Instruction Bulletin

Class 8030 Type CRM270 Distributed Remote IO/NETTM Interface Module for the I/O System
TM

Bulletin No. 30598-816-01A2 January 1993 Raleigh, NC, U.S.A.

! WARNING
UNINTENTIONAL EQUIPMENT OPERATION
The application of this product requires expertise in the design and programming of control systems. Only persons with such expertise should be allowed to program, install, alter and apply this product.

Failure to observe this precaution can result in severe personal injury or death!

! CAUTION
EQUIPMENT DAMAGE HAZARD To avoid improper handling of equipment: 1. Never remove this device while power is ON. 2. Do not subject to static discharge. This module contains electronic components that are very susceptible to damage from electrostatic discharge. Failure to observe this precaution can result in equipment damage.

PLEASE NOTE Electrical equipment should be serviced only by qualied electrical maintenance personnel, and this document should not be viewed as sufcient instruction for those who are not otherwise qualied to operate, service or maintain the equipment discussed. Although reasonable care has been taken to provide accurate and authoritative information in this document, no responsibility is assumed by Square D for any consequences arising out of the use of this material.

TRADEMARK NOTICE SY/MAX, SY/NET, SY/LINK, and SY/MATE are registered trademarks of Square D Company. PASSPORT and IO/NET are trademarks of Square D Company.

Table of Contents Section

1

Title

Page

Overview ...............................................................................................................................1-1
1.1 General Information .........................................................................................................................1-1 1.2 DRIO Module Features ....................................................................................................................1-1 1.3 Where to Find Additional Information ..............................................................................................1-2

Specications .......................................................................................................................2-1
2.1 2.2 2.3 2.4 2.5 Compliance Information ..................................................................................................................2-1 Electrical Specications ...................................................................................................................2-1 Environmental Specications ...........................................................................................................2-1 Physical Specications.....................................................................................................................2-1 Functional Specications .................................................................................................................2-1 2.5.1 Register Capabilities .............................................................................................................2-1 2.5.2 Communications Capabilities ................................................................................................2-2 2.5.3 Compatibility with Processors ...............................................................................................2-2 2.5.4 Compatibility with TBX I/O Base Units ..................................................................................2-2 2.5.5 Compatibility with IO/NET Interface Devices.........................................................................2-2

Installing the DRIO Module..................................................................................................3-1

3.1 General Information ........................................................................................................................3-1 3.2 Installing the Module ........................................................................................................................3-2 3.2.1 TBX Base Unit Mounting Information ....................................................................................3-2 3.2.2 Base Unit Spacing .................................................................................................................3-3 3.2.3 Enclosure Sizing....................................................................................................................3-4 3.3 Setting the DRIO DIP Switches........................................................................................................3-6 3.4 Field Wiring ...................................................................................................................................3-8 3.3.1 Communication Cable ...........................................................................................................3-8 3.3.2 Local Connections.................................................................................................................3-9 3.3.3 Terminators .........................................................................................................................3-11

Operating the DRIO Module ................................................................................................4-1

4.1 General Information .........................................................................................................................4-1 4.2 DRIO Module Registers ...................................................................................................................4-1 4.2.1 I/O Registers .........................................................................................................................4-3 4.2.2 Conguration Registers.........................................................................................................4-3 4.2.3 Diagnostic Registers .............................................................................................................4-4 4.2.4 Base Unit Identity Data Request and Reply Registers..........................................................4-4 4.3 Rack Addressing ..............................................................................................................................4-6 4.4 Rack Addressing Example ...............................................................................................................4-7 4.5 LIO Channel/Drop Control Registers ...............................................................................................4-9 4.6 DRIO Module LED Operation...........................................................................................................4-9

Troubleshooting

................................................................................................................5-1

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1
1.1 GENERAL INFORMATION

OVERVIEW

The SY/MAX Class 8030 Type CRM270 Distributed Remote IO/NET Interface Module (DRIO) is one of the Remote IO/NET devices that allow the PASSPORT I/O System to control input and output devices located up to 7,500 feet away from the CPU rack. Access to as many as 32 remote IO/NET devices is possible through serial communication from the Local IO/NET Interface Module. Throughout this instruction bulletin the Local IO/NET Interface Module, or CRM250, is referred to as the LIO, while the Remote IO/NET Interface Module, or CRM260, is referred to as an RIO. The Distributed Remote IO/NET Interface Module, or CRM270, is referred to as the DRIO. These three devices, along with an expansion unit (the CBS010) are collectively referred to as the PASSPORT I/O System. This instruction bulletin provides specications, installation, and troubleshooting information for the DRIO module. More information about the IO/NET Interface System is contained in the Class 8030 Type CRM250 Local IO/NET Interface Module Instruction Bulletin (#30598-782). The DRIO modules are mounted on the TBX series of distributed I/O base units and are connected to the Local IO/NET Interface module (LIO) by way of either a single shielded, twisted-pair or twin-axial cable. The cable is wired to a removable terminal block connector on the face of each module. Up to two base units can be supported by a single DRIO module. When two base units are required at a single drop, the DRIO module is mounted on the primary base unit and a TBX CBS010 Expansion Interface is mounted on the second base unit, providing the electrical connection to the DRIO. Information exchanged between the DRIO and the LIO consists of I/O, diagnostic, and conguration register data, register status, DRIO status, and base unit EEPROM data. The continuous exchange of data between the LIO and the DRIO is independent of the CPU scan. Serial drops connected on the single physical channel of the LIO must be daisy-chained together. There can be up to 32 drops per LIO. Type CRM270 (DRIO) and Type CRM260 (RIO) modules can be combined on the same LIO channel. Depending on the bit rate and cable type, the maximum cable distance per LIO may be as much as 7,500 feet. Figure 1-1 illustrates the main features of the DRIO module. 1.2 DRIO MODULE FEATURES The DRIO module fully supports the IO/NET Communications network, including these features: User-selectable DIP switches to identify the DRIO module as 1 of up to 32 drops per LIO Up to 64 addressable registers per DRIO module Communication rates that can be selected by DIP switch, from 62.5K to 1M bits per second, allowing an end-to-end cable link length of up to 7,500 feet.

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Four LEDs to indicate status of the DRIO module Support for these diagnostic functions: - Failure Override - Auto Restart - Freeze Outputs (last state and preset fall-back) - Drop Shutdown User-selectable message retry count (Transmission Fault Tolerance) Continuous I/O updates even when power and/or communications are lost to one or more drops (with Failure Override set)

NOTE
The Local IO/NET Interface Module (CRM250), the Remote IO/NET Interface Module (CRM260), and the Distributed Remote IO/NET Interface Module (CRM270) can be used only with SY/MAX Model 400, 450, 600, and 650 processors (Revision 4.0 and higher). Contact a Square D distributor for upgrade information. 1.3 WHERE TO FIND ADDITIONAL INFORMATION Details about the components of the PASSPORT I/O System, programming, and processor information can be found in the following instruction bulletins: SY/MAX Class 8030 Type CRM260 Remote IO/NET Interface Module Instruction Bulletin (#30598-795) SY/MAX Class 8030 Type CRM270 Distributed Remote IO/NET Interface Module Instruction Bulletin (#30598-816) TBX CBS010 Expansion Interface for PASSPORT I/O System Instruction Bulletin (#30598-371). SY/MATE Plus Class 8010 Type SFW472/73/74 Programming Software Instruction Bulletin (#30598-322) SY/MAX Class 8020 Type SCP4XX Model 400 Processor Instruction Bulletin (#30598-503) SY/MAX Class 8055 Type SCP452/453 Model 450 Processor Instruction Bulletin (#30598-526) SY/MAX Class 8020 Type SCP6XX Model 600 Processor Instruction Bulletin (#30598-609) SY/MAX Class 8055 Type SCP654/55 Model 650 Processor Instruction Bulletin (#30598-730)

Chapter 1 - Overview

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PHYSICAL BIT DROP NUMBER RATE 1 2 3 4 5 6 7 8 RUN COM ACTIVE OUT TERMINATOR IN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 RCK ERR COM ERROR 9 10 11 12 13 14 15 16

8030 CRM270

66 mm

2.6 in

1 2 SHLD

8.3 in 210 mm
Removable Terminal Block Connector

CRM270 Top view

36 mm

1.4 in

Connector to TBX Base Unit CRM270 Side view

Figure 1-1 Class 8030 Type CRM270 Distributed Remote IO/NET Interface Module (DRIO)

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2
2.1 COMPLIANCE INFORMATION

SPECIFICATIONS

The DRIO module complies with UL 508 and CSA C22-2 requirements; FM approval is pending. 2.2 ELECTRICAL SPECIFICATIONS

Input Power Requirements

Input power to the DRIO module is supplied from the base unit. No user-supplied power is required. Voltage Range Current Draw 24 VDC nominal (19-30 VDC) Without base: 80 mA typical, 120 mA maximum; refer to the appropriate TBX I/O base unit instruction bulletin for the total current draw rating for a DRIO and a TBX base unit.

2.3 ENVIRONMENTAL SPECIFICATIONS Ambient Temperature: Operational 32 F to 140 F (0 C to 60 C) Storage -40 F to 176 F (-40 C to 80 C) Humidity 2.4 PHYSICAL SPECIFICATIONS Dimensions Weight (DRIO unit only) 2.5 FUNCTIONAL SPECIFICATIONS 2.5.1 Register Capabilities Each DRIO module has a maximum of 64 available registers. These registers are used for external I/O addressing, conguration and diagnostic data, and TBX base unit EEPROM access. All 64 registers can be assigned to any actual or virtual slot. For any slot that you assign registers to, you must assign the minimum number of registers required. The minimum number of registers depends on the base unit type. See Chapter 4 for more information; refer also to the Class 8030 Type CRM250 Local IO/NET Interface Module Instruction Bulletin (#30598-782) and to the appropriate base unit instruction bulletin. 2.6 x 8.3 x 1.4 in (66 x 210 x 36 mm) 0.67 lb (0.31 kg) 5-95%, non-condensing

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2.5.2 Communications Capabilities Method Transmission rate Half-duplex NRZI-encoded synchronous RS-485, with the LIO acting as the polling master 62.5 Kbps to 1 Mbps (bits per second). Message packet integrity ensured with a 16-bit CRC; other agged error conditions include message timeouts (no reply), collisions, and improper replies. 300 VDC, optically coupled 7,500 feet maximum (see Table 3-1)

Isolation Distance

2.5.3 Compatibility with Processors The PASSPORT I/O System is compatible with all SY/MAX Model 400, 450, 600, and 650 (Revision 4.0 and later) processors. (Contact a Square D distributor for upgrade information.) 2.5.4 Compatibility with TBX I/O Base Units The DRIO module is compatible with the TBX family of bases and expansion interfaces. 2.5.5 Compatibility with IO/NET Interface Devices DRIO modules are compatible with Class 8030 Type CRM250 Local IO/NET Interface Modules (LIO) and may coexist on the IO/NET link with the Class 8030 Type CRM260 Remote IO/NET Interface Module. A DRIO module cannot be wired to more than one LIO. The CRM270 module is not compatible with Class 8030 Type CRM210, CRM211, or CRM230 Local Interface Modules.

Chapter 2 - Specifications

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INSTALLING THE DRIO MODULE

3.1 GENERAL INFORMATION

CAUTION

EQUIPMENT DAMAGE HAZARD To prevent possible equipment damage, remove power from local or remote racks before inserting or removing any component, including interface modules or communication cable. Failure to observe this precaution can result in equipment damage. The form factor for the TBX Distributed I/O system is a block that is split lengthwise. The bottom half of the block, the TBX base unit, houses the I/O power electronics and serves as the mounting base for the system (see Figure 3-1). The top half of the block is the CRM270, which is physically mounted to the bottom half. Up to two I/O base units can be electrically connected to one CRM270 communications interface, using a TBX CBS Expansion Interface to connect to the second base unit. The CRM270 and CBS interfaces are always mounted on TBX base units.

CRM270 DRIO

Ground Terminal

TBX BASE

Figure 3-1 Base Unit and DRIO Module

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3.2 INSTALLING THE DRIO

NOTE
To prevent exposed wiring and potential product damage, the Distributed I/O blocks should be mounted in protective enclosures. They are not designed for freestanding installation. The enclosure must be large enough to provide for proper airow and heat dissipation. See TBX Base Unit Mounting Information . 3.2.1 TBX Base Unit Mounting Information The mounting dimensions for the TBX base units are shown in Figure 3-2. The base units can be panel mounted using either #6 machine or sheet metal screws. The base units also include clips and spring latches for DIN rail mounting. The base units must be mounted only in a horizontal orientation, as shown in Figure 3-3. The base unit is attached electrically to the CRM270 using a multi-pin connector. Four base attachment screws are used for mechanical connections. After aligning the electrical connector, the four corner interface-to-base mounting screws should be secured (6-9 in-lbs) to complete an assembled unit.

0.24 in (6.1 mm)

0.22 in (5.6 mm) (33 mm) 1.30 in

3.43 in (87 mm)

2.13 in (54 mm)

DIN Rail Center Line

40 Position I/O Terminal Strip 8.27 in (210 mm) 8.74 in (222 mm) 9.25 in (235 mm)

Figure 3-2

TBX Base Unit Mounting Dimensions

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Spacing: 1 in. (25 mm)

IO/NET Connection

LED Array

Expansion Base Connector

Expansion Interface Cable

Wire Trough

Mounting Panel

Terminal Strip Mounting Panel

Figure 3-4 Base Unit Spacing

Chapter 3 - Installing the DRIO Module

Cabinet Edge

IO/NET Cable

Figure 3-3

TBX Base Mounting Conguration

3.2.2 Base Unit Spacing To ensure proper airow for cooling the TBX Distributed I/O blocks, air-gaps must be maintained around the base unit. In general, there should be air gaps of at least one inch on each side and two inches above and below each base unit (Figure 3-4).

non-heat producing device 2 in (50.8 mm)

1 in (25.4 mm)

1 in (25.4 mm)

Base Unit

2 in (50.8 mm)

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These dimensions assume that there are no signicant heat-producing devices directly below the base unit. The vertical spacing requirement must be increased by 0.012 inches per watt dissipated by any heat-producing device to ensure proper cooling of the base units. For example, if a power supply that dissipates thermal 25W is mounted directly below the base unit, a gap of 0.3 inches (25 x 0.012 in) should be added to the minimum 2-inch clearance between the power supply and the base unit. 3.2.3 Enclosure Sizing Airow and heat dissipation are the two factors that affect the size of a control enclosure for TBX Distributed I/O. To ensure proper airow around the base units, there should be at least a 3-inch airspace between the front of the enclosure and the top of the DRIO (Figure 3-5). A standard NEMA enclosure with a depth of 6 inches or greater is sufcient.

Cabinet Front or Door

3 in (76.2 mm)

DRIO

Base Unit

2.9 in (73.7 mm)

Mounting Panel

Figure 3-5 Airow Spacing for Base Unit and DRIO Module Heat Dissipation
Typically, the panel space requirement for a control panel, and the associated enclosure size, is large enough to ensure a sufcient heat dissipation to keep the control components within their rated temperature limits. However, because of the compact size of TBX Distributed I/O, it is necessary to check the enclosure size to ensure proper heat dissipation.

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The total heat into the enclosure must be dissipated out of the enclosure within the allowable temperature rise. The maximum allowable temperature rise is the difference between the maximum operating temperature of the base units (60 C) and the ambient air temperature outside the enclosure. Assuming the size of the enclosure is known, the heat rise for a non-vented enclosure can be calculated using the following equation (note that this equation is for nominal conditions): Heat rise ( C) = 2.3f [144P / (mHW + 2HD + DW)] where f = P = m= H= W= D= material factor (painted steel = 1.0, stainless steel or aluminum = 1.5) total power dissipation by devices in enclosure (Watts) mounting factor (pole-mounted = 1.7, wall-mounted = 1) enclosure height (inches) enclosure width (inches) enclosure depth (inches)

For example, a wall-mounted, stainless steel enclosure with the dimensions of 24 H x 24 W x 8 D, with a total power dissipation of 60W will have a heat rise of the following: 2.3(1.5) [144(60) / (1(24)(24) + 2(24)(8) + (8)(24))] = 25.88 C Rounding up to 26 C, the maximum allowable ambient temperature is 34 C (60 C 26 C). Assuming the ambient temperature is lower than 34 C, the enclosure is sufciently large to dissipate the internal heat. If the ambient is higher than 34 C, either the enclosure size can be increased or a painted steel enclosure can be used.

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3.3 SETTING THE DRIO SWITCHES The DRIO module has an eight-position DIP switch bank above the removable IO/NET cable connector (Figure 3-6). Set the eight switches to the appropriate drop number and bit rate for each DRIO, according to Table 3-1 and Table 3-2.
Drop # Switches Bit Rate Switches

ON

1 2 3 4 5 6 7 8

SHLD

1 2

Figure 3-6

DRIO DIP Switches

NOTE
All drops must have a unique drop number, and all devices on the IO/NET link must be set to the same bit rate.

WARNING

UNINTENTIONAL EQUIPMENT OPERATION For remote IO/NET devices, be sure that DIP switch settings for each drop correspond with the correct bit rate and drop number in accordance with Tables 3-1 and 3-2 in this instruction bulletin. Improperly set switches cause equipment to act in an unpredictable manner. An improperly coded bit rate could disrupt communication to active drops. An improperly coded drop number: - when not a rack addressed drop, will be ignored. - when addressing is identical for two or more drops, may create a situation where drops conict or where one drop will respond while the other is ignored. The LIO may not detect identical drops for all situations. Failure to observe this precaution can result in equipment damage, severe personal injury, or death!

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Table 3-1: DRIO Switch Settings

Switch Number Physical Drop #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Logical Channel
1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4

Drop
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

1
OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON

2
OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON

3
OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON

4
OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON

5
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON

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Table 3-2: Bit Rate Settings

ON

Switch Numbers Bit Rates 6

1M 500K 250K 125K 62.5K OFF ON OFF ON OFF

7
OFF OFF ON ON OFF

8
OFF OFF OFF OFF ON

NOTE
All devices on each IO/NET link must be set to the same bit rate.

3.4 FIELD WIRING 3.4.1 Communication Cable The recommended communication cable between the LIO and DRIO modules is a shielded twisted-pair cable (Belden 9841). The characteristics of Belden 9841 provide for the greatest cable distance at the highest bit rate. A shielded twin-axial cable, Belden 9463 (the cable used for the SY/NET network) may also be used for limited distances. Table 3-3: Communication Cable Distances
Maximum Length (ft.) Belden 9463 (twin-axial)
850 1700 2500 4500 5000

Bit Rate

Maximum Length (ft.) Belden 9841 (single twisted pair)

1700 2500 4500 6500 7500

1 Mbps 500 Kbps 250 Kbps 125 Kbps 62.5 Kbps

The detachable cable connector can be removed from the DRIO for easier cable termination. To reinstall the connector, align the connector with the module pins and press rmly back in place. Be sure to observe the following: 1. Route the communication cable in different wire ducts than the power wiring. 2. Connect each end of the communication cable shield to the SHLD terminal on each module.

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CABLE INSTALLATION NOTES

Do not mix cable types. When installing the communication cable to the removable cable connector, do not strip more jacketing, shielding, or insulation than necessary from the cable wires. The jacketing (outer sleeve or insulator) and shielding should be stripped back approximately 1-1/2 inches. Cut the jacketing and all shielding (do not cut the drain wire) so that the braided shield and the foil shield are not exposed and have no chance of making inadvertent contact with metallic surroundings. This will leave only the insulated twisted pair wires and the drain wire extending from the jacketing. The exposed drain wire that attaches to terminal SHLD must be insulated with tubing, to prevent inadvertent contact with metallic surroundings and eliminate exposure during cable connector handling. The tubing should be cut to allow only 1/2 inch of bare drain wire for connecting to SHLD. Wrap the cut jacketing, shielding, and drain wire tubing with electrical tape to ensure no inadvertent contact. On the twisted pair wires, the maximum exposed bare wire for terminals 1 and 2, after stripping the insulation, should be approximately 1/2 inch. Be consistent with color codes so that only one color is connected to terminal 1 and the other color is connected to terminal 2 in all cases. 3.4.2 Local Connections The PASSPORT I/O System is designed to operate using serial communication. The required method of wiring from one module to the next must be by daisy chain. Note from Figure 3-7 (opposite page) that wiring from the LIO can branch in two directions without violating the daisy chain rule, provided its terminator is set OUT. Figure 3-8 shows correct and incorrect methods of setting up a daisy chain conguration.

YES
LIO

YES
LIO

NO
LIO LIO

NO

Figure 3-8 Correct and Incorrect Daisy Chain Congurations

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OUT

IN

1 2
SHLD

1 2 SHLD

1 2
SHLD

1 2 SHLD

N/C

IN CRM250
1 2
SHLD

Figure 3-7

LIO/DRIO Terminations (Two DRIO Drops)

For more information, refer to the Class 8030 Type CRM250 Local IO/NET Interface Module Instruction Bulletin (#30598-782).

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IN

OUT

IN

DRIO

1 2
SHLD

1 2
SHLD

1 2
SHLD

1 2
SHLD

CRM250

CRM260

CRM260

CRM260

DRIO

LIO

RIO

RIO NOTE

RIO

The LIO can be located anywhere on the link, but its terminator is set IN only if it is located at either end.

Figure 3-9 LIO/DRIO Terminations (Larger Network)

Wiring for all modules on the IO/NET link is straight through, with all terminal #1s connected together, all terminal #2s connected together, and all terminal #3s (shield) connected together. 3.4.3 Terminators To electrically terminate the PASSPORT I/O System, set the terminator switch for the two end modules only to the IN position.

NOTE
The LIO itself does not need to be on either end of the daisy chain. Figure 3-7 on page 3-10 is an example of a network terminated at two DRIO drops, with the LIO in between. Figure 3-9 shows a larger network terminated with an LIO on one end and a DRIO on the other end. All modules in between the two end modules must have their terminators set OUT.

WARNING

UNINTENTIONAL EQUIPMENT OPERATION Be sure that two (and only two) terminators are used in each network. Follow the diagrams shown in Figures 3-7 and 3-9. For more information about terminations, refer to the instruction bulletins for the CRM250 (LIO) and for the CRM260 (RIO). Failure to observe this precaution can result in equipment damage, severe personal injury, or death!

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NOTES

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OPERATING THE DRIO MODULE

! WARNING
UNINTENTIONAL EQUIPMENT OPERATION
The application of this product requires expertise in the design and programming of control systems. Only persons with such expertise should be allowed to program, install, alter and apply this product.

Failure to observe this precaution can result in severe personal injury or death!
4.1 GENERAL INFORMATION The DRIO module is a serial communications interface between an IO/NET Communications network and up to two TBX Distributed I/O base units. The module provides visual indication of operating status of both the DRIO and the base units by way of status LEDs. Each DRIO module must be assembled with a TBX base assembly to function as a complete drop on the IO/NET communications link. An expansion interface module (for example, the TBX CBS010) can be attached to the DRIO interface to give the system additional I/O capabilities at any drop. The connection of the expansion base to the interface is with a small cable enclosed with the expansion interface. Refer to the TBX CBS010 Expansion Interface instruction bulletin (#30598-371) for a diagram of typical mounting and cabling for an assembled DRIO interface with a CBS expansion cable. 4.2 DRIO MODULE REGISTERS There are four kinds of DRIO registers that provide information about the base units. DRIO registers can be global or point registers. Global registers affect the operation for the entire system; point registers affect the operation of individual I/O points. The four kinds of DRIO registers are: I/O Conguration In each base unit, one or more registers are used for the physical I/O. These registers should be rack addressed. Two types of conguration registers affect the operation of I/O points on the base unit: Base Conguration Registers affect the operation of all points on the base; Output Fall-Back State Conguration Registers affect the operation of each corresponding I/O point. Only base units with outputs have conguration registers. Two types of diagnostic registers exist: the Control Input Voltage Status Register indicates the state of the control voltage; the Output Fault Register shows the state of individual outputs with output voltage detection. Each base unit has 128 bytes of Identity data. The Identity data provides information about the base unit, such as series and revision codes. The data is read-only; it cannot be altered.
Chapter 4 - Operating the DRIO Module

Diagnostic

Base Identity

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Each of these types of registers is explained in more detail in the following sections. 4.2.1 I/O Registers In each base unit, one or more registers are used for the physical I/O. These are I/O registers, which do not have to be rack addressed. If they are addressed, however, the minimum required number of registers to be addressed is 1 for an input base unit. If you are addressing a base with any outputs, however, you must assign at least 2. If less than the minimum required number of registers is addressed, the DRIO module will send a Rack Address error to the LIO, and then halt. In mixed I/O or bases with fewer than 16 I/O points, some of the bits of the physical I/O registers are not used. For the TBX DMS1625 base unit example shown in Table 4-1 on page 4-5, only bits 1-8 of the Input register and bits 9-16 of the Output Register are used. All Distributed I/O registers use positive logic; that is, a bit with a value of 0 indicates the I/O point is off, while a bit with a value of 1 indicates the I/O point is on.

! WARNING
UNINTENTIONAL EQUIPMENT OPERATION Do not use reserved registers and bits in ladder programs. Erratic operation may result. Refer to the base unit instruction
bulletins for specific information about reserved registers and bits.

Failure to observe this precaution can result in severe personal injury or death!
4.2.2 Conguration Registers There are two types of conguration registers: Base Conguration Output Fall-Back State Conguration The Base Conguration Registers affect the operation of all I/O points on the base and are Global registers. The Output Fall-back State Conguration Registers affect the operation of individual I/O points on the base; therefore, they are Point registers. Only base units with outputs have conguration registers.

Base Conguration Registers

The bits of these registers are used to congure each base unit for particular modes of operation. Because all output registers are reset after a RUN-to-HALT transition, or after a power cycle to the processor, all base conguration registers should be controlled by the users ladder logic program. This will ensure that proper conguration and status information is transmitted to the DRIO module following a power failure or keyswitch from HALT to RUN. The denition of these bits is included in the Instruction Bulletin for each base. Most of the bits in the Base Conguration Register are set once to initialize the base, and are not altered by the ladder logic program.

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Output Fall-back State Conguration Register

TBX base outputs feature an enhancement to the Freeze Outputs capability of the PASSPORT I/O system. In the default conguration, when the PASSPORT I/O Freeze bit is set and if communications between the LIO and DRIO fail, the DRIO Module maintains the outputs in their last state before the communications failure. This operation is the same as the Freeze state for the RIO. The Output Fall-back State Conguration register is a Point register; if a bit in the register corresponding to an individual output point is set to 1, and the base conguration register is set for Fall-back, the associated output will be set ON if outputs are frozen. By default, all bits are set to 0 or OFF. 4.2.3 Diagnostic Registers

Control Input Voltage Status Register

Many TBX base units monitor the control voltage supplies. The status of these voltages is indicated in bits 1 or 2 of this Global register. When proper voltage is applied to the base, all bits are set to 0 or off. For more information, refer to the base unit Instruction Bulletins.

Output Fault Register

The bits in this Point register show the state of outputs with output voltage detection. When a bit is set to 1, a fault has been detected in the corresponding output. 4.2.4 Base Unit Identity Data Request and Reply Registers The DRIO module can optionally be rack addressed to access the base unit Identity data. This data can be used to determine exact system conguration, or to monitor the system for equipment changes, for example. Each base unit has 128 bytes of Identity data. The Identity data can only be read by the user program; it cannot be changed. The rst four registers of Slot 1 are designated as the Identity Data Request and Identity Data Reply Registers. The four registers are allocated as: Register 0001 Register 0002 Register 0003 Register 0004 Primary Base Identity Data Request Register Primary Base Identity Data Reply Register Expansion Base Identity Data Request Register Expansion Base Identity Data Reply Register

The number of bases used affects how many registers should be rack addressed: 1 Base: 2 Bases: Specify 0, 2, 3 or greater Specify 0, 2, 4 or greater (Do not specify 1) (Do not specify 1 or 3)

If an invalid number of registers is rack addressed, the DRIO module returns an error code to the LIO indicating an invalid remote rack address and halts. The DRIO remains halted until proper rack addressing is received. If more than 4 registers are rack addressed, the system will use them as internal storage registers.

Accessing the Identity Data

To access the Identity data in the primary base unit, use a programmer or programming software like SY/MATE Plus. Place the address of the byte to be read in the lower byte of the rst register assigned to Slot 1. The address number is zero-based; therefore, the
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range of byte addresses is 0-127 (00H-7FH). The upper eight bits of register 1 must be zeroes. After the address is placed in register 1, and at least one update scan of the DRIO module has been completed, the value of register 2 changes to reect the requested data. At this point, register 2 contains the requested address in bits 1-8, and the requested data in bits 9-16. Comparing the two registers provides conrmation that a valid read was completed. When the lower eight bits of register 1 match the lower eight bits of register 2, the Identity data for the requested address has been read and is located in the upper eight bits of register 2. See Figure 4-1.

16 Reserved

9 8 Requested Address

Identity Data Request Register

16 Requested Data

9 8 Requested Address

Identity Data Reply Register

Figure 4-1 Identity Access Registers

Users can retrieve information such as the Module Version Number and the Module Designation from the Identity Data Request Register. The following sections outline procedures for accessing this data.

Reading the Module Version Number

Byte 18 of the Identity Data Request Register contains the Module Version Number. To read this value, use the following steps: 1. Place the value 17 (11 hex) into the lower 8 bits of the Identity Data Request Register. 2. After the next DRIO update scan is complete, check the upper half of the Identity Data Request Register. The Module Version Number (in hexadecimal) will be contained in the upper half of the register.

Reading the Module Designation

The number of characters in the Module Designation may vary from model to model. For each module, Byte 19 of the Identity Data Request Register contains the number of characters that are used for the designation of that module. To read this value, use the following steps: 1. Place the value 18 (12 hex) into the lower 8 bits of the Identity Data Request Register.

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2. After the next DRIO update scan is complete, check the upper half of the Identity Data Request Register. The number of characters in the Module Designation will appear in the upper half of the register. 3. Beginning at address 19 (13 hex), request bytes from the Identity Data Request Register sequentially until the total number of bytes indicated by the character number byte have been read. Each byte of Module Designation contains one ASCII character. For example, a 16 input 24 VDC base module is a TBX DES 1622. Counting the spaces, 15 characters are contained in this designation (3 blanks follow the 1622), so addresses 19 (13 hex) through 33 (21 hex) would be read to obtain the full Module Designation. There are 16 bytes allocated for Module Designation; therefore, 16 is the largest designator that can be stored in the Identity Data Request Register. Table 4-1 outlines an example of possible register usage for a base unit.

Table 4-1: Example of Register Usage for a TBX DMS1625 Base Unit (8 Function 24VDC Input / 8 Function Relay Output)
Reg. Type
In

Point Denitions Class Point/Global 0

I/O Point (01-08) Input Off/Low

Register

Name/Function

1
Input On/High

S0001

Input register (bits 01-08) Output register (bits 09-16) Control input voltage status register Base conguration register (Reserved) Output fall-back state register

S0002

Out

I/O

Point (09-16)

Output Off/Low

Output On/High

S0003

In

Diagnostic

Global

S0004

Out

Conguration

Global

S0005 S0006

In Out Conguration Point (09-16) Set Off/Low Set On/High

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4.3 RACK ADDRESSING To maintain consistency with SY/MAX I/O products, each DRIO drop is addressed like a remote register rack, with each TBX base unit resembling one slot. Slot allocation in the DRIO is as follows: Slot 1 Slot 2 Slot 3 Base identity Primary base Expansion base

When rack addressing an RIO module in a remote register rack, rack addressing begins with Slot 2 with no registers addressed to Slot 1. This is because the RIO uses all registers in Slot 1 for internal storage. Unlike the RIO, the DRIOs rst four registers of Slot 1 are optionally used as Identity Data Request and Reply registers. Any registers beyond the rst four registers rack addressed to Slot 1 become internal storage registers. If the Identity registers are not needed, rack addressing begins with Slot 2 for the primary base and Slot 3 for the expansion base. The DRIO module can be rack addressed for a total of 64 registers in different combinations. These 64 registers can be entirely allocated to just one slot, or they can be allocated across 16 slots (the Identity registers and the two bases being slots 1, 2 and 3).

Required Rack Addressing

A connected primary or expansion base does not need to be rack addressed for the DRIO to run. If a rack addressed base unit used with the DRIO module is for inputs only, at least one register must be addressed for that base. If the base unit is for outputs only or is mixed input/output, at least two registers must be addressed for that base. Refer to the base unit instruction bulletins for specic information about register usage. A rack addressing example appears on page 4-7.

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4.4 RACK ADDRESSING EXAMPLE

SLOT #2 START ADDRESS

LOCAL (CPU) RACK

S1001 S1

C L P I U O

END ADDRESS

S1009 S32

DROP #1 (LOGICAL CHANNEL 1, DROP 1)

DRIO
SLOT #1 SLOT #9

CBS010

DES1622

DSS1622

Figure 4-2 Rack Addressing Example

R I O
RIM RIM RIM RIM ROM ROM ROM ROM 101 101 101 101 221 221 221 221

Figure 4-2 provides an example of a DRIO module with a TBX DES1622 16 Function 24 VDC Input Base Unit as the primary base unit and a TBX DSS1622 16 Function 24 VDC 0.5A Solid State Output Base as the expansion base unit. The DES1622 base unit, which is the primary base unit, requires a minimum of one register to be rack addressed for the I/O register. A total of three registers (shown in Figure 4-3 as registers S1001-S1003) are addressed to include the diagnostic register. Six registers (S1004-S1009) are assigned to the DSS1622 expansion base, including all I/O, conguration, and diagnostic registers. No registers can be assigned to the TBX CBS010 Expansion Interface. The CBS010 is a passive device providing the electrical connection between the DRIO and the expansion base.

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CPU RACK ADDRESSING PLC Model: 400 First Last Slot# Addr Addr 01 02 03 04 05 06 07 08 0001 1001 ------------------1000 1009 ------------------Module First Last Info Slot# Addr Addr INT 13 LI ------------------------09 10 11 12 13 14 15 16 ------------------------------------------------Module Info -----------------------------------------

Legal Addresses: 0001 to 4000 Use ^, v, >, < to move cursor. Use Home, End, PgUp, PgDn to view other racks.

LI Slot #: 02 1

REMOTE RACK ADDRESSING Channel #: 1

Drop #:

First Last Slot# Addr Addr 01 02 03 04 05 06 07 08 ---1001 1004 ------------------1003 1009 ----------------

Module First Last Info Slot# Addr Addr ----IN E6 IN E6 --------------------09 10 11 12 13 14 15 16 -------------------------------------------------

Module Info -----------------------------------------

Legal Addresses: 1001 to 1009 Use ^, v, >, < to move cursor.

Figure 4-3 Example of Rack Addressing Assignments (SY/MATE Plus Programming Software)

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4.5 LIO CHANNEL/DROP CONTROL REGISTERS The DRIO Module supports all of the Channel and Drop Control functions of the PASSPORT I/O System. Chapter 5 of the CRM250 LIO instruction bulletin (#30598-782) explains the use and operation of these registers in detail.

Freeze State Control

TBX base outputs feature an enhancement to the Freeze Outputs capability of the PASSPORT I/O system. In the default conguration, when the PASSPORT I/O Freeze bit is set and if communications between the LIO and DRIO fail, the DRIO Module maintains the outputs in their last state before the communications failure. This operation is the same as the Freeze state for the RIO. With TBX base outputs, the user can also have the DRIO set the outputs to a pre-dened state. In the example on page 4-6, by dening the Output Fall-back States in register S0006 and setting the Freeze State control bits in S0004 to the fall-back option, the DRIO will now set the outputs to the fall-back state when a Freeze condition occurs. When communications are restored, the outputs return to normal operation. 4.6 DRIO MODULE LED OPERATION The DRIO Module has 36 LED indicators, as shown in Figure 4-4 on page 4-10. The top four LEDs indicate DRIO, Base Unit, and Communication Status. Chapter 5 provides more detailed information on the use of the LED indicators, particularly as they are used in troubleshooting.

NOTE
The LED indicators are logic-side, not load-side indicators. During normal operation the state of each LED corresponds to the state of the addressed SY/MAX register bit as maintained by the DRIO module (1 = LED On, 0 = LED Off). The 32 I/O status LEDs are divided into two groups of 16, one group for each base unit. Each base status eld is organized as two columns of 8 rows of LEDs labeled as shown in Figure 4-4. For base units containing discrete I/O points, a one-to-one correspondence exists between the number of the base status LED, the bit position of the I/O point in a SY/MAX register (1..16) and the I/O point number labeled on the base. During normal operation the state of each LED corresponds to the state of the addressed SY/MAX register bit as maintained by the DRIO module (1 = LED On, 0 = LED Off). In bases with fewer than sixteen I/O points, the LEDs corresponding to non-existent I/O points are always OFF.

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RUN COM ACTIVE

RCK ERR COM ERROR

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

Figure 4-4 DRIO Module LED Display Drop Fault Indication

Drop faults are indicated by two occurrences: A ashing RCK ERR LED The processors going into HALT. The RCK ERR LED is the only LED that may ash at two speeds: slowly (once per second) or quickly (5 times per second). The other LEDs always ash at the faster rate. If the condition that caused the rack error still needs to be cleared, the LED ashes at the slower rate (once per second). For example, if the DRIO detects an internal base fault or missing expansion base power, the processor goes into HALT and the RCK ERR LED ashes slowly (once per second). When the fault is cleared (if expansion base power is restored, for instance), the RCK ERR LED ashes quickly (5 times per second). You must turn the processor keyswitch to RUN for normal operation to resume. The RCK ERR LED will ash for both drop faults (which HALT the processor) and non-drop faults. If a non-drop fault such as low or missing control voltage occurs, the RCK ERR LED ashes at the faster rate, and the processor does not HALT. If the DRIO detects that an output point has a fault (for example, a short-circuit condition), the LED for that output ashes, but the processor does not HALT, as a drop fault did not occur. Chapter 5 explains in more detail how to interpret the ashing LEDs. For specic information about I/O fault indications for each base unit, refer to the appropriate base unit instruction bulletin.

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5
5.1 GENERAL INFORMATION

TROUBLESHOOTING

This chapter provides troubleshooting information for the DRIO module. Some PASSPORT system problems can be diagnosed using Tables 5-1 and 5-2. Table 5-1 explains the DRIO front panel LED usage, whereas Table 5-2 lists possible system IO/NET conditions and their associated DRIO front panel LED usage. For more information about troubleshooting, refer to the Class 8030 Type CRM250 Local IO/NET Interface Module Instruction Bulletin, #30598-782. Table 5-1: DRIO Module LEDs
An all LEDs OFF condition indicates loss of power (the power supply is either off or is delivering inadequate power to the base). RUN (Green) ON FLASHING OFF COM ACTIVE (Amber) ON FLASHING OFF COM ERROR (Red) ON FLASHING OFF RCK ERR (Local Rack Error) (Red) ON FLASHING (FAST/SLOW) OFF

CPU is in RUN mode. CPU is in DISABLE OUTPUTS mode. CPU is in HALT or an error condition exists.*

Communication with LIO is active. Halt Drop bit set. An error condition exists.*

Communication between LIO and DRIO is inactive. Outputs are frozen. Valid communication exists between the LIO and DRIO.

The DRIO module has had an internal error. Error in base 1 or base 2 modules; loss of control voltage; see Table 5-2 for specic information. The DRIO module is functioning correctly.

* An error condition is defined as a loss of communication or a drop error.

When the hardware is installed and congured properly, the most common problem associated with a DRIO communicating with its LIO but not controlling its associated I/O lies in the rack addressing of the drop. Check to ensure the following are true: All the modules are properly mounted. The power supply is operating. All switches are properly set. Registers have been assigned properly. The IO/NET connector is wired properly and is securely seated.

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WARNING

UNINTENTIONAL EQUIPMENT OPERATION For remote IO/NET devices, be sure that DIP switch settings correspond with the correct bit rate and drop number in accordance with Tables 3-1 and 3-2 of this instruction bulletin. Improperly set switches cause equipment to act in an unpredictable manner. An improperly coded bit rate could disrupt communication to active drops. An improperly coded drop number: - when not a rack addressed drop, will be ignored. - when addressing is identical for two or more drops, may create a situation where the drops conict or where one drop will respond while the other is ignored. The LIO may not detect identical drops for all situations. Failure to observe this precaution can result in equipment damage, severe personal injury, or death!

Table 5-2: PASSPORT I/O System Conditions and Corresponding DRIO LED States (Page 1 of 2)
COM ACTIVE
OFF ON

Possible Conditions

RUN

COM ERROR
OFF OFF

RCK ERR (Local Rack Error)

OFF OFF

Comments

Loss of power CPU in HALT.

OFF OFF

Check power to the DRIO. Normal operation; CPU is not scanning, communication is active and outputs are reset. Normal operation; CPU is scanning and communication is active. Communication failure between LIO and DRIO.

CPU in RUN

ON

ON

OFF

OFF

Loss of communication. Outputs are reset (CPU state is unknown). Loss of communication. Outputs are frozen (CPU state is unknown). CPU in RUN. LIO Halt Drop bit is set.

OFF

OFF

ON

OFF

OFF

OFF

FLASH

OFF

Communication between LIO and DRIO has failed and outputs have been frozen as dictated by control bit. Normal operation; CPU is scanning, comunication is active, and outputs are reset as dictated by control bit. Normal operation; CPU is scanning (outputs are disabled) and communication is active. Normal operation; CPU is scanning, communication is active, and outputs are reset as dictated by control bit.

ON

FLASH

OFF

OFF

CPU in DISABLE OUTPUTS mode.

FLASH

ON

OFF

OFF

CPU in DISABLE OUTPUTS mode. LIO Halt Drop bit set.

FLASH

FLASH

OFF

OFF

Note to Table 5-2: Only the RCK ERR LED flashes at two speeds (FAST FLASH = 5 times per second; SLOW FLASH = 1 time per second). All other LEDs flash at one speed.

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Table 5-2: PASSPORT I/O System Conditions and Corresponding DRIO LED States (Page 2 of 2)
COM ACTIVE
ON

Possible Conditions

RUN

COM ERROR
FLASH

RCK ERR (Local Rack Error)

OFF

Comments

CPU in HALT. Outputs are frozen.

OFF

CPU is not scanning due to an error; communication between LIO and DRIO is active, and outputs are frozen as dictated by control bit. Normal operation; CPU is not scanning, communication is active, and outputs are reset as dictated by control bit. Communication between LIO and DRIO has been shut down and error condition still exists. Power cycle is required to restart. Communication between LIO and DRIO was shut down and error condition is cleared. Keyswitch is required to restart. DRIO module failure; outputs are reset regardless of control bit settings. Check power supply and leads.

CPU in HALT. LIO Halt Drop bit is set.

OFF

FLASH

OFF

OFF

Drop fault occurred and communication was shut down between the LIO and DRIO. Temporary loss of power to the expansion base unit

OFF

OFF

ON

SLOW FLASH

OFF

OFF

ON

FAST FLASH

DRIO had internal error (CPU state is unknown). CPU in RUN; loss of control voltage.

OFF

OFF

OFF

ON

ON

ON

OFF

FAST FLASH

Note to Table 5-2: Only the RCK ERR LED flashes at two speeds (FAST FLASH = 5 times per second; SLOW FLASH = 1 time per second). All other LEDs flash at one speed.

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NOTES

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Page A-1

APPENDIX A
USING AN EXPANSION INTERFACE CABLE
Spacing: 1 in. (25 mm)

IO/NET Connection

LED Array

Expansion Base Connector

Expansion Interface Cable

Remove end tab to close hinged snap-lock connector cover

EXPANSION CABLE MOUNTING

IO/NET Cable

Captive cable

Expansion Interface Cable

CRM270 Remote Interface

CBS Expansion Interface

Figure A-1 Installing the Expansion Interface

The CRM270 cable connector is positioned vertically on the side of the interface below the hinged connector cover. The cable connector is mounted horizontally on the upper left side (see Figure A-1). The cable connectors include a description to identify which end of the cable must be attached to the CRM270 interface, and to the TBX base unit. The connectors should be rmly seated. Ensure that the connector is aligned with the interface or base unit connector pins before seating the cable connector. Note that in the event the expansion base loses power, the expansion base will not automatically restart unless power is recycled at the primary base.

Appendix A - Expansion Interface Cable

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NOTES

Appendix A - Using an Expansion Interface Cable

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Page B-1

APPENDIX B
READING TBX BASE UNIT IDENTITY DATA

The Identity Data Request Register contains the TBX base unit identity information. The programmable logic controller cannot write to the Identity Data Request Register. From the ladder logic in the programmable controller, users can retrieve information such as the Module Version Number and the Module Designation. The following sections outline procedures for accessing this data. 5.1 READING THE MODULE VERSION NUMBER Byte 18 of the Identity Data Request Register contains the Module Version Number. To read this value, use the following steps: 1. Place the value 17 (11 hex) into the lower 8 bits of the Identity Data Request Register. 2. After the next DRIO update scan is complete, check the upper half of the Identity Data Request Register. The Module Version Number will be contained in the upper half of the register. 5.2 READING THE MODULE DESIGNATION The number of characters in the Module Designation may vary from model to model. For each module, Byte 19 of the Identity Data Request Register contains the number of characters that are used for the designation of that module. To read this value, use the following steps: 1. Place the value 18 (12 hex) into the lower 8 bits of the Identity Data Request Register. 2. After the next DRIO update scan is complete, check the upper half of the Identity Data Request Register. The number of characters in the Module Designation will appear in the upper half of the register. 3. Beginning at address 19 (13 hex), request bytes from the Identity Data Request Register sequentially until the total number of bytes indicated by the character number byte have been read. Each byte of Module Designation contains one ASCII character. For example, a 16 input 24 VDC base module is a TBX DES 1622. Counting the space, 15 characters are contained in this designation (3 blanks follow the 1622), so addresses 19 (13 hex) through 34 (22 hex) would be read to obtain the full Module Designation. There are 16 bytes allocated for Module Designation; therefore, 16 is the largest designator that can be stored in the Identity Data Request Register.

Appendix B - Base Unit Identity Data

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