Owner’s Guide 0300199-01 Rev.
Important Notes 1. Please read all the information in this owner’s guide before installing the product. 2. The information in this owner's guide applies to hardware version A and firmware version 2.0 or later. 3. This guide assumes that the reader has a full working knowledge of the relevant processor. Notice The products and services described in this owner's guide are useful in a wide variety of applications.
Preface Read this preface to familiarize yourself with the rest of the owner’s guide. This preface covers: • who should use this guide • what this guide covers • related Allen-Bradley documents • terms & abbreviations you should know Who Should Use This Guide Use this guide if you design, install, program, or maintain a control system that uses Allen-Bradley ControlLogix Controllers. You should have a basic understanding of ControlLogix products.
vi ControlLogix™ Counter Module 1756 Series ControlLogix Module Installation Instructions (Each module has separate document for installation) 1756-L1, Logix5550 Controller User Manual -L1M1, -L1M2 1756-DHRIO ControlLogix Data Highway Plus Communication Interface Module User Manual 1756-5.5, -5.42 1756-6.5.12 1756-6.5.2 1756-ENET ControlLogix Ethernet Communication Interface Module User Manual 1756-6.5.
Preface vii DC - Direct Current - This is typically associated with a DC squarewave pulse signal from a flowmeter. dB (decibel) – A logarithmic measure of the ratio of two signal levels. Digital filter - A low-pass mathmatic single order filter applied to the signal. The digital filter provides high-frequency noise rejection. Effective resolution – The number of bits in the channel data word that do not vary due to noise.
viii ControlLogix™ Counter Module
Table of Contents ix Table of Contents Preface v Chapter 1 Module Overview Chapter 2 Installing Your Module Who Should Use This Guide ................................................................................... v What This Guide Covers .......................................................................................... v Related Allen-Bradley Documents ........................................................................... v Table A. Related Allen-Bradley documents ...................
x ControlLogix™ Counter Module Chapter 5 Configuring module attributes: Chapter 6 Programming Examples Chapter 7 Troubleshooting Chapter 8 Maintaining Your Module Appendix A Module Specifications Appendix B Programming Your Module Configuration, Data, and Status Tags ...................................................................................................... 31 Send Configuration Data to the Module ................................................................ 31 Configuration Tags ......
Chapter 1 Module Overview This chapter describes the counter module and explains how the ControlLogix controller reads analog input data from the module. Read this chapter to familiarize yourself further with your counter module. This chapter covers: • general description and hardware features • an overview of system and module operation General Description This module is designed exclusively for use in the Allen-Bradley ControlLogix 1756 I/O rack systems.
2 ControlLogix™ Counter Module Input Types The 1756-CTR supports both AC and DC input signal types. The module input type is configured on a channel pair basis. Each pair must be configured for the same input type. Hardware Features The module fits into any single slot for I/O modules in a ControlLogix modular system. The module has a unique generic profile which may be configured using your RSLogix 5000 programming software.
3 Chapter 1: Module Overview System Operation At power-up, the module checks internal circuits, memory, and basic functions. During this time the SYS LED remains on. If the module does not find any faults, it turns off the SYS LED. After completing power-up checks, the module wait for a connection to an owner controller then valid channel configuration data from your ladder logic program.
4 ControlLogix™ Counter Module
Installing And Wiring Your Module Read this chapter to install and wire your module. This chapter covers: Electrostatic Damage • avoiding electrostatic damage • determining power requirements • installing the module • wiring signal cables to the module’s terminal block Electrostatic discharge can damage semiconductor devices inside this module if you touch backplane connector pins.
Using your module in the ControlLogix System Place your module in any slot of a ControlLogix modular, or modular expansion chassis. An analog I/O module translates an analog signal into, or from, a corresponding digital representation which controllers can easily operate on for control purposes. A ControlLogix I/O module mounts in a ControlLogix chassis and uses a Removable Terminal Block (RTB) to connect all field-side wiring.
Removal and Insertion Under Power These modules are designed to be installed or removed while chassis power is applied. ATTENTION: When you insert or remove a module while backplane power is applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by: · sending an erroneous signal to your system’s field devices causing unintended machine motion or loss of process control. · causing an explosion in a hazardous environment.
This equipment is classified as open equipment and must be installed (mounted) in an enclosure during operation as a means of providing safety protection. CAUTION POSSIBLE EQUIPMENT OPERATION ATTENTION: The module is designed to support Removal and Insertion Under Power (RIUP). However, when you remove or insert an RTB with field-side power applied, unintended machine motion or loss of process control can occur. Exercise extreme caution when using this feature.
2. Key the RTB in positions that correspond to unkeyed module positions. Insert the wedge-shaped tab on the RTB with the rounded edge first. Push the tab onto the RTB until it stops. Keying the Removable Terminal Block Key the RTB to prevent inadvertently connecting the incorrect RTB to your module. When the RTB mounts onto the module, keying positions will match up.
• If the field wiring must cross ac or power cables, ensure that they cross at right angles. • To limit the pickup of electrical noise, keep signal wires as far from power and load lines as possible. • Ground the shield drain wire at only one end of the cable. The preferred location is at the shield connections at the ControlLogix chassis. (Refer to IEEE Std. 518, Section 6.4.2.7 or contact your sensor manufacturer for additional details.) • Tighten screw terminals with care.
Important: If noise persists, try grounding the opposite end of the cable, instead (Ground one end only.) Wiring Single-ended Inputs The following figure shows the general terminal block layout. A single-ended input uses a pair of terminals, Hi(x) and Com. Gate lines are wired with their respective Gate(x) and Com terminals.
Wiring BiDirectional or Quadrature Inputs Input use channel pairs, for example Hi2(A), Com, Hi2(B), Com. There is one gate input per channel pair.
Chapter 3 Operation Within the ControlLogix System This chapter describes how the 1756sc-CTR8 analog module works within the ControlLogix system. This chapter covers: Ownership and Connections • Ownership and connections to the module • Direct connections • Listen only mode • Configuration changes with multiple owners. Every I/O module in the ControlLogix system must be owned by a Logix5550 Controller to be useful.
Chapter 3: Operation within the System 15 1. Configure all I/O modules for a given controller using RSLogix 5000 and download that information to the controller. 2. If the I/O configuration data references a module in a remote chassis, run RSNetWorx. Important: RSNetWorx must be run whenever a new module is added to a networked chassis. When a module is permanently removed from a remote chassis, we recommend that RSNetWorx be run to optimize the allocation of network bandwidth.
16 ControlLogix™ Counter Module Real Time Sample (RTS) This configurable parameter instructs the module to perform the following operations: 1. scan all of its input channels and store the data into on-board memory 2. multicast the updated channel data (as well as other status data) to the backplane of the local chassis Requested Packet Interval (RPI) This configurable parameter also instructs the module to multicast its channel and status data to the local chassis backplane.
Chapter 3: Operation within the System 17 The timing of this “reserved” spot may or may not coincide with the exact value of the RPI, but the control system will guarantee that the owner controller will receive data at least as often as the specified RPI. The “reserved” spot on the network and the module’s RTS are asynchronous to each other. This means there are Best and Worst Case scenarios as to when the owner controller will receive updated channel data from the module in a networked chassis.
18 ControlLogix™ Counter Module Important: Only input modules can have multiple owners. If multiple owners are connected to the same input module, they must maintain identical configuration for that module. In the example below, Controller A and Controller B have both been configured to be the owner of the input module. When the controllers begin downloading configuration data, both try to establish a connection with the input module. Whichever controller’s data arrives first establishes a connection.
Chapter 3: Operation within the System 19
Chapter 4 Programming Your Module This chapter explains how to program your module in the ControlLogix system. It also describes how the module’s input configuration are incorporated into your ladder logic program. Topics discussed include: • importing the module’s configuration profile • reviewing accessing and altering configuration options.
Chapter 4: Programming Your Module Step 1- 21 Open the sample project with the CTR8 information. Open your project. Drag and drop the CTR8 module into the I/O configuration section of your project. 1. Open the sample project. 2. Open your new project. 3. Click once on the CTR8 in the sample project. 4. Drag and drop it into the I/O Configuration section of your project. See Appendix D for the I/O module property details.
22 ControlLogix™ Counter Module Step 2- Drag and drop the CTR8 user-defined data types from the sample project into your project. There are three CTR8 user defined data types that need to be moved. ConfigurationBlock InputBlock OutputBlock 1. Click on the data type 2. Drag it into your new project. 3. Continue to drag and drop the data types until all four have been moved. Note: These can only be moved one at a time.
Chapter 4: Programming Your Module 23 Step 3- Drag and drop the controller configuration tags from the sample project into your project. 1. Right click on the Controller Tags item of the sample project and select edit. 2. Right click on the Controller Tags item of your project and select edit. 3. Scroll down to the Controller tags of the sample project and select all the tags by highlighting them. 4. Drag and drop these tags into your project.
24 ControlLogix™ Counter Module Step 4- Create a new ladder logic routine in your project. 1. In your project, right mouse click on the MainRoutine item and select “New Routine...” CTR8 was entered in the example above. 2. Double click on the MainRoutine item in the sample project and then double click on the added new routine in your project to display their corresponding ladder logic. 3. Left mouse inside the MainProgram ladder logic in the sample project and press crtl-A to select all the rungs. 4.
Chapter 4: Programming Your Module Configuring module attributes: Configuration Tags 25 The module has settings that are global and channel specific. These are accessed via the controller tags. Specific information regarding these tag settings may be found in Chapter 5. Channel Specific Tags These settings control channel specific behavior such as input type, range, filter frequency, units, and alarms. Specific information regarding these tags may be found in Chapter 5.
26 ControlLogix™ Counter Module Data Tags These tags represent the process data values in their final form. Status Tags These tags report module status such as alarm conditions, faults, and errors.
Chapter 4: Programming Your Module 27
28 Chapter 5 ControlLogix™ Counter Module Configuration, Data, and Status Tags Read this chapter to: • send configuration data to the module • configure global module properties • configure each input channel • check each input channel’s data • check module and individual channel status This chapter outlines the detailed settings for the 1756sc-CTR8. These settings determine the modules input types, filter frequencies, scan rates, and various attributes.
Chapter 5: Channel Configuration, Data, and Status Configuration Tags Channel Specific Settings 29 The following Global Module Settings and Channel Specific Settings sections allow custom configuration of the module. These tags can be found within the CTR8_config controller tags. [x] designates the channel number (C) designates the value may be changed during module operation CountLimit[x] 0 - 16777215 FLOAT (C) Designates the channel rollover value. The maximum value is 1677215 when scaling is off.
30 ControlLogix™ Counter Module Uni-Directional With this configuration, the input increments in an upward direction. All 8 channels may be configured in the unidirectional mode. Every clock pulse will increment the counter on the rising edge. Note: The direction of the counter may be inverted by setting the Count Direction bit described in the Configuration chapter. Bi-Directional The bidirectional counter requires 2 input channels.
31 Chapter 5: Channel Configuration, Data, and Status A Quadrature Encoder Input A B Input B Forward Rotation Reverse Rotation A B 1 2 3 2 1 0 x1 Count x4 Count 1 2 3 4 5 6 7 8 9 10 11 12 11 10 9 8 7 6 5 4 3 2 1 0 StorageMode[x] 0-4 INT (C) This mode determines how the gate behavior effects counter behavior.
32 ControlLogix™ Counter Module StorageMode = 2 - Store/Wait/Resume StorageMode = 3 - Store-Reset/Wait/Start StorageMode = 4 - Store-Reset/Start InputRange[x] 0,1 INT This setting determines the threshold were the counter will begin to trigger. Select the range that is best suited to your sensor’s range. 0= AC 50mVpp threshold 1= AC 200mVpp threshold 2= 5V 3= 12V/24V FLOAT (C) KFactor[x] 0 - 1x1032 The K scale factor is used for counter scaling.
33 Chapter 5: Channel Configuration, Data, and Status The M factor value expressed as a floating point number. This value is multiplied by the counter actual count value, and gives the M factor a range of +- TBD (Prior counter modules we produced have been +/3.2765). Most M factors will be within +- 5% of 1.0000. FLOAT (C) MFactor[x] 0 - 1x1032 The R scale factor can be used for scaling of the output frequency. The output frequency is divided by the R scale value.
34 ControlLogix™ Counter Module Output Tags Disable[x] 0,1 Enable the counter for channel [x]. 0=enable 1=disable BOOL ResetCounter[x] 0,1 Resets counter 0 and begins counting. 0 = do not reset 1 = reset BOOL LoadPreset[x] 0.1 BOOL Loads preset count value into counter [x] and begins counting. 0 = no action 1 = load preset ResetFlags[x] Reset all flags. 0=not Reset 1=Reset Input Tags 0,1 BOOL CounterInvert[x] 0,1 Invert current direction of counter.
Chapter 5: Channel Configuration, Data, and Status StoredValue[x] 0-16777215 FLOAT Displays the value of the stored stored counts register. The maximum value is 1677215 when scaling is off. When scaling is applied the maximum value is 1677215/K*M. Rate[x] Current rate value. 0-65,000 REAL EnableEcho[x] 0,1 BOOL Software enable for the channel. This is an echo of the output tag. 0=Enable 1=Disable WasReset[x] 0,1 Displays whether the channel counter was reset.
36 ControlLogix™ Counter Module CST DINT Coordinated System Time. This is the time that the processor reads data from the FPGA. It is not the actual time that the count occurred. There will only be one CST tag for the entire module.
Chapter 5: Channel Configuration, Data, and Status 37
38 ControlLogix™ Counter Module Chapter 6 Programming Examples Earlier chapters explained how the tag configuration defines the way the module operates. This chapter shows some basic programming which controls the operation of the module. It also provides you with segments of ladder logic specific to unique situations that might apply to your programming requirements. Initial Programming Figure 6.
Chapter 6: Ladder Program Examples Figure 5.1 39 Sample Ladder Logic Rung 0 - This rung copies the configuration data (CTR8_Config) into the module’s configuration image memory. This rung is required. Rung 1 - This rung copies the input data received from the module’s input memory into the CTR8_Input tag for monitoring and ladder usaged. this rung is required. Rung 2 - This is an optional example rung indicating how to reset the module via ladder logic.
40 ControlLogix™ Counter Module You may use either the SetAttributeAll to accomplish this.
Chapter 6: Ladder Program Examples 41 Using the gate storage mode The gate storage mode allows you to configure the external gate to react in several ways. The StorageMode[x] tag has 5 valid configurations: StorageMode[x] This mode determines how the gate behavior effects counter behavior.
42 ControlLogix™ Counter Module StorageMode = 2 - Store/Wait/Resume This mode may be used in a situation were accumulated count is important but the process may stop. For instance, if you are running filling line and want to know the daily production a flowmeter will measure the total quantity even through start/stop cycles. StorageMode = 3 - Store-Reset/Wait/Start This mode could be used in a bottle filling line when you want to control the precise amount being dispensed.
Chapter 6: Ladder Program Examples 43 Installation Recommendations High Impedance Inputs If the input device is an open collector type if may be necessary to use a pull up or pull down resistor in order to achieve the proper threshold crossover point. We recommend stating is a 1kohm resistor and typing it between the input path and ground to pull down or the input path an a +12/ 24V source for pull up. Filter Frequency Settings Use of digital filters will insure best possible performance.
44 ControlLogix™ Counter Module Meter Proving The 1756sc-CTR8 module provides a feature that allows the user to perform meter proving functions. A typical meter proving application would include two detector sensors that are located a fixed distance from each other within a section of pipe used specifically for meter proving. The operation does not disrupt the in situ flowmeter’s operation.
Chapter 6: Ladder Program Examples 45
Chapter 7 Troubleshooting Using Module Indicators to Troubleshoot The count module has indicators which provide indication of module status.
Chapter 7: Testing Your Module 47 The following LED display is used with ControlLogix analog input modules: Using RSLogix 5000 to Troubleshoot Your Module In addition to the LED display on the module, RSLogix 5000 will alert you to fault conditions.
48 ControlLogix™ Counter Module Fault information on the properties screen. Determining Fault Type When you are monitoring a module’s properties dialog in RSLogix 5000 and receive a fault message, the module fault area lists the type of fault. Module Configuration Errors The “Additional Fault Code” value details the configuration error if the “(16#0009) module configuration rejected: Parameter Error” was received. Global Errors 16#0F04 - .ConfigurationRevError If the .
Chapter 7: Testing Your Module 49 Channel Specific Errors Note: n = channel number (0-7) 0x010(n) Preset is defined larger than rollover limit for channel (n). 0x0200 Input Range mismatch for channel pair 0 and 1. 0x0202 Input Range mismatch for channel pair 2 and 3. 0x0204 Input Range mismatch for channel pair 4 and 5. 0x0206 Input Range mismatch for channel pair 5 and 7. 0x030(n) Invalid operational mode for channel (n). 0x040(n) Invalid storage mode for channel (n).
50 Chapter 8 ControlLogix™ Counter Module Maintaining Your Module And Ensuring Safety Read this chapter to familiarize yourself with: • preventive maintenance • safety considerations The National Fire Protection Association (NFPA) recommends maintenance procedures for electrical equipment. Refer to article 70B of the NFPA for general safety-related work practices.
Chapter 8: Maintaining Your Module And Ensuring Safety 51 Standing Clear Of Machinery – When troubleshooting a problem with any ControlLogix system, have all personnel remain clear of machinery. The problem may be intermittent, and the machine may move unexpectedly. Have someone ready to operate an emergency stop switch. ! CAUTION POSSIBLE EQUIPMENT OPERATION Never reach into a machine to actuate a switch.
52 ControlLogix™ Counter Module WARNING ! EXPLOSION HAZARD WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES. WARNING ! THIS DEVICE IS INTENDED TO ONLY BE USED WITH THE ALLEN-BRADLEY CONTROLLOGIX 1756 I/O SYSTEM.
Chapter 8: Maintaining Your Module And Ensuring Safety 53
Appendix A Module Specifications This appendix lists the specifications for the 1756sc-CTR8 Counter Module. Electrical Specifications Backplane Current Consumption 230 mA at 5 VDC 75 mA at 24 VDC Backplane Power Consumption 3.00W maximum (0.6W @ 5 VDC, 2.4W @ 24 VDC) Maximum Power Dissipation 4.
55 Appendix A: Module Specifications Environmental Specifications Operating Temperature 0°C to 60°C (32°F to 140°F) Storage Temperature -40°C to 85°C (-40°F to 185°F) Relative Humidity 5% to 95% (without condensation) Certification CE, UL & CUL approved Hazardous Environment Class1 Division 2 Hazardous Environment Classification Groups A, B, C, D UL 508 73/23/ EEC Low Voltage Directive 89/336/ EEC Electromagnetic Compatibility CSA (Class 1, Div 2, Group A,B,C,D) CE compliance to EN 61010-1 and EN
56 ControlLogix™ Counter Module Accuracy Frequency Mode 1HzAccuracy max 65kHzAccuracy typ max Instant* Average +/-354Hz +/-1Hz +/-0.00Hz +/-0.5Hz +/-354Hz +/-2Hz 0.060% 2 0.050% 0.040% 1.5 0.030% 1 0.020% 0.5 0.010% 0 0.000% Error(%) 2.5 Error(Hz) Error(%) Fr e 30 q 0 70 0 11 00 0 15 00 0 19 00 00 23 0 0 27 00 0 31 00 0 35 00 0 39 00 0 43 00 0 47 00 00 51 0 0 55 00 0 59 00 0 63 00 00 0 Error (Hz) Average Mode Frequency Error Freq(Hz) Instantaneous Mode Frequency Error 400.000 0.
Appendix A: Module Specifications 57
Appendix B Programming Your Module This chapter explains how program your module in the ControlLogix system. It also describes how to the module’s input configuration are incorporated into your ladder logic program. Topics discussed include: • importing the module’s configuration profile • reviewing accessing and altering configuration options.
Appendix B: Installing the module using a Generic Module profile 59 1. Open your project and go to the “Add I/O module” menu under controller configuration. 2. You will now see the list of all I/O modules. Select the “Generic 1756 I/O” option. 3. After clicking “OK” you are presented with the following dialog for setting up the general information about the module.
60 ControlLogix™ Counter Module Owner Controller Connection (Controller provides configuration) Listen-only controller connection. (Controller does not provide configruration but monitors input data only. Another owner controller must exist.
Appendix B: Installing the module using a Generic Module profile 4. Specify an RPI interval between 10.0 and 750.
62 ControlLogix™ Counter Module
Getting Technical Assistance If you need technical assistance, please review the information in Chapter 6, “Testing Your Module,” before calling your local distributor of Spectrum Controls. Note that your module contains electronic components which are susceptible to damage from electrostatic discharge (ESD). An electrostatic charge can accumulate on the surface of ordinary plastic wrapping or cushioning material.
©2003 Spectrum Controls, Inc. All rights reserved. Specifications subject to change without notice. The Encompass logo and ControlLogix are trademarks of Rockwell Automation. Publication 0300199-01 Rev. B December 2003. Printed in U.S.A. Corporate Headquarters Spectrum Controls Inc. P.O. Box 5533 Bellevue, WA 98006 USA Fax: 425-641-9473 Tel: 425-746-9481 Web Site: www.spectrumcontrols.com E-mail: spectrum@spectrumcontrols.
