Notes for MiraCosta Classes:

1. Rockwell Introduction:
a. RSLinx is a data server
b. RSLogix is the PLC configuration server
c. There are only two logins to the PLC (Logix 5000/Logix designer) – students don’t
necessarily have access
d. Login to FTView aligns with the laptop’s name
e. We will not be simulating values
f. Students will not be building new modules or applications (no access to PLC)
g. Administration Console is used when multiple applications need to be edited together.
Everything it can do can be done in individual FTView applications.
h. FTView is configuration of graphics and visualizations, PLC (Logix Designer) holds
functional configuration.
i. Go through PIDE Add-on instruction
j. Displays are whole screens, there are templates for these. Objects are the individual
pieces within the display (ie. Valves)
k. Faults need to be enabled/disabled on PLC side
l. Displays don’t work unless Global Objects are in system (required files)
2. Hardware:
a. Spares: 1DO, 3 AI, 2 AO
b. Be aware of power requirement when considering expansion
c. Serial: sends one bit at a time, slow , long distances
d. Profibus: Siemens, Open, Serial-bus, reliable, fast
e. DeviceNet: Allen-Bradley, lower processing requirement, low cost, robust, built on
Controller Area Network (CAN)
f. Expansion – second pump, agitator, temperature RTD
3. Process Control:
a. Feed Strategies – used when there is an indicator of glucose level, pump is turned off
and on according to specifications.
b. Dosing – Pump can send doses per specification
c. Other indicators: Dissolved oxygen (DO),temperature, mixing, gassing, foam, level, and
pressure
d. P = 100/Gain, I = 1/Reset, D = Rate - These can be calculated but are often tested
through guess and check
4. IO Workshop:
a. Troubleshooting: Tug test wires, trace wires, try new probe
b.
5. PID Workshop:
a.
6. Data Acquisition:
a.
INFORMATION from Orlando:

FTVIEW
Area:
 HMI Server
o Graphics – Global Objects (PlantPAx) need to be imported from the library and
must have Images already imported.
o Logic and Commands – Macros are the commands, ie. Startup begins data
logging
o Parameters – Indirect addressing is used (like tag groups)
 Alarm Server
o PlantPAX objects have preconfigured alarms that do not need to be configured
in Alarm server (can be enabled in faceplate)
o This is where criticality and alarm messages are configured
 Communications Server/OPC
o Set up channel communication
o Link OPC Server to CPU
o FTLinx is used

Logix Designer – Studio 5000

Main Routine calls Subroutines. One task per station contains all subroutines.

 Calibration
 MathMoves – All ladder logic is here, because it is too complicated for function blocks.
Resets pumps, calculates pulse time, calculates and trigger deadband, simulates
feedback to “fake” PID for pumps.
 Motors – P_motor template works with P_INTLK and P_PERM (Interlocks and
permissions). This is start/stop for the pump
 PID
 Scaling – converts units (ie. Calibrations used minutes but CPU uses milliseconds)

Acid pump tag can be addressed to another station to use two pumps together.

Spare channels are disabled in IO configuration

Communication Protocols

Profibus:

ProfiBus DP normally operates using a cyclic transfer of data between master(s) and slave(s) on an
RS485 network. That is, an assigned master periodically requests (polls) each node (slave) on the
network. All data communication exchanges between a master and slave originate from the master
device. Each slave device is assigned to one master and only that master may write output data to that
slave. Other masters may read information from any slave, but can only write output data to their own
assigned slaves.
 Masters can address individual slaves, a defined group of slaves (multi-cast), or can broadcast a
telegram to all connected slaves. Slaves will return a response to all telegrams addressed to them
individually, but do not respond to broadcast or multi-cast telegrams from a master device. ProfiBus
sends Broadcast and Multi-Cast messages as global control telegrams using address 127 and an optional
group number for a targeted group of slaves.

Because ProfiBus uses a cyclic (periodic) polling mechanism between masters and slaves, it is also
deterministic. That is, the behavior of a ProfiBus system can be reliably predicted over time. In fact,
ProfiBus was designed to guarantee a deterministic response. To contrast, CAN and Ethernet are event-
driven bus systems and consequently form non-deterministic systems.

The length (and timing) of the I/O data to be transferred from a single slave to a master is
predefined in the slave’s device data base or GSD file. The GSD files of each device connected via the
network (slaves and class 1 masters only) are compiled into a master parameter record which contains
parameterization and configuration data, an address allocation list, and the bus parameters for all
connected stations. A master uses this information to set up communication with each slave during
startup.

After a master receives its master parameter record, it is ready to begin exchanging data with its slaves.
During startup, after a system reset, or upon return to power, a master will attempt to re-establish
contact with all the slaves assigned to it before assuming the cyclic exchange of I/O data. Each slave
must already have a unique valid address from 0-125 in order to communicate with the master. Any
slave that has a default address of 126 will await the Set_Slave_Address command from a class 2 master
before it can be parameterized. In attempting to establish communication, the master starts with the
lowest address slave and ends with the highest address slave. A master will send parameterization and
configuration telegrams to all of its assigned slaves (a slave may only be write-accessed by its assigned
master, the master that parameterized and configured it during startup). The parameterization and
configuration telegrams ensure that the functionality and configuration of a slave is known to the
master. If an additional slave is added to the network bus and is not already accounted for in the master
record, a new master record must be generated and a new configuration performed so that the master
is informed of the status of the new device
Serial:
Serial is a device communication protocol that is standard on almost every PC. Do not confuse it with universal serial
bus (USB). Most computers include two EIA-232 based serial ports. Serial is also a common communication protocol
for instrumentation in many devices, and numerous GPIB-compatible devices come with an EIA-232 port.
Furthermore, you can use serial communication for data acquisition in conjunction with a remote sampling device.
Note that EIA-232 and EIA-485/422 may also be referred to as RS-232 and RS-485/422.

The concept of serial communication is simple. The serial port sends and receives bytes of information one bit at a
time. Although this is slower than parallel communication, which allows the transmission of an entire byte at once, it is
simpler and you can use it over longer distances. For example, the IEEE 488 specifications for parallel
communication state that the cabling between equipment can be no more than 20m (65ft) total, with no more than 2m
(6.5ft) between any two devices; serial, however, can extend as much as 1200m (4000ft).

Typically, engineers use serial to transmit ASCII data. They complete communication using three transmission lines --
 ground, transmit, and receive. Because serial is asynchronous, the port can transmit data on one line while receiving
data on another. Other lines are available for handshaking but are not required. The important serial characteristics
are baud rate, data bits, stop bits, and parity. For two ports to communicate, these parameters must match:
1. Baud rate is a speed measurement for communication that indicates the number of bit transfers per second. For
example, 300 baud is 300 bits per second. When engineers refer to a clock cycle, they mean the baud rate, so if
the protocol calls for a 4800 baud rate, the clock is running at 4800 Hz. This means that the serial port is
sampling the data line at 4800 Hz. Common baud rates for telephone lines are 14400, 28800, and 33600. Baud
rates greater than these are possible, but these rates reduce the distance by which engineers can separate
devices. They use these high baud rates for device communication where the devices are located together, as is
typically the case with GPIB devices.
2. Data bits are a measurement of the actual data bits in a transmission. When the computer sends a frame of
information, the amount of actual data may not be a full 8 bits. Standard values for frames are 5, 7, and 8 bits.
Which setting you choose depends on what information you are transferring. For example, standard ASCII has
values from 0 to 127 (7 bits). Extended ASCII uses 0 to 255 (8 bits). If the data you are transferring is standard
ASCII, sending 7 bits of data per frame is sufficient for communication. A frame refers to a single byte transfer,
including start/stop bits, data bits, and parity. Because the number of actual bits depends on the protocol
selected, you can use the term "frame" to cover all instances.
3. Stop bits are used to signal the end of communication for a single frame. Typical values are 1, 1.5, and 2 bits.
Because the data is clocked across the lines and each device has its own clock, it is possible for the two devices
to become slightly out of sync. Therefore, the stop bits not only indicate the end of transmission but also give the
computers some room for error in the clock speeds. The more bits used for stop bits, the greater the lenience in
synchronizing the different clocks, but the slower the data transmission rate.
4. Parity is a simple form of error checking used in serial communication. There are four types of parity -- even,
odd, marked, and spaced. You also can use no parity. For even and odd parity, the serial port sets the parity bit
(the last bit after the data bits) to a value to ensure that the transmission has an even or odd number of logic-
high bits. For example, if the data is 011, for even parity, the parity bit is 0 to keep the number of logic-high bits
even. If the parity is odd, the parity bit is 1, resulting in 3 logic-high bits. Marked and spaced parity does not
actually check the data bits but simply sets the parity bit high for marked parity or low for spaced parity. This
allows the receiving device to know the state of a bit so the device can determine if noise is corrupting the data
or if the transmitting and receiving device clocks are out of sync.

DeviceNet:
 High-level protocol that runs on top of Controller Area Network (CAN)
 Master/Slave network that supports peer-to-peer communications (as opposed to J1939
which is specifically a peer-to-peer network)
 Uses 11-bit identifiers in the message headers (unlike J1939, which uses 29-bit
identifiers)
 Supports up to 64 nodes on a single network
 Standard network transmission rates are 125k, 250k and 500k bits per second
 Network max length is determined based on the network transmission rate and the type
of cable being used (e.g. at 500k the max length can be as short as 246 feet with flat
cable and as long as 1,640 feet at 125k with thick cable)
 DeviceNet Slaves must support a minimum of 1 of the 3 data exchange methods
identified as Cyclic, Polled or Change of State (COS)
 Since DeviceNet runs over a standard CAN network, the physical layer requires two 120
ohm resistors (terminators) at each end of the network
 DeviceNet cable includes 24vdc Network Power as well as the CAN H/L connections