Legacy Remote I/O Upgrade to Ethernet

Upgrading a Legacy LL984 Remote I/O system to Unity

● Benefits of Ethernet Remote I/O ● Daisy chain loop for reliability

● No infrastructure hardware for dependability

● Increased communications Speed

● Future forward the system with PlantStruxure products

● Distributed I/O (up to 128 nodes) on the same network (must use the Connexium Dual ring switches (DRS) )

● Remote access to the PLC from the RI/O drops thru the available service port

Upgrading a Legacy LL984 Remote I/O system to Unity

Unity version 7.0 has all of the previously mentioned features PLUS:

● The ability to add an Ethernet RI/O head into the Quantum PLC system while maintaining the Legacy S908 network.

● M340 (x80 I/O) Remote I/O drops in the Ethernet RI/O network

● Hardware Upgrade Overview 20 minutes

● Legacy Application Import Tool60 minutes

● Add Quantum Ethernet DIO drops 45 minutes

● Add new X80 Ethernet DIO drops 45 minutes

●LL984 Editor and Unity Overview 60 minutes

Legacy Upgrade Agenda

● Upgrading

● Enhancing

● Monitoring

● Distributed I/O

Ethernet Remote I/O

What will we discuss:

Upgrading

Demonstration the steps to Upgrade your PLC Remote I/O system

● Import Project and Analyze Error Elimination

● Modify the Unity configuration for QEIO

● Upgrade the Remote I/O hardware

● Analyze error elimination of your program

● Verify process operating in the Unity QEIO environment

Import and Elimination of Analyze errors

After Importing the Legacy application into Unity 6.0 or greater, Analyze and correct all errors until you have the application in the Built state. This step is done to get the original Legacy application ready to confirm the process operation on the Unity PLC.

Modify the Unity configuration for QEIOEthernet RI/O uses DTM (Device Type Manager) technology. The DTM should be installed as part of Unity. But if this is the first time using QEIO you should check to see that it was loaded. This can be done by exposing the Project Browser by either opening an I/O Drop or selecting Tools>> Project Browser. Select the DTM tab at the bottom of the window.

Open Vendors and select Schneider Electric. If it is listed in the devices, the Ethernet RI/O head can be configured in the local Quantum drop (1).

If it is not in listed in the Device list, you will need to update the DTM catalog. 1) Select “External Update Tool” 2) Select the correct device then “Update” and 3) Select “Reload catalog”

1)

2)

3)

Note: This is also how you would add a new DTM to the Unity catalog.

Upgrade the Remote I/O hardware

Prior to Upgrading the Remote I/O network you need to replace the PLC with a QEIO compatible version. If there are Communication Adapter modules in the system, they may also need to be Upgraded.

After replacing the PLC, don’t forget about the PLC configuration selections“Operating Mode on Cold Start”. These need to be selected if you want the source applications State Ram PLC values moved into Unity State Ram and/or if you want the PLC to power up in the Run state.

Insert the QEIO Head into an empty backplane slot. Right click and select New Device then the 140 CRP 312 00 Head.

To add a Remote Drop, open the ERIO Bus. Right click on the empty Drop box and select New Device. Select Quantum drop and the appropriate rack size. If the drop number is not sequential, the address can be a changed in the Topological Address window. Changing it here will update all of the required parameters. For this example the remote drop will be changed to 4.Note: The QEIO address range is 1-31 which differs from legacy RI/O that is 2-32.

The drop number can also be manually changed by modifying two default settings. Again the drop number will be changed to 4.

1) Change the Drop number, double click on the number and enter new drop number that matches the CRA 312 rotary switch settings.

2) In the Project Browser, double click on the RI/O drop number, select the Parameter tab and change the address to match the rotary switch settings

Copy the I/O Modules the modules from the legacy S908 drops to the new QEIO. Once all modules have been copied / pasted you can delete the legacy S908 RI/O head from the local drop.

Don’t forget to set your drop number rotary switches to match the drop number in the configuration before applying power to the Remote drop.

Analyze error elimination of your programAfter adding the Remote I/O drops, an Analyze of the program will produce invalid RIO Drop! ” errors. Ethernet RI/O does not get referenced to the LL984 Segments as the legacy RI/O did. You will need to “Clear” the Read and Write Drop references for all Imported Legacy RI/O drops to eliminate these errors.

Ethernet Remote I/O servicing is handled differently than Legacy Remote I/O. This example is for a traditional 3 Segment, 3 I/O Drop Segment Scheduler.

Legacy Remote I/O servicing: In legacy and Unity PLC’s

Ethernet Remote I/0 LL984 servicing in Unity

PLC Scan

If the migration has more than one Remote I/O drop then additional IEC Sections can be added between the LL984 Sections to initiate the required drop reads and writes.

Verify process operating in the Unity QEIO environment

Once all of the Analyze errors are eliminated perform a “Rebuild All”, and confirm system operation.

Lab Exercise 7 – Quantum Ethernet IO

At the completion of this module the participant should be able to:

● Configure a new CRP head EIO Processor (140 CRP 312 00)

● Configure a new CRA EIO Adapter (140 CRA 312 00)

● Successfully “Build” and download the Unity project.

● Run and Test the newly configured QEIO drop

● Hardware Upgrade Overview 20 minutes

● Legacy Application Import Tool 60 minutes

● Add Quantum Ethernet DIO drops 45 minutes

● Add new X80 Ethernet DIO drops 45 minutes

● LL984 Editor and Unity Overview 60 minutes

Legacy Upgrade Agenda

Enhancing

Demonstration the steps to Enhance a PLC system●Import and Analyze error elimination of your program●Modify the Unity configuration for QEIO

Adding Ethernet IO Head

Once the source application is successfully Imported, modified and in the Built state, we will enhance the Unity project. This will be done by adding a QEIO head to backplane slot position 10 and adding one X80 remote drop. This is done by left clicking on an empty backplane slot, select New Device, Communications and select part number 140CRP31200. Note, make sure you select a compatible PLC for this mixed RI/O system.

Modify the Unity configuration for QEIO

Right click and Open will open the QEIO bus for configuring open the EIO bus

Right click on the Drop number box

Select New Device

Select the x80 EIO drop type

Select the correct rack P/N for the drop

Now the x80 Remote I/O drop will be added to the new QEIO network. This can be done with a right mouse click, open the enter the drop

Finally, add the appropriate x80 hardware as a new EIO drop. Analyze the project and correct any errors. Once the Analyze errors are corrected, Rebuild All, download to the PLC and confirm system operation.

Again, don’t forget to set your drop number rotary switches to match the drop number in the configuration before applying power to the Remote drop.

Lab Exercise – X80 Ethernet IO At the completion of this module the participant should be able to:

● Configure a new CRP head EIO Processor (140 CRP 312 00)

● Configure a new CRA EIO Adapter (140 CRA 312 00)

● Successfully “Build” and download the Unity project.

● Run and Test the newly configured QEIO drop

Monitoring

Demonstrate how to Monitor the QEIO Network● Unity System Words (%SW) and Bits (%S)● Unity Device DDT’s

STAT monitoring of the QEIO network is not available. Here are two methods that can be implemented to monitor different aspects of the Legacy STAT instruction.

Monitor the System Bits (%S) and Words (%SW): Unity provides a vast amount of diagnostics data through the system bits and words.These can be monitored like the original STAT data or they can be moved into the same 4x area of the application. Example: Battery Failed: LL984 STAT word 1, bit 12 = Unity %S68.Drop Address 4 (both), Rack 1 module health: LL984 STAT word 27 = Unity %SW647

Unity System Words (%SW) and Bits (%S)

Attached is a spreadsheet that contains cross referencing, Note: This spreadsheet is not an exhaustive list.

STAT to %S and %SW

Unity Device DDT’s

Use the Unity Device DDT’s for Quantum and M340 QEIO : Unity provides Device DDT’s that can be used to access Remote I/O drop status.These DDT’s are automatically created when the QEIO drop is configured. The DDT name can be found under the Device DDT tab of the QEIO drop The Device DDT for Quantum is T_U_DROP_STD_IN.The Device DDT for M340 is T_M_DROP_EXT_IN.

Distributed I/O

Demonstrate how to incorporate DI/O onto the QEIO Network

●Discuss how the QEIO network can support DI/O (Advantys, Momentum etc.) on the same media

Distributed I/O connected to the QEIO network thru a Connexium DRS switch

Ethernet Remote I/O Quick Start

• Upgrading a Remote I/O system• Enhancing a Remote I/O system• Monitoring the PLC and Remote I/O system• Distributed I/O on the QEIO network

During this presentation we covered:

Questions?

Thank You