OPTO 22 SNAP-PAC-R1 User manual

SNAP PAC R-SERIES
CONTROLLER
USER’S GUIDE
SNAP-PAC-R1
SNAP-PAC-R2
SNAP-PAC-R1-FM
SNAP-PAC-R2-FM
SNAP-PAC-R1-W
SNAP-PAC-R2-W
Form 1595

SNAP PAC R-SERIES CONTROLLER
USER’S GUIDE
SNAP-PAC-R1
SNAP-PAC-R2
SNAP-PAC-R1-FM
SNAP-PAC-R2-FM
SNAP-PAC-R1-W
SNAP-PAC-R2-W
Form 1595-131202—December 2013
43044 Business Park Drive • Temecula • CA 92590-3614
Phone: 800-321-OPTO (6786) or 951-695-3000
Fax: 800-832-OPTO (6786) or 951-695-2712
www.opto22.com
Product Support Services
800-TEK-OPTO (835-6786) or 951-695-3080
Fax: [phone]
Email: [e-mail]
Web: support.opto22.com

SNAP PAC R-Series Controller User’s Guide
iv
SNAP PAC R-Series Controller User’s Guide
Form 1595-131202—December 2013
Copyright © 2008–2012 Opto 22.
All rights reserved.
Printed in the United States of America.
The information in this manual has been checked carefully and is believed to be accurate; however, Opto 22 assumes no
responsibility for possible inaccuracies or omissions. Specifications are subject to change without notice.
Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the
manufacturing date code. This warranty is limited to the original cost of the unit only and does not cover installation, labor,
or any other contingent costs. Opto 22 I/O modules and solid-state relays with date codes of 1/96 or newer are guaranteed
for life. This lifetime warranty excludes reed relay, SNAP serial communication modules, SNAP PID modules, and modules
that contain mechanical contacts or switches. Opto 22 does not warrant any product, components, or parts not
manufactured by Opto 22; for these items, the warranty from the original manufacturer applies. These products include,
but are not limited to, OptoTerminal-G70, OptoTerminal-G75, and Sony Ericsson GT-48; see the product data sheet for
specific warranty information. Refer to Opto 22 form number 1042 for complete warranty information.
Wired+Wireless controllers and brains and N-TRON wireless access points are licensed under one or more of the following
patents: U.S. Patent No(s). 5282222, RE37802, 6963617; Canadian Patent No. 2064975; European Patent No. 1142245;
French Patent No. 1142245; British Patent No. 1142245; Japanese Patent No. 2002535925A; German Patent No. 60011224.
Opto 22 FactoryFloor, groov, Optomux, and Pamux are registered trademarks of Opto 22. Generation 4, groov Server,
ioControl, ioDisplay, ioManager, ioProject, ioUtilities, mistic, Nvio, Nvio.net Web Portal, OptoConnect, OptoControl,
OptoDataLink, OptoDisplay, OptoEMU, OptoEMU Sensor, OptoEMU Server, OptoOPCServer, OptoScript, OptoServer,
OptoTerminal, OptoUtilities, PAC Control, PAC Display, PAC Manager, PAC Project, SNAP Ethernet I/O, SNAP I/O, SNAP OEM
I/O, SNAP PAC System, SNAP Simple I/O, SNAP Ultimate I/O, and Wired+Wireless are trademarks of Opto 22.
ActiveX, JScript, Microsoft, MS-DOS, VBScript, Visual Basic, Visual C++, Windows, and Windows Vista are either registered
trademarks or trademarks of Microsoft Corporation in the United States and other countries. Linux is a registered
trademark of Linus Torvalds. Unicenter is a registered trademark of Computer Associates International, Inc. ARCNET is a
registered trademark of Datapoint Corporation. Modbus is a registered trademark of Schneider Electric. Wiegand is a
registered trademark of Sensor Engineering Corporation. Nokia, Nokia M2M Platform, Nokia M2M Gateway Software, and
Nokia 31 GSM Connectivity Terminal are trademarks or registered trademarks of Nokia Corporation. Sony is a trademark of
Sony Corporation. Ericsson is a trademark of Telefonaktiebolaget LM Ericsson. CompactLogix, MicroLogix, SLC, and RSLogix
are trademarks of Rockwell Automation. Allen-Bradley and ControlLogix are a registered trademarks of Rockwell
Automation. CIP and EtherNet/IP are trademarks of ODVA.
groov includes software developed by the OpenSSL Project for use in the OpenSSL Toolkit. (http://www.openssl.org)
All other brand or product names are trademarks or registered trademarks of their respective companies or organizations.
Opto 22
Automation Made Simple.

SNAP PAC R-Series Controller User’s Guide v
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Table of Contents
Chapter 1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wired+Wireless Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I/O Mounting Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SNAP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About this Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What You Will Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installing Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installing Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing Modules on the Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
What’s Next?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Configuring I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Using PPP Over a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Configuring PPP on the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Attaching the Modem to a SNAP PAC R-Series Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Configuring Microsoft Windows Dial-up Networking on Windows XP . . . . . . . . . . . . . . . . . .14
Chapter 3: System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Simultaneous Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accessing SNAP R-Series Controllers over the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Choosing Communication Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
System Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Understanding the SNAP PAC R-series Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The I/O Side of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The Control Side of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Controlling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using Data for Peer-to-Peer Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Communicating with Enterprise Systems and Third-Party Software . . . . . . . . . . . . . . . . . . . . 24
The Complete System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting the Controller Directly to a PC or Master Controller . . . . . . . . . . . . . . . . . . . . . . . 27
Crossover Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Attaching the Controller to an Existing Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Segmenting the Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Using the Controller in an Independent Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Communicating with the System via Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Using the Controller in a Wireless LAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Network Architecture Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Basic Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Network Segmenting: Wired and Wireless Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Network Segmenting: Ethernet Connections to Host and I/O Units . . . . . . . . . . . . . . . . 33
Ethernet Link Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Specifications, Connectors, and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connectors and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connectors and LEDs—Wired+Wireless Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dimensions for Wired+Wireless Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Information on Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Digital Point Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Analog Point Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
PID Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SNAP-PAC-R1 and -R2 Comparison Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 4: Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Maintaining the SNAP PAC R-Series Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Changing the Controller’s IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Loading New Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Resetting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Using the MicroSD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Card Type and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MicroSD Card Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Storing and Accessing Data or Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Displaying Free Space on the Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking Firmware and Loader Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Replacing a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Updating Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Booting from Firmware on the Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Updating, Running, or Testing a Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Disabling or Enabling Firmware and Strategy Updates Via the Card . . . . . . . . . . . . . . . .65
Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
STAT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
PPP LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
232 LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
WLAN LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Troubleshooting the SNAP PAC R-Series Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Getting Device and Firmware Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Communicating with the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Pinging the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Accessing the Controller with PAC Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Solving Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Additional Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Making Sure the Controller is in Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TCP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Troubleshooting I/O Modules: Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SNAP Digital Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SNAP Analog Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix: SNAP Mounting Racks and Power Supplies . . . . . . . . . . . . . . . . . . . .79
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SNAP PAC Mounting Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SNAP Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Primary Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Determining Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Wiring the Primary Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Loop Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

SNAP PAC R-Series Controller User’s Guide
viii

SNAP PAC R-Series Controller User’s Guide 1
1
Chapter 1
1: Overview
Introduction
The affordable and compact SNAP PAC R-series
programmable automation controllers provide
powerful, real-time control and communication to
meet your industrial control, monitoring, and data
acquisition needs. Part of the Opto 22 SNAP PAC
System
™
, the R-series PAC is a rack-mounted,
industrially hardened unit that can handle
multiple tasks involving digital and analog control,
serial string handling, communication, and
enterprise connectivity.
Used with the included PAC Project Basic software
suite (or PAC Project Professional, purchased
separately), the Ethernet-based SNAP PAC R-series controller runs control programs written
in Opto 22’s PAC Control
™
software. It can monitor and control a wide range of devices and
equipment wired to the I/O on its own rack and to I/O on distributed racks equipped with
SNAP PAC EB-series brains. Alternatively, the R-series controller can be used as a slave to a
larger, SNAP PAC S-series standalone industrial controller.
SNAP PAC R-series controllers are well suited to original equipment manufacturers (OEMs),
system integrators, and end-users in process control, discrete manufacturing, or hybrid
industries and applications.
Six models of the SNAP PAC R-series controller are available:
• SNAP-PAC-R1, SNAP-PAC-R1-FM, and SNAP-PAC-R1-W each control a mix of SNAP
analog, digital (both standard and high-density), and serial modules. Full digital
functions include high-speed counting, quadrature counting, pulse measurement, and
period and frequency measurement. The -FM model is Factory Mutual approved. The
-W model adds wireless LAN capability (see “Wired+Wireless Communication” on
page 2 for more information).
• SNAP-PAC-R2,SNAP-PAC-R2-FM, and SNAP-PAC-R2-W also control a mix of SNAP
analog, standard and high-density digital, and serial modules. High-speed digital
SNAP-PAC-R1 controller

INTRODUCTION
SNAP PAC R-Series Controller User’s Guide
2
functions are not included. The -FM model is Factory Mutual approved. The -W model
adds wireless LAN capability (see page 2 for more information).
Built-in functions and comparisons of the SNAP-PAC-R1 and SNAP-PAC-R2 are shown in the
table on page 44.
Ethernet Communication
All SNAP PAC R-series controllers communicate over standard 10/100 Mbps Ethernet
networks and can be attached to an existing network. The controllers can also be used in an
independent control network built with standard, off-the-shelf Ethernet hardware.
SNAP PAC R-series controllers include two 10/100 Mbps Ethernet interfaces for networking
to Ethernet hosts and to other I/O units. These independent Ethernet ports have separate IP
addresses that can be used with PAC Project
™
Professional software to set up redundant
network links to safeguard the availability and reliability of an I/O system, or to segment a
control system’s network from the enterprise LAN.
Supported protocols over Ethernet include EtherNet
™
/IP, Modbus
®
/TCP, SMTP, SNMP, FTP,
and OptoMMP.
Wired+Wireless Communication
SNAP-PAC-R1-W and SNAP-PAC-R2-W controllers add wireless capability to
communications. In addition to the two wired network interfaces, these models have a
wireless network interface as well, so each PAC has a total of three separate IP
addresses—two wired and one wireless. Wired+Wireless PAC can be
used wirelessly or on a wired network, or both at once.
For flexibility in designing your wireless network, wireless
communication includes support for 802.11a, b, and g standards.
Wired+Wireless PACs can be used with a variety of wireless switches
and other infrastructure hardware. For the best security, the 802.11i
WPA2/AES standard is supported, while older WPA and WEP security
standards are included for backwards compatibility.
Because wireless functionality is in the PAC itself, no additional parts
are required within the control system for wireless use. All SNAP
PAC racks and SNAP I/O modules can be used either wired
or wirelessly. You can switch from one network to the other
without reconfiguring I/O or changing field wiring.
Just like a laptop computer with a wireless connection, all
functionality remains the same whether the
Wired+Wireless PAC is used wirelessly or as part of a wired
network. Supported protocols remain the same. And
control programs run the same on both networks without
reprogramming.

CHAPTER 1: OVERVIEW
SNAP PAC R-Series Controller User’s Guide 3
3
Serial Communication
SNAP PAC R-series controllers provide an RS-232 serial link to support Point-to-Point
Protocol (PPP) modem connections—for creating TCP/IP networks over serial or PSTN
(Public Switched Telephone Network) lines—as well as remote serial device
communication.
The RS-232 serial interface supports either a modem connection using PPP or
general-purpose communication with serial devices, allowing you to send and receive data
from a serial device connected directly to the controller. For additional serial interfaces, you
can add one or more SNAP serial communication modules on the rack.
NOTE: The R-series controller does not include an RS-485 port and cannot be used to control
Opto 22 serial I/O processors, such as the SNAP PAC SB-series brains. Use an S-series controller for
serial brains.
I/O Mounting Racks
SNAP PAC R-series controllers must be connected to the appropriate rack to avoid damage
to the controller. Both the SNAP-PAC-R1 and R2 are designed to work with SNAP PAC
mounting racks, which are available with 4, 8, 12, or 16 positions for Opto 22 SNAP I/O
modules. Part numbers are SNAP-PAC-RCK4, SNAP-PAC-RCK8, SNAP-PAC-RCK12, and
SNAP-PAC-RCK16. Factory Mutual-approved versions of these racks, with part numbers
ending in -FM, are also available.
SNAP I/O
The SNAP PAC R-series controllers support all SNAP I/O modules available on our website.
SNAP digital I/O modules contain four input or output points, and SNAP high-density digital
modules contain 16 or 32 input or output points. SNAP analog modules contain 2 to 32
points, depending on the module.
Software
SNAP PAC controllers use Opto 22’s PAC Project Microsoft
®
Windows
®
-compatible
automation software for programming, human-machine-interface (HMI) development, and
OPC connectivity.
Two versions of PAC Project are available:
•PACProjectBasicincludes PAC Control™ for developing control programs, PAC
Display
™
for creating operator interfaces, and PAC Manager™ configuration software.
• PAC Project Professional adds expanded versions of
PAC Control and PAC Display plus
OptoOPCServer
™
software for exchanging data with OPC 2.0-compliant client software
applications and OptoDataLink
™
for exchanging SNAP PAC System data with databases
(including Microsoft SQL Server, Microsoft Access, and MySQL), text files, and email
systems).

INTRODUCTION
SNAP PAC R-Series Controller User’s Guide
4
PAC Control Basic is a graphical, flowchart-based programming tool for machine control
and process applications. Using PAC Control, you create, download, and run strategies on a
SNAP PAC controller. In addition to flowchart programming with subroutine capability,
PAC Control includes a powerful, built-in scripting language based on C and other
procedural languages. PAC Control Professional adds the ability to import legacy
OptoControl strategies, support for older mistic™ serial I/O units, and support for the dual
independent Ethernet ports on a SNAP PAC controller. A SNAP R-series controller
simultaneously runs up to 16 PAC Control flowcharts, although the PAC Control strategy can
actually contain a much larger number of flowcharts. The total number of flowcharts is
limited only by the memory available for strategy storage.
PAC Display Basic is an intuitive HMI package for building operator interfaces, or projects,
for communicating with a SNAP PAC controller. PAC Display offers a full-featured HMI
including alarming, trending, and a built-in library of 3,000 industrial automation graphics.
PAC Display Professional adds the ability to import projects created in OptoDisplay, part
of the legacy Opto 22 FactoryFloor
®
software suite, and using redundant Ethernet
communication links on SNAP PAC controllers. PAC Display Professional can also connect to
Ethernet-based FactoryFloor controllers running OptoControl strategies.
OptoOPCServer is a fast, efficient OPC 2.0-compliant server for communicating with many
Opto 22 products, including SNAP PAC controllers and I/O units, plus legacy Opto 22
Ethernet-based controllers and I/O. Using OptoOPCServer, you can consolidate data from all
these Opto 22 systems into the OPC client software of your choice, such as third-party HMI
and data acquisition packages, and custom software applications you create with tools such
as Visual C++
®
.
OptoDataLink is a software application that makes it easy to share data from the SNAP PAC
System with commonly used databases, including Microsoft SQL Server, Microsoft Access,
and MySQL, as well as text files. The I/O points and strategy variables already created in your
PAC Control strategy are automatically available for OptoDataLink to use for data exchange.
PAC Manager is a utility application for assigning IP addresses to SNAP PAC controllers and
brains, reading or changing basic controller configuration, and configuring and testing I/O.
Software Availability
PAC Project Basic is included with SNAP PAC controllers and is a free download from the
Opto 22 website.
PAC Project Professional is available for purchase on our website. To get it immediately, you
can buy and download the software from the Opto 22 website at www.opto22.com; the CD
and printed documentation will be shipped to you. You can also separately purchase
PAC Control Professional, PAC Display Professional, OptoOPCServer, and OptoDataLink as
needed. For additional information, see the PAC Project data sheet, Opto 22 form #1699.

CHAPTER 1: OVERVIEW
SNAP PAC R-Series Controller User’s Guide 5
5
About this Guide
This guide shows you how to install and use SNAP PAC R-series controllers. This guide
assumes that you have some familiarity with TCP/IP and Ethernet networking, and also with
wireless networking if you are using wired+wireless models. If you are not familiar with
these subjects, we strongly suggest you consult commercially available resources to learn
about them before attempting to install or use SNAP PAC R-series controllers.
If you are using Modbus/TCP for communicating with SNAP PAC R-series controllers, this
guide assumes that you are already familiar with Modbus/TCP. See the Modbus/TCP Protocol
Guide, form #1678, for additional information.
If you are using EtherNet/IP for communication, you should already be familiar with
EtherNet/IP. See the EtherNet/IP for SNAP PAC Protocol Guide, form #1770.
The following sections are included in this user’s guide:
Chapter 1: Overview—information about the guide and how to reach Opto 22 Product
Support.
Chapter 2: Installation—quick-start steps to get SNAP PAC R-series controllers up and
running quickly.
Chapter 3: System Information—conceptual information on networking and
communicating with SNAP PAC R-series controllers; descriptions of features, capabilities,
and specifications for SNAP PAC R-series controllers.
Chapter 4: Maintenance and Troubleshooting—assigning and changing IP addresses,
resetting the controller to factory defaults, upgrading firmware, and tips for resolving
difficulties you may encounter while working with SNAP PAC R-series controllers.
Appendix: SNAP Mounting Racks and Power Supplies— wiring diagram examples for
assembling your SNAP PAC R-series controller, SNAP PAC rack, and power supply.
Related Documentation
See the following documents for additional information:
For this information See this guide Form #
Configuring I/O points and system functions PAC Manager User’s Guide 1704
Designing flowchart-based control programs for the
system
PAC Control User’s Guide 1700
PAC Control Command Reference 1701
PAC Control Commands Quick Reference
Card 1703
Communicating with I/O units using OPC OptoOPCServer User’s Guide 1439
Communicating with I/O units using Modbus/TCP Modbus/TCP Protocol Guide 1678
Communicating with I/O units using EtherNet/IP EtherNet/IP for SNAP PAC Protocol Guide 1770

FOR HELP
SNAP PAC R-Series Controller User’s Guide
6
All of this documentation is on the CD that came with the controller; all forms are also
available on our website (www.opto22.com) for downloading. The easiest way to find one
is to search on the form number.
For Help
If you have problems installing or using SNAP PAC R-series controllers and cannot find the
help you need in this guide or on our website, contact Opto 22 Product Support.
Phone: 800-TEK-OPTO (800-835-6786)
951-695-3080
(Hours are Monday through Friday,
7 a.m. to 5 p.m. Pacific Time)
Fax: [phone]
Email: [e-mail]
Opto 22 website: www.opto22.com
When calling for technical support, be prepared to provide the following information about
your system to the Product Support engineer:
•Software and version being used
•Controller firmware version
•PC configuration (type of processor, speed, memory, and operating system)
•A complete description of your hardware and operating systems, including:
– loader and kernel versions for the controller, and date codes of controllers (available
through PAC Manager). See page 68.
– IP addresses and net masks for devices on the system
– type of power supply
– third-party devices installed (for example, barcode readers)
•Specific error messages seen.
Programming your own applications for R-series PACs
usingthe OptoMMP Communication Toolkit(previously
called the SNAP Ethernet I/O Driver Toolkit) or the
OptoMMP memory-mapped protocol
OptoMMP Protocol Guide 1465
For this information See this guide Form #
NOTE: Email messages and
phone calls to Opto 22 Product
Support are grouped together
and answered in the order
received.

SNAP PAC R-Series Controller User’s Guide 7
7
Chapter 2
2: Installation
If you already know how you will use the SNAP PAC R-series controller and want to get it
running quickly, follow the sections in this chapter.
To learn about communication options and networking, start on page 17. Specifications are
listed on page 35.
What You Will Need
You’ll need the following items to install a SNAP PAC R-series controller:
•PC running Microsoft
®
Windows
®
2000 or higher, with a 10/100 MB Ethernet adapter
card, the TCP/IP protocol installed, and a valid IP address, on the same subnet as the
controller. (For more information, see “Networking” on page 27.)
•Crossover cable (for direct connection to the PC), or an available connection to a
standard 10BASE-T or 100BASE-TX Ethernet network. (NOTE: Wired+wireless models
must be configured on a wired network before being used on a wireless network.)
•SNAP PAC R-series controller
•SNAP PAC mounting rack and SNAP I/O modules. Choose rack and modules based on
your needs.
•A SNAP-PS5 or SNAP-PS5U power supply or other 5 VDC power supply (5.0 to 5.2 VDC
at 4.0 A) applied to the rack. Additional power may be required for SNAP I/O modules
and depends on the number and type of modules used. For more information, see
“Determining Power Requirements” on page 80.
Installing Software
In your CD-ROM drive, insert the CD that came with the controller. The installation wizard
should start automatically. If it doesn’t, use Windows Explorer to navigate to your CD-ROM
drive and then double-click setup.exe. Follow directions to install the software.

INSTALLING HARDWARE
SNAP PAC R-Series Controller User’s Guide
8
NOTE: If you run PAC Project applications in Microsoft Windows XP, make sure you have Service
Pack 3 installed. Otherwise, a Microsoft bug may cause the system to crash. See OptoKB article
#KB49838 for details.
Installing Hardware
Assemble the rack and power supply according to the directions that came with them. For
help with wiring, see the product data sheets, which are available on our website at
www.opto22.com.
Installing Modules on the Rack
CAUTION: Make sure you are using a SNAP PAC rack for your SNAP PAC R-series controller. Using
the wrong rack will severely damage the controller.
Modules snap into any position in the row of connectors on the SNAP PAC rack. Each
module connector has a number.
NOTE: R-series controllers with serial numbers lower than 600,000 are limited to eight 4-channel
digital modules per rack, located in the first eight positions.
1. Place the rack so that the module connector numbers are right-side up, with zero on
the left.
2. Position the module over the module connector, aligning the small slot at the base of
the module with the retention bar on the rack.
Controller
connector
Module
position zero
Controller connector
Module connectors

CHAPTER 2: INSTALLATION
SNAP PAC R-Series Controller User’s Guide 9
9
3. With the module correctly aligned
over the connector, push on the
module to snap it into place.
When positioning modules next
to each other, be sure to align the
male and female module keys
(shown in the detailed view in the
illustration at right) before
snapping a module into position.
Modules snap securely into place
and require a special tool
(provided) to remove them. To
remove a module, see the next
section.
4. (Optional) Use standard 4-40 x 1/4
truss-head Phillips hold-down
screws to secure both sides of each module. Do not over-tighten screws.
5. Plug the wiring connector into each module to attach modules to the devices they
monitor.
See the wiring diagrams in the module’s data sheet.
6. Continue with “Installing the Controller” on page 10.
Removing a Module
1. If the modules are held in place with
screws, remove them.
2. Holding the SNAP module tool
(provided) as shown in the illustration
at right, insert it into the notch at the
base of the module.
3. Squeeze the module tool against the
module to open the release latch, and
pull straight up on the module to
remove it.
Optional hold-
down screws
Module keys

INSTALLING HARDWARE
SNAP PAC R-Series Controller User’s Guide
10
Installing the Controller
CAUTION: Make sure you are using a SNAP PAC rack for your SNAP PAC R-series controller. (Legacy
SNAP M-series racks can also be used.) Using the wrong rack will severely damage the controller.
1. Remove the controller from its
packaging.
2. Turn off power to the rack assembly.
3. Align the controller connector with the
mating connector on the mounting
rack.
4. Seat the controller onto the connector
and use the hold-down screw to secure
the controller in position. Torque: 8
lbf-in (0.9 N-m). Do not overtighten.
5. Using Category 5 or superior solid
unshielded twisted-pair cable, connect
the controller in one of the following ways:
– (Recommended for initial configuration) Connect to a PC directly, using an Ethernet
crossover cable.
NOTE: Wired+wireless models must be configured using a wired network before they can be
used on a wireless network.
NOTE: If you use a crossover cable, make sure to assign a fixed IP address to the network card
(NIC)on your computer. Otherwise, if your network card is configured to get its IP address via
DHCP, when you unplug the computer from the network, the computer will no longer have
an IP address. When you are finished using the crossover cable, you can change the setting
back to DHCP.
– Connect to a standard 10BASE-T or 100BASE-TX Ethernet network that has a PC on
the same subnet as the controller and does NOT have a Dynamic Host
Configuration Protocol (DHCP) server.
NOTE: When connecting the contoller to a managed switch, make sure the managed
switch's port configuration is set to Auto for the Duplex setting and Auto for the Speed setting.
Maximum cable or segment length is 100 meters; minimum cable length is one meter.
For more information on cables, see page 27.
6. For controllers used with a modem: Follow the steps in “Using PPP Over a Modem”
on page 12.
7. See the Appendix (page 79) for information on power supplies and wiring.
8. Before turning on power to the rack, follow instructions in Opto 22 form #1704, the
PAC Manager User’s Guide, to assign an IP address to the controller (required for both
standard and wired+wireless models). The PAC Manager Guide is in Adobe Acrobat

CHAPTER 2: INSTALLATION
SNAP PAC R-Series Controller User’s Guide 11
11
PDF format on the CD that came with the controller and is also available from our
website, www.opto22.com.
What’s Next?
To start configuring controllers and I/O points, see “Configuring I/O,” below.
To learn more about SNAP PAC R-series controller capabilities and network options, see
Chapter 3: System Information.
To create PAC Control strategies to run on the controller, see the PAC Control User’s Guide and
the PAC Control Command Reference. Both are available in PDF format on the CD that came
with the controller and on our website, www.opto22.com.
To work with the following items on the controller, see instructions in the PAC Manager
User’s Guide:
•File system and FTP
•Security settings
•Port and interface configuration, including wireless communication for a
wired+wireless model
To use OLE for process control (OPC) with SNAP PAC R-series controllers, purchase
OptoOPCServer and see Opto 22 form #1439, the OptoOPCServer User’s Guide.
To communicate with controllers using Modbus/TCP, see the Modbus/TCP Protocol Guide,
form #1678.
To communicate with an Allen-Bradley Logix PLC or other system using EtherNet/IP, see the
EtherNet/IP for SNAP PAC Protocol Guide, form #1770.
To program your own applications, see Opto 22 form #1465, the OptoMMP Protocol Guide.
Configuring I/O
No matter how you communicate with SNAP PAC R-series controllers, you will need to
configure I/O points and controller features.
If you are not using PAC Control (Opto 22’s flowchart-based control software), follow
instructions in the PAC Manager User’s Guide (Opto 22 form #1704).
If you are using PAC Control, I/O units and points must be configured to match the PAC
Control strategy you will run. You can configure most controller features and point
functions either in PAC Control or in PAC Manager.
In most cases, if you are already in PAC Control, configuration is easier there and you can use
the loopback IP address for SNAP PAC R-series controllers controlling themselves. However,
some functions cannot be configured in PAC Control.
If you use PAC Manager, you can save your configuration to a file, load it to multiple I/O units
at once, and use it for referencing points in OPC. You can also configure some controller

USING PPP OVER A MODEM
SNAP PAC R-Series Controller User’s Guide
12
features that are not available in PAC Control. However, you cannot use the loopback
address in PAC Manager.
Choose your configuration tool based on what you need to do:
Whichever tool you use for configuring I/O, be aware of the impact if you later change
configuration. For example, if you configure I/O in PAC Manager, download the
configuration file to I/O units, and then later add a point in PAC Control, remember that your
configuration file doesn’t contain that point.
Using PPP Over a Modem
Use the rest of this chapter only if you have SNAP PAC R-series controllers installed at
remote locations or in other places where an Ethernet network is not available, and you are
using modems to communicate between the controller and a PC. The modems use the
point-to-point protocol (PPP) to communicate. You can set up communication so that the
controller can dial in to a PC, so that PCs can dial into the controller, or both.
NOTE: You can communicate with a SNAP PAC R-series controller using a modem and PPP at the
same time you are communicating with the controller over an Ethernet network.
Use PAC Control for I/O configuration if… Use PAC Manager for I/O configuration if…
•You have only one I/O unit or I/O unit configurations are
different.
•The strategy will run on I/O units that are controlling
themselves using the loopback IP address (127.0.0.1).
•You are using a wired Ethernet network for communications.
•The strategy handles all logic; you are not also configuring
events and reactions on I/O units.
•You have multiple I/O units whose configurations are exactly
the same or similar.
•You are using a wireless LAN, a modem connection (PPP), or
SNMP.
•You are using event messages or email.
•You are configuring events and reactions on the I/O unit in
addition to strategy logic.
•You are using OPC to communicate with I/O units.
•You are not using PAC Control.
PC dials in to
controller
SNAP PAC R-series
controller
Modem
Modem
PC with dial-up
networking
Modem