VersaMax GFK-1551D User manual

Network Interface Unit
October 2000 GFK-1551D
1
Preinstallation Check _____________________________
Carefully inspect all shipping containers for damage. If any equipment
is damaged, notify the delivery service immediately. Save the damaged
shipping container for inspection by the delivery service. After
unpacking the equipment, record all serial numbers. Save the shipping
containers and packing material in case it is necessary to transport or
ship any part of the system.
Quick Start Guide ________________________________
1. Install the NIU on the DIN Rail by simply clicking it into place.
Note: The NIU and connecting carriers
must be installed on the same section
of 35mm x 7.5mm DIN rail.
The DIN rail must have a conductive
(unpainted) finish for proper grounding.
(Refer to the heading Module Installation for information about
space requirements or module orientation, or if you are installing
the NIU in an area of excessive vibration).
2. Install the Power Supply on the NIU.
The latch on the power supply must be
in the unlocked position.
Align the connectors and the latch post
and press the power supply module
down until the two tabs on the bottom of
the power supply click into place.
Turn the latch to the locked position to
secure the power supply to the top of the
NIU.
Complete the power supply wiring as described in the installation
instructions provided with the Power Supply.
3. Adjust the rotary switcheson the front of the NIU using a
2.44mm (3/32in) flat screwdriver.
0
1
0
0
76 4
5
89 1
1
BAUD
RATE
SBA
X10
3
2
3
2
3
2
SBA
X1
N
N
AU
§Select the serial bus address with the two upper rotary
switches, SBA X10 (for the tens digit) and SBA X1(for the
ones digit). Each device on a bus must have a unique serial
bus address in the range 0 - 31.
§Select the baud rate to match that used by the other devices
on the bus by setting the bottom rotary switch: (3) 153.6
Kbaud extended, (2) 153.6 Kbaud standard, (1) 76.8 Kbaud,
or (0) 38.4 Kbaud.
§Cycle power to the NIU after changing the switch settings.
4. Connect the communications bus to the NIU. (Refer to the
heading Bus Installation Guidelines if the NIU is at the end of the
bus, or for detailed bus installation instructions.)
Main Bus
Connections
SHIELD OUT
SERIAL B2
SHIELD IN
SERIAL A2
SHIELD OUT
SERIAL B1
SHIELD IN
SERIAL A1
Redundant
Connections
The NIU has two sets of bus
terminals. The upper terminals are
for the main bus cable. The lower
bus terminals are for an optional
redundant (dual) bus cable.
5. Remove the connector cover on the righthand side of the
NIU. Do not discard this cover; you will need to install it on the last
carrier. It protects the connector pins from damage and ESD during
handling and use. Do not remove the connector cover on the
lefthand side.
Connector Cover
Connector Cover
6. Install additional modulesby mounting modules on their carriers
and sliding them along the DIN rail to fully engage the connectors in
the sides of the carriers.
7. Power up the NIU. The modules in the I/O station will automatically
be configured, starting at slot 1 in each rack including expansion
racks. If an empty slot or faulted module is encountered,
autoconfiguration for that rack stops. Autoconfiguration then skips to
the next rack and continues until all racks are configured.
Note: If the I/O station includes any additional power supplies, those
power supplies should be turned on at the same time.
8. Observe the NIU LEDs, which indicate the presence of power and
show the operating mode and status of the NIU.
BUS B
SBAERR
I/O ENBL
FORCE
PWR
FAULT
OK
PWR Indicates that the NIU is receiving
power.
OK Indicates diagnostics executed
successfully.
FAULT Is ON if there are one of more
faults.
I/O ENBL This bicolor LED is green if the I/O
scan is enabled and data is being
received from the bus. Otherwise,
this LED is amber.
FORCE Is ON if one of more I/O points is
forced.
SBA ERR Is ON if a duplicate device SBA or
invalid SBA exists.
BUS B Is ON if bus B is active.

Network Interface Unit
October 2000 GFK-1551D
2
General Module Installation Instructions______________
133.35mm
(5.25in)
1
2
3
85.85mm
(3.38in)
Modules may be mounted on a
horizontal or vertical DIN rail. When
mounted on a vertical DIN rail, the NIU
must be located at the bottom.
1. Allow sufficient finger clearance for
opening NIU door.
2. Allow adequate clearance for serial
port cables.
3. Allow adequate space for power
wiring.
The NIU with power supply attached fits
into a 70mm deep enclosure.
Rated thermal specifications are based
on a clearance of 5.1cm (2in) above and
below the equipment and 2.54cm (1in) to
the left of the NIU module.
Panel-Mounting
For best stability, the DIN rail should be installed on a panel using
screws spaced approximately 5.24cm (6in) apart.
If excessive vibration is a factor the NIU should also be screwed down
to the mounting panel.
Note 1. Tolerances are +/- 0.13mm (0.005in) non-cumulative.
Note 2. 1.1-1.4Nm (10-12 in/lbs) of torque should be applied to M3.5
(#6-32) steel screw threaded into material containing internal
threads and having a minimum thickness of 2.4mm (0.093in).
SEE NOTE 2.
M3.5 (#6) SCREW
15.9mm
0.62in REF
SPLIT LOCK
WASHER
FLAT WASHER
NIU
TAPPED HOLE
IN PANEL
5.1mm
0.200in
4.3mm
0.170in
4.3mm
0.170in
Removing the NIU from the DIN Rail
1. Turn off power to the power supply.
2. (If the NIU is attached to the panel with a screw) remove the
power supply module. Remove the panel-mount screw.
3. Slide the NIU away from the other modules until the connector on
the right side disengages from the next carrier.
4. With a small flathead screwdriver, pull the DIN rail latch out while tilting the other
end of the NIU down to disengage it from the DIN rail.
Bus Installation Guidelines ________________________
The maximum exposed length of unshielded wires should be 5cm (2in).
For added protection, each shield drain wire should be insulated with
spaghetti tubing to prevent the Shield In and Shield Out wires from
touching each other, or the signal wires.
1. Connect Serial 1 to the Serial 1 terminals of the previous device and
the next device.
2. Connect Serial 2 to the Serial 2 terminals of the previous device and
the next device.
3. Connect Shield In to Shield Out of the preceding device. Connect
Shield Out to Shield In of the next device. If the NIU is the first device
on a bus, Shield In can be left unconnected. If it is the last device on
a bus, Shield Out can be left unconnected.
4. When inserting two wires into the same terminal block position, the
wire size must be 0.86mm2(18AWG) or smaller. Both wires should
be of the same size and style. Do not mix stranded with solid wire in
the same position.
Terminating the Bus
Serial 1
Serial 2
Shield In
Shield Out
Serial 1
Serial 2
Shield In
Shield Out
Start
of Bus End of Bus
Terminating
Resistor
Terminating
Resistor
If either bus will terminate at the NIU, connect a 75, 100, 120, or 150-ohm
terminating resistor across the Serial 1 and Serial 2 terminals. The use of
a ferrule is recommended to crimp each resistor lead to the corresponding
serial line. If ferrules are not used, twist each resister lead with the
corresponding serial line and solder them together before inserting the
wires into the terminal block.
System Bus Installation Guidelines
The serial bus can be treated as a Class 2 circuit when appropriate wiring
practices are followed. Maximum bus lengths may be affected when
installation requires the high-voltage rated CM rating. CM types can
replace CL2, but not vice versa.
Do not mix cables of different impedance, regardless of cable run length.
Do not mix cable types in long and/or noisy installations. Other, small-
size twisted pair shielded wire of unspecified impedance can be used for
short runs of 50 feet or less, using 75 ohm terminations. Selection of wire
type may be limited by local and national codes and industry standards.
Consult the cable manufacturer to determine the cable's suitability for a
particular type of installation.
Installing Suppression at the Communications Line
S1
S2
SHLD IN
SHLD OUT
(bus cable
not shown)
MOVs
For an individual NIU, suppression can
be supplied by connecting two small
MOVs from Serial 1 and Serial 2 to the
Shield Out terminal. Suitable MOVs
include Harris part number V220MA2A,
Panasonic ERZ-CO5FK221U, and
Siemens 505K140. Higher energy-rated
devices can also be used. Follow the
wiring instructions above for installing
MOVs. Be sure the MOV leads do not
cause shorts between the serial data
and shield connectors.

Network Interface Unit
October 2000 GFK-1551D
3
Product Description ______________________________
Revision Letters: AD
Firmware version: 2.00
Firmware upgrades: 44A748000-G03
Specifications ___________________________________
8 per rack, up to eight racks.
Network inputs per bus scan 128 bytes
Network outputs per bus scan 128 bytes
Discrete Input Memory 1024 points
Discrete Output Memory 1024 points
Analog Input Memory 128 bytes
Analog Output Memory 128 bytes
Power Consumption +5V@250mA, +3.3V@10mA
Serial Bus Address 0 to 31
Network data rate 153.6 Kbaud extended, 153.6
Kbaud standard, 76.8 Kbaud, or
38.4 Kbaud.
New Feature of this NIU Version ____________________________
§Supports configuration with the Remote I/O Manager configuration
software.
Operating Note/Restrictions for this NIU Version _______
§If the NIU is configured via datagrams from the bus, the value of
the Force BSM bit is accessible but must not be changed.
§No analog modules or intelligent I/O modules should be used in a
Duplex Redundancy system.
§During a firmware upgrade to an intelligent I/O module (ALG320,
321, 322, 324), outputs hold last state regardless of their
configuration. When performing a firmware upgrade on an
intelligent I/O module in the NIU station, the controller should be
put in stop mode or the NIU should be removed from the bus.
§During a firmware upgrade for an intelligent I/O module in an
expansion rack, the informational message indicating the module
is in Firmware Upgrade mode may not be reported to the PLC
until the upgrade is complete.
§No intelligent I/O modules should be used in an expanded
distance) expansion system.
§Faults generated by storing a bad configuration may not be
reported to the host.
To recover, a correct configuration must be stored, or the NIU
system must be autoconfigured.
Fixed for this Version _____________________________
§The NIU now detects a configuration mismatch for jumper
configurations on the ALG260 and 230 modules and the ALG262
and 264 modules.
§If the NIU is configured for BSM Present but not BSM Controller,
the NIU switches busses correctly. Its functionality is not
affected by temporary loss of communications with the bus
controller.
§The NIU does not default outputs after switching to a redundant
bus.
§Firmware upgrades can be performed on intelligent modules in a
large NIU expansion system.
Compatibility _________________________________
Any type of PLC or computer capable of controlling the bus can be used
as the host. This Network Interface Unit is compatible with:
§For an IC697 PLC
-CPU firmware, release 3.0 or later.
-Bus Controller release 5.4 or later
-If the IC641SWP701/704 programming and configuration software
is used, it must be release 3.0 or later.
§For an IC693 PLC
-CPU firmware: any version for NIU compatibility. If the NIU I/O
station includes any expansion racks, the CPU must be a model
350, 352, 360, 363, or 364, Release 10.0 or later. If an earlier
version of CPU firmware is used or if any other Series 90-30 CPU
model is used, a Loss/Add of Rack fault causes the CPU to go to
Stop/Faulted mode.
-Bus Controller: any version.
§For an IC600PLC:
-CPU: rev. 105 or later
-Programming Software: Release 4.02 or later
-Bus Controllers: CBB902 or 903, version 1.7 or later
§To be used in an expansion rack, analog modules IC200ALG320, 321,
322, and 432 must be revision B or later. Analog modules
IC200ALG430 and 431 that are used in expansion racks must be
revision C or later.
Expansion Systems _______________________________
This section summarizes the expansion capabilities of this NIU version.
For more information about expansion modules, installation and required
equipment, please refer to current version of the I/O Modules, Power
Supplies, and Carriers Manual, and to the documentation supplied with
Expansion Transmitter and Receiver Modules.
Regardless of the number of racks used, the maximum I/O capacity of the
NIU system is 128 bytes of discrete +analog inputs and 128 bytes of
discrete + analog outputs. Any additional I/O is ignored.
Two-Rack Local System
This type of system uses one Non-Isolated Expansion Receiver *ERM002
to connect just one expansion rack to the NIU I/O Station without having
an Expansion Transmitter Module in the main rack.
This “single-ended” configuration has a maximum cable length of 1 meter.
No terminator plug is required in the expansion rack.
PS
ERM
Expansion Rack
Cable *CBL600
(1M)
NIU I/O Station Main Rack
PS
NIU

Network Interface Unit
October 2000 GFK-1551D
4
RS-485 Differential Expansion System
A multi-rack expansion system requires an Expansion Transmitter
Module in the NIU I/O Station. Up to seven expansion racks can be
included in the system. With any non-isolated Expansion Receiver
Module in the system, the total overall length of the expansion cable
can be up to 15 meters.
With all Isolated Receiver Modules, the total overall length of the
expansion cable can be up to 750 meters.
The expansion bus must be terminated with terminator plug *ACC201
(included with the Expansion Transmitter).
PS
NIU
PS
ERM
PS
ERM
ETM
ExpansionRack 1
Terminator
Plug
15M with any
ERM002 Modules
750M with all
ERM001 Modules
I/O Station Main Rack (0)
ExpansionRack 7ICBL601,
602, 615
Communications in an Expansion System
The NIU in the main rack communicates with the expansion racks
through a high-speed serial interface. The frequency used depends on
the types of expansion receivers in the expansion rack(s).
§In a Two-Rack Local system, the communications frequency is
3MHz.
§In Differential system, the NIU communications frequency is 3MHz
unless at least one isolated expansion receiver is installed.
Modules for an Expansion System
Expansion racks are built from the same carrier bases and I/O
modules that are allowed in main rack applications. Note the special
revisions required for some analog modules mentioned above.
Configuration and Installation Notes for Expansion Systems
§The NIU must have its rack dial set to rack 1 or it will not auto-
configure. The Expansion Receiver modules also have Rack ID
selection dials. Each must be set correctly as described in the
Expansion Module datasheets.
§In a multiple-rack expansion system, any available rack number
can be used for a new expansion rack but they must all be
unique (no duplicate rack numbers). It is best to assign
expansion racks numbers from lowest (1) to highest (7) as they
are installed. That is most compatible with the NIU auto-
configuration feature. Auto-configuration automatically assigns
reference addresses to I/O points and channels as it configures
them. Autoconfiguration starts in the main rack and proceeds
through the slots and additional racks in order, assigning
references from lowest to highest.
§To force auto configuration for expansion racks, first power down
the NIU. Remove the transmitter module from the NIU or remove
the expansion cable at the transmitter. Power up the NIU and let
it autoconfigure. Power the NIU down again, reattach the
transmitter or cable and power up the NIU again.
§In an local system, the NIU rack and the expansion rack may be on
different power supplies if desired. If so, on a single-ended or
differential system, disconnecting the cable between the
NIU/transmitter and receivers may cause disruptions on the bus.
§In a multiple-rack expansion system, if a new expansion rack is added
in the future, it should be assigned a rack address that is higher than
the racks that are already installed. If a new expansion rack with a
lower rack number than those previously auto-configured is installed
and the system is auto-configured, the racks numbered higher than
the new rack number have their I/O reference addresses shifted in the
reference tables. Any existing program logic that uses those
references must then be adjusted to use the new references.
§To add a new expansion rack to the system, the system must be
powered down. After adding the module, according to the
instructions in the Expansion Module datasheet, power up the
system. It will then autoconfigure.
Fault Handling for an Expansion System
This version of the NIU can detect extra, lost, and added expansion racks
as a result of a power cycle.
§When a complete rack is lost, only a “Loss of Rack” fault is generated.
Individual “Loss of Module” faults are suppressed.
§When a rack is added only an “Addition of Rack” fault and any I/O
module mismatch or loss conditions are reported. Individual I/O
module additions are suppressed.
§An “Extra rack” fault is generated when an expansion rack is present
but has not been configured. The Scan LED on the Expansion
Receiver Module is green instead of yellow whenever the Expansion
Receiver is properly configured and is working.
§Hot swapping of Expansion Transmitter Modules is not supported. The
NIU detects the loss and addition of the Expansion Transmitter
Module and generates the appropriate faults.
§If the run-time expansion frequency changes, an “Expansion bus
speed change” fault is generated.
The table below summarizes programmer faults in an expansion system:
Programmer Fault Text
VP/C90 LM90 Fault Description
Expansion Bus
Speed Change Reset of, Addition of, or extra option
module Expansion bus operating frequency has changed from
250kHz to 3MHz or vice versa.
Addition of rack Addition of, or
extra rack Occurs when a receiver is first configured and when it returns after being lost.
Loss of, or missing
rack Loss of, or missing rack Occurs when a properly configured receiver is not physically present at power up or lost at run-time.
System
Configuration
Mismatch
System
Configuration
Mismatch The configuration stored for a receiver does not match
the physical receiver present.
Extra Rack Addition of, or
extra rack Generated when a receiver is present that is not currently configured. Also indicates improperly-
numbered rack ID.
Loss of, or missing
option module Loss of, or missing option module Generated when a properly configured transmitter module in a differential rack system is not present.
Reset of module Reset of, Addition
of, or extra option
module
Generated when a transmitter in a differential rack
system is either configured for the first time or is now
present after being lost.
Extra module
present but not
configured
Reset of, Addition
of, or extra option
module Generated when a system is configured for single-
ended operation and a transmitter module is present.
Extra Transmitter Expansion Transmitter installed in 2-rack local system