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PLC Communications

PLC Communications

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PLC Communications

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  1. PLC Communications Rockwell Automation 2013

  2. Agenda • Overview • Terms and Definitions • Indicator Setup • PLC Setup • Common Issues

  3. About METTLER TOLEDO METTLER TOLEDO is a leading global supplier of precision instruments and is the world’s largest manufacturer and marketer of weighing instruments for use in laboratory, industrial, and food retailing applications. METTLER TOLEDO provides weighing solutions that help customers by automating processes, increasing yields, controlling product quality and complying with industry standards and regulations.

  4. About METTLER TOLEDO The METTLER TOLEDO industrial product portfolio includes a broad range of weighing platforms and instrumentation. • High precision weigh modules with 1 microgram resolution to heavy duty modules with a 300 metric ton capacity • Bench and floor scales • Truck and railroad scales • Transactional indicators for parts counting, over/under checkweighing, vehicle weighing • Process indicators for filling, batching and weight transmission • Hazardous area scales, terminals and barriers

  5. About METTLER TOLEDO METTLER TOLEDO products covered in the Rockwell Automation Encompass program include the following. • Bench scales • Floor scales • Load cells and weigh modules • High precision weigh modules • Hazardous area equipment • Indicators • PLC interface bridges

  6. PLC Interfaces • METTLER TOLEDO scale terminal PLC interfaces include the following: • CC-Link • ControlNetTM • DeviceNetTM • EtherNet/IPTM • Modbus RTU • Modbus TCP • PROFIBUS DP • Remote I/O • METTLER TOLEDO also offers external PLC interface bridges that are used with laboratory balances and high precision weigh modules: • DeviceNetTM • EtherNet/IPTM • PROFIBUS DP • PROFINET

  7. PLC Communications Overview • This session will cover the METTLER TOLEDO scale terminal setup, a description of what needs to be set up in the PLC and some basic troubleshooting steps • The scale terminal setup is similar between terminals and between PLC interfaces • Each scale terminal's setup is divided into two sections • Communication parameters • Data Format

  8. Agenda • Overview • Terms and Definitions • Indicator Setup • PLC Setup • Common Issues

  9. Weighing Terminology • The terms instrument, indicator and terminal are used interchangeably. • Zero • Scale zero means the scale is empty. A zero command will establish a new zero point within a small range (2% to 20% as set up). • Gross • Total weight on the scale. Gross weight is the default value sent in cyclic data. • Tare • Weight subtracted from the gross weight. This is used to remove the weight of an empty container or items already weighed, but still on the scale • Net • The weight showing after a tare is subtracted. • Divisions • The scale capacity divided by the increment size. Example: a 50,000 lb capacity tank scale set up for 10 lb increments would equal 5,000 divisions.

  10. Data Format There are six possible Data Formats. Not all formats are available on all terminals or for all PLC interfaces. • Integer • 16 bit signed integer weight value, plus one status word. • Divisions • Internal scale divisions to support large weight values in an integer format. 16 bit signed integer weight value plus one status word. • Floating Point • IEEE 754, single precision floating point (32 bit), plus two 16 bit status words. • Template • Set up as a non-delimited set of numeric values and fixed length strings. • Application • Used for TaskExpertTM and Q.iMPACTTM application data to/from the IND560 or IND780. • Shared Data • Allows direct access of the scale terminal's internal shared data.

  11. Byte Order There are four byte order choices based on the PLC model for compatibility. • Byte Swap • Makes the floating point format compatible with Siemens S7. • Historic or Standard • Makes the floating point format compatible with some older PLC's, including PLC5. • Word Swap • Takes the IEE 754 single-precision floating point format and swaps the two words in the 32-bit double word. This format is compatible with Rockwell Automation RSLogix 5000 processors (CompactLogix and ControlLogix). • Double Word Swap • Takes the IEE 754 single-precision floating point format and swaps the two words plus byte swaps in the 32-bit double word. This format makes floating point data compatible with Modicon Quantum processors.

  12. Message Slots • Message Slots are used by the IND560 and IND780 and apply to all PLC fieldbus interfaces. • The IND560 supports up to 4 message slots • The IND780 supports up to 12 message slots • Each message slot can convey a different value or command. • Using multiple message slots is the only practical way to read multiple scales from an IND780.

  13. Support Files • Add-On-Profile • Current AOP now supports models IND131, IND331, IND560 and IND780. • Add-On-Instructions • AOI's are availble for IND131, IND331, IND560 and IND780. • AOI's support Integer and Divisions data formats. • EDS – Electronic Data Sheet • EDS files are available for IND131, IND331, IND560 and IND780. • EDS files are supplied for ControlNet, DeviceNet and EtherNet/IP. • Logix5000 example programs. • Example programs are available for IND131, IND331, IND560 and IND780. • Example programs are supplied for Integer and Floating Point data formats. • Floating point examples include explicit message examples. • Distribution • The AOP and AOI's are available through the Rockwell Automation sample code site. • AOI's, EDS files and example programs are included on CD-ROM's packed with the scale indicators and available from www.mt.com.

  14. Indicator Documentation • The METTLER TOLEDO scale indicator manuals required for PLC interface setup include the following • PLC Interface Manual • Communication parameter and data format setup • Data definitions for each of the supported data formats • Share Data Reference Manual • Listing of internal shared data for the IND560 and IND780. • User Guide • Basic setup and operating instructions. • Installation Manual • Distribution • Documentation is included on CD-ROM's packed with the scale indicators • The PLC Interface Manuals, Installation Manuals and User Guides are also available from www.mt.com

  15. Additional Documentation • Numerous METTLER TOLEDO Technical Notes addressing PLC interfacing have been published including: • IND560 PLC Data Sizes for EtherNet/IP (ITN-08-09) • IND780 PLC Data Sizes for EtherNet/IP (ITN-08-08) • JAGXTREME EtherNet/IP Replacement with IND780 (ITN-11-04) • JAGXTREME RIO Replacement with IND560 or IND780 (ITN-10-07) • Using Multiple PLC Message Slots with IND560 and IND780 (ITN-12-03) • Distribution • The above Technical Notes and others are available from the Rockwell Automation Knowledgebase

  16. Agenda • Overview • Terms and Definitions • Indicator Setup • IND131 & IND331 • IND560 & IND560x • IND780 • PLC Setup • Common Issues

  17. Indicators Indicators with PLC interfaces • IND131, IND331 • Simple weight transmitter • Universal AC or 24VDC • IND131xx, IND331xx for Division 2 areas • IND560 • Configurable terminal with standard and optional weighing application software • IND560x for Division 1 areas • IND560xx for Division 2 areas • IND780 • Configurable terminal with standard and optional weighing application software • Supports up to 4 scales • Division 2 area approved

  18. IND131 IND331 Setup • IND131, IND331, IND131xx and IND331xx PLC interface options include: • CC-Link (IND131 and IND331 only) • ControlNet (24VDC models only) • DeviceNet • EtherNet/IP & Modbus TCP • Modbus RTU • PROFIBUS DP • Remote I/O

  19. IND131 IND331 PLC Data • Data Format setup is common to all PLC interfaces • Some interfaces limit choices below • Data Format choices include: • Integer • Divisions • Floating Point • Byte Order is used to make the data compatible with different PLC models and includes these selections: • Historic – for PLC5 • Word Swap – for Logix5000 • Byte Swap – for Siemens • Double Word Swap – for Modicon • Standard – for Mitsubishi

  20. IND560 & IND560x Setup • IND560, IND560x and IND560xx PLC interface options include: • EtherNet/IP • Modbus TCP • DeviceNet • PROFIBUS DP • Remote I/O

  21. IND560 & IND560x PLC Data • Data Format setup is common to all PLC interfaces • Some interfaces limit choices below • Data Format choices include: • Integer • Divisions • Floating Point • Byte Order is used to make the data compatible with different PLC models and includes these selections: • Standard – for AB PLC5 • Word Swap – for AB Logix5000 • Byte Swap – for Siemens • Double Word Swap – for Modicon • Up to 4 Message Slots are possible depending on the interface and Data Format

  22. IND780 Setup • IND780 and IND780 Division 2 PLC interface options include: • EtherNet/IP • Modbus TCP • ControlNet • DeviceNet • PROFIBUS DP • Remote /IO • An interface menu can only be entered if the selected option is present

  23. IND780 PLC Data • Data Format setup is common to all PLC interfaces • Some interfaces limit choices below • Data Format choices include: • Integer • Divisions • Floating Point • Template • Application • Byte Order is used to make the data compatible with different PLC models and includes these selections: • Historic – for AB PLC5 • Word Swap – for AB Logix5000 • Byte Swap – for Siemens • Double Word Swap – for Modicon

  24. IND780 PLC Data • Up to 12 Message Slots are possible • Some interfaces and Data Formats limit the number of Message Slots • Changing the Data Format clears any existing Message Slots • Any Message Slot may be assigned to any Scale, including remote terminals. • There are no Message Slots assigned by default. • Message Slot setup • Press the Table softkey on the Data Format screen • Press the New softkey • Select the data source and press OK • Repeat for each Message Slot • The Data Format screen will show the number of bytes to be transferred

  25. Agenda • Overview • Terms and Definitions • Indicator Setup • PLC Setup • Common Issues

  26. PLC Setup • Message size must match • Note this Generic Ethernet Module example does NOT match

  27. Add-On-Profile • AOP setup simplifies data size matching

  28. Add-On-Instructions • AOI's available • Indicator AOI's include Divisions multipliers • High precision weigh module AOI includes command and control

  29. Agenda • Overview • Terms and Definitions • Indicator Setup • PLC Setup • Common Issues

  30. Common Issues

  31. Thank you! Questions?