EEC conforming following standards: 50081-2:1993 Generic Industrial Emissions 50082-2:1995 Generic Industrial Immunity 61131-2:1994/A11:1996 voltage directive requirements programmable controllers Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) EN61000-4-2 electromagnetic fields EN61000-4-3, 50141, ENV50204 Electrical fast transients EN61000-4-4 Magnetic fields EN61000-4-8 Refer Guidelines more information.
C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
File E126417 NRAQ Programmable Controllers 1.6" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
DeviceNetModule
NOTES
ETHERNET- TCP/IP Module
Introduction
ETHERNET TCP/IP module provides with Ethernet access Internet connectivity. Connections 10Base 10Base (Attachment Unit Interface) provided following IEEE 802.3 specification. data transfer rate Mbps. Applications range from connecting several PiCs, connecting groups PiCs PCs, connecting system that includes Internet access. this document partial list Internet links useful information about Ethernet TCP/IP networking. Remote Programmer Access (future feature) will allow enable/disable PiCPro Windows running over Ethernet. DIAG goes briefly while diagnostic tests running shortly after power applied.
Figure B4-1. Ethernet TCP/IP Module
ETHERNET TCP/IP
Name module Diagnostic Ethernet Port LEDs
DIAG GDLNK ETHERNET PREV
RS232-1 RS232-2
RS232 COMM Ports
REMOTE PROGRAMMER ACCESS Enable Disable
Remote Programmer Access
(Future)
RS232 COMM Port
RS232 COMM Port
10Base RJ-45 8-pin connector
15-pin connector Door
10Base connector
ETHERNET- TCP/IP Module
Connections
PiCPro cable used make connection between PiC.
Connect RS232 Port Ethernet TCP/IP module download TCP/IP configuration file. Connect PiCPro Port download application LDO.
Figure B4-2. PiC/PC Connections
ETHER
PiCPro Port
choose three connection choices your Ethernet TCP/IP system.
10Base Mbps, baseband, over twisted pair cable) (Attachment Unit Interface, over shielded twisted pairs wires with overall shield covering these individual shielded wire pairs) NOTE: 15-pin connector does have traditional slide lock clip. Instead, #4-40 screw lock bushings provided. want standard transceiver cable, remove slide lock posts from male cable. Plug cable into connector secure with #4-40 screws. screw retainer with captivation clips available from (part number 2059801). inch ribbon cable available from Giddings Lewis connecting microtransceivers. advantage allowing access door Ethernet TCP/IP module close. 10Base Mbps, baseband, over thin coaxial cable)
ETHERNET- TCP/IP Module
table below summarizes specifications (IEEE 802.3) Ethernet connections available Ethernet TCP/IP module.
Connections 10Base 10Base
Category rec- shielded twisted- RG-58 thinnet coaxial ommended) pair transceiver (unshielded twisted-pair)
Type Cable Connection Terminator resistance Topology
Shielded category cable optional. RJ-45 Star
DB-15 Point Point
connector Minimum (23") between computers, maximum (607') (607')
(328') between transceiver (TCP/IP module)
Distance Maximum cable segment length Computers segment
(328')
(164')
ETHERNET- TCP/IP Module
typical 10Base connection shown below.
Figure B4-3. Ethernet TCP/IP 10Base Connections
ETHER
10Base Twisted Pair
Segment
Node
Node
Node
Maximum segment length (328').
typical connection shown below.
Figure B4-4. Ethernet TCP/IP Connections
ETHER
Cable
(Transceiver Cable)
Maximum length (164') Fiber Optic (Transceiver Microtransceiver) Fiber Optic Cable another computer optical hub)
ETHERNET- TCP/IP Module
typical 10Base connection shown below.
Figure B4-5. Ethernet TCP/IP 10Base Connections
ETHER
10Base Coax Cable
connector Minimum cable length (23") Termination connection Coax Cable
Node
Node
Node
taps Node segment
Termination
Maximum segment length (607')
Ethernet Ports
There three ethernet ports module shown Figure 4-3. these ports used make your ethernet connections depending type medium using. 10Base-T port uses RJ-45 style 8-pin connector using unshielded twisted pair category (IEEE 802.3 section 14.4). maximum length twisted pair cable segment (328 ft.). NOTE: connector also suitable shielded cable will ground shield chassis. connection uses shielded style 15-pin connector using shielded twisted pair cable (IEEE 802.3 section 7.4.3). maximum length twisted pair cable (164 ft.). 10Base-2 (found bottom module) uses style coax connector coax (IEEE 802.3 section 10.5). maximum length coax cable (607 ft.).
ETHERNET- TCP/IP Module
RS232 COMM Ports
There RS232 ports module shown Figure 4-3. COMM will used modem connections (future). COMM used download your configuration file PiC.
Signal Name
LEDs
Receive Data Transmit Data Ground Ready send Clear send
There nine LEDs Ethernet TCP/IP module addition DIAG LED. They located directly under DIAG shown below.
Figure B4-6. Ethernet TCP/IP LEDs DIAG GDLNK Diagnostic (yellow) Ethernet receiving data (green) Ethernet transmitting data (green) Ethernet 10Base-T good link (green) Polarity reversed 10Base-T receiver (yellow) Ethernet collision (yellow) receive data (green) transmit data (green) receive data (green) transmit data (green)
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ETHERNET- TCP/IP Module
Theory operation
Ethernet TCP/IP module contains 32-bit processor handle TCP/IP, (future), Ethernet protocols. allows Ethernet network architecture TCP/IP standard protocols communicate access other modules, computers, Internet resources. topology alternatives include linear star bus. CSMA/CD (Carrier Sense Multiple Access with Collision Detection) access method used regulate traffic main cable segment. design based IEEE 802.3 specifications. data rate Mbps. diagram below provides overview.
Figure B4-7. Ethernet TCP/IP Overview
Application Program
Ethernet TCP/IP Module Software
Transmission Control Protocol User Datagram Protocol
Internet Protocol
Ethernet TCP/IP Module Hardware Ethernet Network Interface Ethernet Physical Mediums
(FUTURE) Point Point Protocol RS232
Modem
Phone Line 10Base 10Base
ETHERNET- TCP/IP Module
Specification Table Characteristics Ethernet TCP/IP Module Specifications
Function Part number RS232 Port RS232 Port 10Base 10Base Logic side power requirements (typical) Operating temperature range Storage temperature range Humidity Compliant Emissions Noise immunity
Provides with Ethernet access Internet connectivity 502-04137-00 Port modem (future) Port (for firmware configuration loading) RJ-45 8-pin connector Maximum twisted pair length (328 ft.). 15-pin connector Maximum twisted pair length (164 ft.). connector Maximum coax cable length (607 ft.). +15V -15V 1250 maximum maximum
(45° 131° -40° (-40° 185° 95%, non-condensing
Operates with emissions below EN55011/ CISPR Class limits Immune Electrostatic discharge contact mode, discharge) 1000-4-2 electromagnetic fields 1000-4-3 Electrical fast transients 1000-4-4 incoming power lines Refer Guidelines more information. File E126417 NRAQ Programmable Controllers 1.6" wide high 8.4" deep (including latch)
10-57 (constant amplitude 2000 (acceleration Four shocks axis (15g/11 msec)
C/UL Listed Physical size
Vibration (per 68-2-6) Shock (per 68-2-27)
ETHERNET- TCP/IP Module
Useful Internet Links 500698.html#6
ETHERNET- TCP/IP Module
NOTES
Profibus Module
Introduction
PiC900 Profibus scanner module interface between Profibus network. module contains on-board processor, Profibus compliant interface, firmware that makes master nodes assigned network. Prior initial operation, file generated with specific configuration information external This file must downloaded RS232 configuration port Profibus scannerProfibus module prior initial operation. indicator LEDs (IN/OUT) connected this configuration port. Directly above Profibus port LEDs that provide operation information; Network Status Profibus Scanner Status. DIAG goes briefly while diagnostic tests running.
Figure B5-1. Profibus Module
Diagnostic
P
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