Converteam GEMTEQ I/O GEM80 User manual
GEM80 GEMTEQ I/O
Series Controllers
Publication No. T2031En Rev.02 (10/10)
Technical Manual
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GEMTEQ I/O Scope
GEM80
GEMTEQ I/O
Technical Manual
Publication No. T2031En
Rev.02 (10/10)
GEMTEQ I/O Technical Manual (T2031En) Page iii
Rev.02 (10/10)
Scope GEMTEQ I/O
Acknowledgement
Issue Information
Publication T2031En Issue 1 (09/10)
Manufacturer
Converteam UK Ltd.
West Avenue,
Kidsgrove,
Stoke-on-Trent,
Staffordshire,
ST7 1TW
England.
Tel: +44 (0) 1782 781000
Fax: +44 (0) 1782 781133
e-mail: product.service-u[email protected]
© CONVERTEAM UK - 2010 - Publication No. T2031En Issue 1 (09/10)
The logo CONVERTEAM and their frameworks are trademarks and service trademark applications of
Converteam UK.
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GEMTEQ I/O Scope
SAFETY INSTRUCTIONS
Care has been taken with the design of this product to ensure that it is safe. However, in common with all
products of this type, misuse can result in injury or death. Therefore, it is very important that the
instructions in this manual and on the product are observed during transportation, commissioning,
operation, maintenance and disposal.
This technical manual should be regarded as part of the product. It should be stored with the product and
passed on to any subsequent owner or user.
Local safety laws and regulations must always be observed.
Persons working on the product must be suitably skilled and should have been trained in that work for
these products.
The product is a component designed for incorporation in installations, apparatus and machines.
The product must not be used as a single item safety system. In applications where maloperation of the
product could cause danger, additional means must be used to prevent danger to persons.
Product approvals and certifications will be invalidated if the product is transported, used or stored outside
its ratings or if the instructions in this manual are not observed.
In the European Union:
Products within the scope of the Low Voltage Directive, 2006/95/EC as amended are CE marked.
The product complies with the essential protection requirements of the EMC directive 2004/108/EC as
amended, when installed and used as described in this manual. The requirements of the EMC Directive
should be established before any installation, apparatus or machine which incorporates the product is
taken into service.
A machine should not be taken into service until the machine has been declared in conformity with the
provisions of the Machinery (Safety) Directive, 98/37/EEC.
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GEMTEQ I/O Scope
Scope
This publication provides details of the GEM80 GEMCAN I/O Scanner module and GEMTEQ I/O structure,
which is a distributed I/O system for GEM80-500 controllers. An overview of the product and its features
and specification are included in this publication as well as details to enable system Configuration,
Programming, Installation and Commissioning, Maintenance and Fault Finding to be carried out.
The host GEM80 controller Technical Manual should be read in conjunction with this GEMTEQ I/O
Technical Manual. This publication (T2031En) should be regarded as part of the GEMTEQ I/O product. It
should be retained for the life of the product and passed on to any subsequent owner or user.
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GEMTEQ I/O Contents
CONTENTS
Section Page
Acknowledgements.......................................................................................................................................... ii
Issue Information .............................................................................................................................. ii
Safety Instructions ........................................................................................................................... iii
Scope................................................................................................................................................v
Contents ......................................................................................................................................... vii
1. INTRODUCTION.................................................................................................................... 1-1
1.1 THE GEM80 GEMTEQ I/O SYSTEM........................................................................... 1-1
1.2 NETWORK OVERVIEW............................................................................................... 1-2
1.2.1 GEMCAN I/O Scanner............................................................................................ 1-2
1.2.2 GEMTEQ I/O Modules............................................................................................ 1-2
1.3 COMPATIBILITY WITH OTHER GEM80 PRODUCTS ................................................ 1-2
1.4 ASSOCIATED PUBLICATIONS................................................................................... 1-3
2. INTRODUCTION.................................................................................................................... 2-1
2.1 INTRODUCTION TO CAN NETWORKS...................................................................... 2-1
2.2 DATA EXCHANGE TO THE HOST CONTROLLER .................................................... 2-2
3. GEM80 GEMCAN NETWORK............................................................................................... 3-1
3.1 INTRODUCTION.......................................................................................................... 3-1
3.2 GEMCAN I/O SCANNER MODULE ............................................................................. 3-1
3.3 GEMCAN NETWORK CONFIGURATIONS................................................................. 3-3
3.3.1 Slave ...................................................................................................................... 3-4
3.3.2 Standard Master..................................................................................................... 3-5
3.3.3 Redundant Master.................................................................................................. 3-6
3.3.4 Change-Over Master.............................................................................................. 3-7
3.4 DATA EXCHANGE WITH HOST CONTROLLER ........................................................ 3-7
3.5 STATES OF THE HOST GEM80 CONTROLLER........................................................ 3-9
4. GEMCAN I/O SCANNER CONFIGURATION........................................................................ 4-1
4.1 INTRODUCTION.......................................................................................................... 4-1
4.2 GEMCAN I/O SCANNER CONFIGURATION DATA.................................................... 4-1
4.2.1 Validity Flag............................................................................................................ 4-3
4.2.2 Node ID .................................................................................................................. 4-3
4.2.3 Baud Rate .............................................................................................................. 4-4
4.2.4 Port Mode............................................................................................................... 4-4
4.2.5 Master Changeover Time (mS) ............................................................................. 4-5
4.2.6 Maximum Input Delay Time (mS) .......................................................................... 4-6
4.2.7 Maximum Output Delay Time (mS) ....................................................................... 4-6
4.2.8 Split Offset.............................................................................................................. 4-6
4.2.9 Sync Period (mS) .................................................................................................. 4-6
4.2.10 Node Guard Period (mS)....................................................................................... 4-7
4.2.11 Configuration of Optional Diagnostics Data ........................................................... 4-7
5. GEMCAN SPECIAL FUNCTION............................................................................................ 5-1
5.1 INTRODUCTION.......................................................................................................... 5-1
5.2 T114 CANCMD SPECIAL FUNCTION........................................................................ 5-2
5.2.1 Control Language................................................................................................... 5-2
5.2.2 Status Word (Zm) and Rung Output (Q)................................................................. 5-3
5.2.3 Y Rung Input – Module, Port & Node ID Selection................................................. 5-4
5.2.4 X Rung Input - Command....................................................................................... 5-4
6. GEMTEQ I/O MODULES ....................................................................................................... 6-1
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6.1 INTRODUCTION...........................................................................................................6-1
6.2 GEMTEQ I/O MODULES ..............................................................................................6-1
6.2.1 24 V d.c 16-way Input Module, Normal/Inverse Logic (9730) .................................6-1
6.2.2 24 V d.c., 0.5A, 16-way Output Module (9731) .......................................................6-1
6.2.3 110 V a.c. 16-way Input Module (9732) ..................................................................6-1
6.2.4 110 V a.c., 1A, 16-way Output Module (9733) ........................................................6-2
6.2.5 8 In / 8 Out Combination Analogue Module (9734).................................................6-2
6.2.6 Relay, 3A, 16-way Output Module (9735) ...............................................................6-2
6.2.7 4 Channel Counter Module (9736)..........................................................................6-2
6.2.8 16 Input / 8 Output Combination Analogue Module (9737).....................................6-2
6.3 MODULE CONFIGURATION........................................................................................6-3
6.3.1 Node ID ...................................................................................................................6-3
6.3.2 Baud Rate ...............................................................................................................6-4
6.4 CONNECTIONS............................................................................................................6-4
6.4.1 CAN Network Connections .....................................................................................6-4
6.4.2 Power Supply Connections .....................................................................................6-5
6.4.3 Plant I/O Connections .............................................................................................6-5
6.5 MODULE DIAGNOSTICS .............................................................................................6-6
6.5.1 Power Supply LEDs ................................................................................................6-6
6.5.2 OK LED ...................................................................................................................6-6
6.5.3 Communications LEDs............................................................................................6-6
6.6 APPLICATION CONFIGURATION DATA.....................................................................6-7
6.6.1 Input Filter Time ......................................................................................................6-7
6.6.2 PDO Silence Time...................................................................................................6-7
6.6.3 Freeze/Fallback.......................................................................................................6-7
6.6.4 Analog Input – Voltage or Current Input Mode........................................................6-8
6.6.5 Analog Input – 0-20mA or 4-20mA Input Mode.......................................................6-8
7. INSTALLATION AND COMMISSIONING ..............................................................................7-1
7.1 INTRODUCTION...........................................................................................................7-1
7.1.1 Unpacking and Checking the Consignment ............................................................7-1
7.1.2 What to do if something is missing or damaged .....................................................7-1
7.2 STORING GEM80 EQUIPMENT BEFORE INSTALLATION ........................................7-2
7.2.1 Environmental Conditions and Protection ...............................................................7-2
7.3 SITE REQUIREMENTS ................................................................................................7-2
7.3.1 Protection of Equipment from Static Damage .........................................................7-2
7.4 COMMISSIONING GUIDANCE ....................................................................................7-3
7.4.1 Preparation..............................................................................................................7-3
7.4.2 Documents Required ..............................................................................................7-3
7.4.3 Handling Precautions During Setting Up of Equipment ..........................................7-3
7.4.4 Radio Frequency Interference (RFI) .......................................................................7-4
8. MAINTENANCE AND FAULT FINDING.................................................................................8-1
8.1 GENERAL GUIDANCE FOR MAINTENANCE .............................................................8-1
8.2 FAULT TABLE DATA....................................................................................................8-1
8.2.1 Module P-Table Configuration Data Errors .............................................................8-2
8.2.2 Communications Statistics ......................................................................................8-4
8.2.3 Node Presence .......................................................................................................8-5
8.3 DIAGNOSTICS DATA...................................................................................................8-5
8.3.1 Node Data (Px+23-24, Px52-P53) ..........................................................................8-5
8.3.2 Input PDO Fault Data..............................................................................................8-6
8.3.3 Output PDO Fault Data ...........................................................................................8-7
8.4 REPAIRS TO GEM80 EQUIPMENT.............................................................................8-8
8.5 FAULT FINDING BACK-UP AND MODULE REPAIR SERVICE ..................................8-8
8.6 DISPOSAL ....................................................................................................................8-9
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APPENDIX A GEM80-500 GEMCAN I/O SCANNER : MODULE 1 DATA SUMMARY............1
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LIST OF FIGURES
Figure 2-1 Network Cabling between 4 Nodes ....................................................................................2-1
Figure 2-2 GEMCAN I/O Scanner Data Exchange with Host PLC......................................................2-2
Figure 3-1 Simple GEMTEQ I/O Network ............................................................................................3-1
Figure 3-2 9720-4020 GEMCAN I/O Scanner Module ........................................................................3-1
Figure 3-3 9720-4020 GEMCAN I/O Scanner Port Identification and Configuration...........................3-2
Figure 3-4 GEMCAN I/O Scanner – Slave Operation..........................................................................3-4
Figure 3-5 GEMCAN I/O Scanner – Master Operation........................................................................3-5
Figure 3-6 GEMCAN I/O Scanner – Redundant Master Operation.....................................................3-6
Figure 3-7 GEMCAN I/O Scanner – Change-over Master Operation..................................................3-7
Figure 6-1 CAN Network Connections – Middle of Link ......................................................................6-4
Figure 6-2 CAN Network Connections – End of Link...........................................................................6-5
Figure 6-3 GEMTEQ I/O Module – Power Supply Connections.........................................................6-5
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LIST OF TABLES
Table 3-1 C/D-Table Allocation – Node ID 1...................................................................................... 3-9
Table 4-1 P-Tables reserved for GEMCAN I/O Scanner Configuration Data.................................... 4-1
Table 4-2 GEMCAN I/O Scanner - Node ID Selection....................................................................... 4-3
Table 4-3 GEMCAN I/O Scanner - Baud Rate Selection & Maximum Bus Length ........................... 4-4
Table 4-4 GEMCAN I/O Scanner - Operating Mode.......................................................................... 4-4
Table 4-5 GEMCAN I/O Scanner – Port Sub Mode........................................................................... 4-5
Table 4-6 Default Node Guard Period................................................................................................ 4-7
Table 5-1 CANCMD - Program Rung Data........................................................................................ 5-2
Table 5-2 CANCMD - Value Data ...................................................................................................... 5-2
Table 5-3 CANCMD – Status Word and Rung Output Values........................................................... 5-3
Table 5-4 CANCMD – Command Data.............................................................................................. 5-4
Table 6-1 GEMTEQ I/O Modules ....................................................................................................... 6-1
Table 6-2 GEMTEQ I/O Module – Node ID Selection........................................................................ 6-3
Table 6-3 GEMTEQ I/O Module - Baud Rate Selection..................................................................... 6-4
Table 6-4 GEMTEQ I/O Module – OK LED........................................................................................ 6-6
Table 8-1 GEMCAN I/O Scanner - F-Table Fault Data...................................................................... 8-1
Table 8-2 GEMCAN I/O Scanner Module Configuration Errors......................................................... 8-2
Table 8-3 Configuration Error Codes ................................................................................................. 8-3
Table 8-4 Communications Statistics................................................................................................. 8-4
Table 8-5 Node Presence .................................................................................................................. 8-5
Table 8-6 Node Data .......................................................................................................................... 8-5
Table 8-7 Input PDO Fault Data......................................................................................................... 8-6
Table 8-8 Output PDO Fault Data...................................................................................................... 8-7
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GEMTEQ I/O 1. Introduction
1. INTRODUCTION
GEMTEQ is a generation of distributed I/O modules specifically for the GEM80-500 range of
programmable logic controllers. Designed as the interface between the plant and the GEM80
controller, the complete modular family provides a flexible, simple and intelligent device.
GEMTEQ I/O is designed with advanced features and functions making them intelligent and
capable, yet easy and intuitive to use. GEMTEQ’s diagnostics and ability to use dual networks
and redundant/changeover masters makes it ideal where high availability, high reliability
architecture is required.
Features
●I/O wherever you need it
- Local to PLC or
- Distributed I/O
●Modular and scaleable architecture
●Redundant PLC and high availability configurations
●Cost efficient solutions
- Fast installation
- Reduced wiring
●GEMTEQ I/O can save system builders and end users considerable time and money
●Quick connect wiring
●Distributed I/O modules
●Redundant link capability
●125 modules per scanner module
●Dual Network Ports
●Each link independently configurable
●Scanner can be configured as master, slave, redundant, change over
●Network length up to 5000 metres
●In current mode configurable 0-20ma or 4-20ma
●Communication speed up to 1M baud
●Digital inputs configurable DBounce time
●Freeze/Fallback configuration on output on a per I/O point basis
1.1 THE GEM80 GEMTEQ I/O SYSTEM
Converteam’s distributed I/O module system provides the latest in compact flexibility allowing the
user to install the required amount of I/O where it is required.
●Redundant link capability allows the user to change modules without shutting down their
machine, optimising productivity and minimising downtime.
●Extensive diagnostics make identifying faults a matter of routine maximising up-time.
●Dual network ports.
●Redundant cabling – I/O modules will always be connected to minimise downtime.
●Module freeze/fall back facility on loss of communications.
●Distributed plant – modules where you require them
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GEMTEQ I/O 1. Introduction
1.2 NETWORK OVERVIEW
Each GEMTEQ I/O system consists of GEMCAN I/O Scanner module fitted in a host GEM80-500
PLC, GEMTEQ slave I/O modules, with the option of GEM80-500 PLC as slave devices.
1.2.1 GEMCAN I/O Scanner
The GEMCAN I/O scanner fits into the GEM80-500 controller to provide the interface to the
GEMTEQ I/O system.
●Up to 125 nodes per scanner
●2 ports per scanner
●2 scanners per host PLC
1.2.2 GEMTEQ I/O Modules
●Advanced diagnostics and embedded LED I/O indicators speed up troubleshooting and
increase productivity.
●Hot-swap minimises downtime by allowing failed I/O modules to be changed without shutting
down the plant.
●Convenient rotary switches are used for setting bus address and baud rate therefore no
programming required.
●Removable wiring connectors save time and speed up commissioning.
●DIN rail mounting – no special tools required.
●Configurable digital DBounce and analogue filter times.
1.3 COMPATIBILITY WITH OTHER GEM80 PRODUCTS
GEMTEQ I/O is only available on the GEM80-500 Series of Controllers. This functionality was
added in the following software releases:-
00S172-4002 Issue “C”
00S203-4001 Issue “E”
For further assistance please contact Customer Support.
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GEMTEQ I/O 1. Introduction
1.4 ASSOCIATED PUBLICATIONS
CONVERTEAM Publications associated with this technical manual are now listed.
T391 GEM80 Ladder Diagram Language Programming Manual
This manual provides a competent user, who is familiar with programming
GEM80 controllers, details for all aspects of programming, including the
language, the Standard Instruction Set and all the GEM80 Special Functions. It
does not include some Additional Instructions which are used for the GEM80-
400 and 500 Series Controllers that are described in the GEM80-400 manual.
T2025En GEM80-500 Series Controllers Technical Manual
This manual provides a competent user who is familiar with GEM80 controllers
details for the installation, commissioning, operation and maintenance of the
GEM80-500 Series Controllers. It includes some software details which are
cross-referenced from the GEM80-400 manual.
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GEMTEQ I/O 2. Introduction to CAN Networks
2. INTRODUCTION
The GEMCAN network is based on the CANopen communication model and uses standard CAN
hardware and cabling.
The CANopen standard consists of an addressing scheme, several small communication
protocols and an application layer defined by a device profile. The communication protocols have
support for network management, device monitoring and communication between nodes.
CAN_H
CAN_L
Gnd
CAN_H
CAN_L
Gnd
CAN_H
CAN_L
Gnd
CAN_H
CAN_L
Gnd
Figure 2-1 Network Cabling between 4 Nodes
2.1 INTRODUCTION TO CAN NETWORKS
Modules on the CAN network must have a unique node address. One node (NMT Master) is
responsible for issuing all the relevant commands to take all the other nodes on the network to an
“operational” state.
Data transfer on a CANopen network is via a Producer and Consumer architecture. Each data
packet has a unique identifier, with each node seperatley configured to define which
packet/packets it will Produce and Consume. This allows a large flexibility in which modules can
talk to each other, but also requires a complex configuration procedure.
There are two types of data packets:
•PDO (Process Data Objects)
•SDO (Service Data Object )
PDO have a high priority for system data exchange and can contain up to 8 bytes of data. The
size and number of PDO’s a module will use on the network is variable and described by the
module hardware profile.
SDO have a low priority and are used for module configuration and can contain more than 8
bytes.
GEMTEQ has simplified the configuration of the CAN network with the introduction of a
theoretical master slave architecture.
When a master scanner module is declared on a GEMTEQ system it will not only perform all the
functions of an NMT master .i.e. ensuring all slaves are taken to the operational state, but will
also become the hub of all message transfers. It will produce all of the slaves consumed PDO’s
and consume of all the slaves produced PDO’s. The mapping between data within the GEM80-
500 controller and the slave modules is a simple correlation between the Node address and the
controllers C/D tables see Appendix A.
Note: There is not facility for a slave module to transfer date directly to another slave module.
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GEMTEQ I/O 2. Introduction to CAN Networks
Slave GEMTEQ modules have a fixed size and number of PDO’s assigned to each module.
There are 16 C/D tables (a maximum of 4 transmit and receive PDO’s) per node ID.
Any configuration data for the module is included within the 16 words of output PDO data, the
GEMTEQ network does not use SDO’s to configure slave modules.
To reduce the network traffic on the GEMTEQ link, data is only normally transmitted when data
changes. A slave input module will transmit data to the GEMTEQ scanner module when it detects
an input change. The scanner will transmit data to a slave output module when it detects that the
output data PDO has changed within the scanner module.
2.2 DATA EXCHANGE TO THE HOST CONTROLLER
The GEMCAN I/O Scanner module resides in the host PLC and provides an interface between
the PLC and the module’s two CAN communication ports. Typically before the host PLC Ladder
Scan, data is transferred between the GEMCAN I/O Scanner module and the host Data Table
memory. At the end of the host Ladder Scan, data is transferred from the host Data Table
memory to the GEMCAN I/O Scanner for transmission on the CAN network. Transfer depends on
the scanner sub mode as detailed in section 4.2.4.2.
GEMCAN I/O Scanner
Module 1
Host GEM80 Controller
Ladder
Scan
Data
Table
Memory
2
3
4
15
Port BPort A
Figure 2-2 GEMCAN I/O Scanner Data Exchange with Host PLC
1 - Slave devices transmit their data to the GEMCAN I/O Scanner, as and
when the Input data from the plant changes
2 - At the beginning of the Ladder Scan, new Input data is transferred from the
GEMCAN I/O Scanner to the Host PLC Data Table memory
3 - During the Ladder Scan data is read from/ written to the Data Table
memory
4 - At the end of the Ladder Scan, Output data is transferred from the Data
Table memory, to the GEMCAN I/O Scanner.
5 - If the Output data has changed for a given Slave device, then new Output
data is transmitted to that Slave via the CAN network
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