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Congrav S
to
Allen-Bradley DF1™
(and Ethernet/IP™)
TABLE OF CONTENTS
1. INTRODUCTION.................................................................................................................................4
2. DATALINK SPECIFICATIONS FOR CONGRAV S INTERFACE...................................................4
3. HARDWARE........................................................................................................................................5
3.1 DL-4000 to Congrav S Connection.......................................................................................5
3.2 DL-4000 to DF1 Device Connection ....................................................................................5
4. SOFTWARE .........................................................................................................................................6
4.1 Communication with DF1 .....................................................................................................6
4.2 Communication with Congrav S ...........................................................................................6
5. USE OF THE DL-4000 COMMUNICATION CONTROLLER ..........................................................7
6. SAMPLE APPLICATION – READ AND WRITE SETPOINT ..........................................................8
6.1 Sample #1 – Read and Write Setpoint with PLC-5 via DF1 .................................................8
6.2 Sample #2 – Read and Write Setpoint with PLC-5 via Ethernet...........................................13
6.3 Sample #3 – Read and Write Setpoint with SLC-500 via DF1 (SLC-5/03, 5/04 or 5/05) ....18
6.4 Sample #4 – Read and Write Setpoint with SLC-500 via Ethernet (SLC-5/05 only)............23
7. APPENDIXES ......................................................................................................................................28
A. Allen-Bradley DF1 Addressing in DL-4000 ..........................................................................29
1. Write data to Congrav S............................................................................................30
2. Read data from Congrav S ........................................................................................39
3. Read communication status.......................................................................................50
B. DATALINK Configuration ....................................................................................................51
1. INTRODUCTION
The Congrav™ line of gravimetric Loss in Weight or weigh belt controllers is provided with a serial interface port
designated for the plant (host) interface.
The communication protocol used is Siemens RK-512 with the 3964R procedure. This protocol is capable of being
converted to Allen-Bradley DF1 (and Etherenet/IP) using the DataLink communication controller (and Allen-
Bradley Ethernet Interface Module). The present documentation refers to the model DL-4000 with the standard
Allen-Bradley DF1 protocol (and Allen-Bradley module 1761-NET-ENI).
The purpose of the DataLink controller is to provide easy interface between the Congrav S controller and the Allen-
Bradley DF1 (Ethernet/IP) where remote access of the feeder(s) is required. All interface software being fully
developed and the application requiring only data handling internally.
To achieve that goal the communication unit is designed to read selected information from the Congrav S and to
write selected information to the Congrav S. The information read from the Congrav S is stored in an internal
database. Information to be written to the Congrav S is read also from the internal database. This database can be
accessed by the Allen-Bradley PLC using the standard DF1 communication instructions (MSG).
The information from/to the Congrav S is processed in commands; each command reads/writes specific data. Each
read command has its own flag to determine whether or not to perform the command. These flags are managed
according to the specific application.
Remark: These flags are necessary because the Congrav S can process only up to two commands per second.
Therefore, only the commands required for the application should be active.
The communication unit shows also the communication status with the Congrav S.
All the information mentioned above is accessed via the DF1 as described in Appendix A – Allen-Bradley DF1
addressing in DL-4000.
3. HARDWARE
The hardware used for the communication with the Congrav S consists of the DataLink DL-4000 unit with two
cables, one connecting to a DF1 device and the other to the Congrav S.
The DL-4000 is connected to the Congrav S through a 4 pin (EURO) connector on the rear panel –
labeled CHB. The connections are made according to the following pinouts for the DL-4000 and
Congrav S.
DL-4000 Congrav S
4 pin 15 Pin (-XS3)
(EURO) (male)
1 RS-422 10 (RX-)
2 2 (TX-)
3 1 (TX+)
4 9 (RX+)
Remark: Pin No. 1 on the EURO connector is the one closer to connector CHC and pin No. 4 is
closer the edge of the unit.
The DL-4000 is connected to the DF1 Device through the 9 pin DB9M (male) connector on the front
panel. The connections are made according to the following pinouts for the DL-4000 and DF1 Device
(the wiring provided for the DF1 Device is only the minimum and additional connections may be
required, according to the DF1 Device used).
4. SOFTWARE
The software for the communication with Congrav S and with DF1 is part of the DL-4000 firmware, which includes
the following modes of operation:
ON-LINE – Communication with DF1 on port A (CHA) and with Congrav S on port B (CHB). Detailed
description of operation is provided in this manual.
OFF-LINE – Configuration, Diagnostic and Debug mode. Very rarely required. Therefore, details of
operation are provided in DataLink’s user’s manual. For configuration please see Appendix B.
The communication with DF1 is written in assembler language and is part of the standard DL-4000
product. This software is compiled, and the code generated is used to program a Flash EPROM, which
becomes part of the DL-4000 firmware.
The communication with Congrav S is written in assembler language and is a custom software for this
customized DL-4000. This software is compiled, linked (together with the DF1 software) and the code
generated is used to program a Flash EPROM, which becomes part of the DL-4000 firmware.
For an Allen-Bradley PLC application the DL-4000 is a DF1 station that contains a database similar to
PLC-5 data file structure. Therefore, to communicate with the DL-4000, the PLC application has to
access the correct addresses as detailed in Appendix A – Allen-Bradley DF1 addressing in DL-4000.
The database in the DL-4000 contains values. The representation of these values (i.e. bits, integers or
floating points) is determined by the PLC address (file type) specified in the MSG instruction.
Some examples, that contain the most frequently used parts of the database, are provided in this manual.
The DL-4000 is designed with two separate virtual databases – one for values “Read” from the Congrav S and one
for values to “Write” to the Congrav S.
The values “Read” from the Congrav S are controlled by the DL-4000 with flags in the database. These flags are
constantly monitored by the software. Setting a flag (to a value of 80 hexadecimal or 128 decimal) signals the
software to “Read” the values pertaining to the command associated with that flag.
Each flag has an address in the database and is structured as part of the related command as detailed in Appendix A.
Each “Write” command interrupts the ‘Read’ cycle and is performed immediately. Therefore, “Write” commands
should be done upon value change and/or other specific logic conditions in the application (such as recipe
download), but NOT continuously, as this will practically disable the ‘Read’ cycle.
We recommend that each “Write” command is followed by the accordingly “Read” command so that data written to
the Congrav S is checked – considering Congrav S’s response time and entering the appropriate delays in the
application.
Remark: Floating Point values are being converted from one format to another. Therefore, when checking a
Floating Point value a narrow band should be used. For example it is possible that when a value of 100 is
written the value read may be 99.999 or 100.001.
The DL-4000 performs up to two commands per second to the Congrav S. Therefore, where response time is of an
importance, we suggest to limit the operations (the “Read” flags set to 80H) to the minimum required.
This section gives four examples of the application required in an Allen-Bradley PLC. The first example is for a
PLC-5 and it is followed by another example for a PLC-5 with Ethernet port. After that an example for an SLC-500
(5/03, 5/04 or 5/05 – the only ones currently available with DF1 communication) and the last example is for an SLC-
5/05 (the only one currently with an Ethernet communication).
6.1 Sample #1 – Read and Write Setpoint with PLC-5 via DF1
This section gives an example of the application required in the PLC-5 for reading and writing the
setpoint from/to the Congrav S via DF1 protocol on Channel 0.
RUNG #1
Write the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of Feeder #1 from the
Congrav S. This flag (when Set) should also be updated at a lower frequency (say every 60 sec.), to ensure
communication will resume after power failure or reset on the DL-4000.
RUNG #2
Control the frequency of polling the values from the DL-4000 on the DF1. This does not control the frequency of
polling from Congrav S, which is controlled by the DL-4000.
The poll is performed while bit B3/24 is set.
RUNG #3
Read the actual values of Feeder #1. The values are read from the DL-4000 via the DF1, so they can be read as fast
as the DF1 allows, and the frequency is controlled by the timer in the previous rung.
RUNG #4
Write a new set-point value. When an OFF to ON transition for bit B3/14 is recognized a new set-point value for the
Feeder is sent. The DL-4000 receives this new value and sends it to the Congrav S.
RUNG #5
Reset possible DF1 errors. The application may require some counting, alarm generation etc.
6.2 Sample #2 – Read and Write Setpoint with PLC-5 via Ethernet
This section gives an example of the application required in the PLC-5 for reading and writing the
setpoint from/to the Congrav S via Ethernet protocol on Channel 2, using an Allen-Bradley Ethernet to
DF1 converter (1761-NET-ENI).
RUNG #1
Write the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of Feeder #1 from the
Congrav S. This flag (when Set) should also be updated at a lower frequency (say every 60 sec.), to ensure
communication will resume after power failure or reset on the DL-4000.
MultiHop Tab:
To Address on line that starts with ‘This PLC5’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #2
Control the frequency of polling the values from the DL-4000 on the DF1 (via Ethernet). This does not control the
frequency of polling from Congrav S, which is controlled by the DL-4000.
The poll is performed while bit B3/24 is set.
RUNG #3
Read the actual values of Feeder #1. The values are read from the DL-4000 via the DF1 (via Ethernet), so they can
be read as fast as the DF1 (and Ethernet) allows, and the frequency is controlled by the timer in the previous rung.
MultiHop Tab:
To Address on line that starts with ‘This PLC5’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #4
Write a new set-point value. When an OFF to ON transition for bit B3/14 is recognized a new set-point value for the
Feeder is sent. The DL-4000 receives this new value and sends it to the Congrav S.
MultiHop Tab:
To Address on line that starts with ‘This PLC5’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #5
Reset possible DF1 (or Ethernet) errors. The application may require some counting, alarm generation etc.
6.3 Sample #3 – Read and Write Setpoint with SLC-500 via DF1 (SLC-5/03, 5/04 or 5/05)
This section gives an example of the application required in the SLC-500 for reading and writing the
setpoint from/to the Congrav S via DF1 protocol on Channel 0.
RUNG #1
Write the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of Feeder #1 from the
Congrav S. This flag (when Set) should also be updated at a lower frequency (say every 60 sec.), to ensure
communication will resume after power failure or reset on the DL-4000.
RUNG #2
Control the frequency of polling the values from the DL-4000 on the DF1. This does not control the frequency of
polling from Congrav S, which is controlled by the DL-4000.
The poll is performed while bit B3/24 is set.
RUNG #3
Read the actual values of Feeder #1. The values are read from the DL-4000 via the DF1, so they can be read as fast
as the DF1 allows, and the frequency is controlled by the timer in the previous rung.
RUNG #4
Write a new set-point value. When an OFF to ON transition for bit B3/14 is recognized a new set-point value for the
Feeder is sent. The DL-4000 receives this new value and sends it to the Congrav S.
RUNG #5
Reset possible DF1 errors. The application may require some counting, alarm generation etc.
6.4 Sample #4 – Read and Write Setpoint with SLC-500 via Ethernet (SLC-5/05 only)
This section gives an example of the application required in the SLC-5/05 for reading and writing the
setpoint from/to the Congrav S via Ethernet protocol on Channel 1, using an Allen-Bradley Ethernet to
DF1 converter (1761-NET-ENI).
RUNG #1
Write the command flag to the DL-4000. This flag tells the DL-4000 to read the actual values of Feeder #1 from the
Congrav S. This flag (when Set) should also be updated at a lower frequency (say every 60 sec.), to ensure
communication will resume after power failure or reset on the DL-4000.
¦ Error bit Control reg. ¦
¦ for message to for message to ¦
¦Set read flag write the read write the read ¦
¦actual values flag for flag for ¦
¦(write MSG) actual values actual values ¦
¦W-AV-FLAG ERR-W-AV-1 CTL-W-AV-1 ¦
¦ B3 N26:80 B3 +--MSG------------------------------ + ¦
+-----¦ ¦-------------------------¦/¦--------------[ONS]-------------- ¦ Read/Write Message +-(EN)- ¦
¦ 22 ER 23 ¦ Type Peer-To-Peer +-(DN) ¦
¦ ¦ Read/Write Write +-(ER) ¦
¦ ¦ Target Device PLC5 ¦ ¦
¦ ¦ Local/Remote Local ¦ ¦
¦ ¦ Control: N26:80 ¦ ¦
¦ ¦ Control Block Length 51 ¦ ¦
¦ ¦ Setup Screen ¦ ¦
¦ +--------------------------------------- + ¦
MultiHop Tab:
To Address on line that starts with ‘This SLC500’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #2
Control the frequency of polling the values from the DL-4000 on the DF1 (via Ethernet). This does not control the
frequency of polling from Congrav S, which is controlled by the DL-4000.
The poll is performed while bit B3/24 is set.
RUNG #3
Read the actual values of Feeder #1. The values are read from the DL-4000 via the DF1, so they can be read as fast
as the DF1 allows, and the frequency is controlled by the timer in the previous rung.
MultiHop Tab:
To Address on line that starts with ‘This SLC500’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #4
Write a new set-point value. When an OFF to ON transition for bit B3/14 is recognized a new set-point value for the
Feeder is sent. The DL-4000 receives this new value and sends it to the Congrav S.
MultiHop Tab:
To Address on line that starts with ‘This SLC500’ (1st line) : 192.168.1.82
To Address on line that starts with ‘ControlLogix Backplane’ (2nd line) : 0
RUNG #5
Reset possible DF1 errors. The application may require some counting, alarm generation etc.
7. APPENDIXES
The following tables detail the addresses required for the “Destination Address” used in the MSG instruction data entry for
a Read/Write operation with the DL-4000.
Each address has the standard Allen-Bradley format of Nxxx:yyy where:
N – File type (always N).
xxx – Command number.
yyy – Offset in words (registers) within the command.
Notes:
1. Each floating point value requires two words (registers).
2. The values for “Write” are stored in a different data table than the values for “Read”, therefore at the same address
we may have different values stored for each category – Write or Read.
3. Wherever “Kg” is mentioned it can be either “Kg” or “Lb”.
Each write command to the Congrav S performs a write of all the associated data even if only one value was changed
by the PLC (the other data is added from the DL-4000 database).
The following table details the addresses of the communication status between the DL-4000 and the Congrav S. This
data is in the DL-4000 and can be accessed by the PLC to ensure reliability of the communication.
Note:
The data is byte swapped; i.e. low byte is actually the high byte and vice versa. Therefore the PLC application
should swap the bytes before using the values in the application.
B. DATALINK Configuration
For most application the unit comes pre-configured with the appropriate data so that it is ready to “plug and play”. However for
those applications where this data is not available or was corrupted for whatever reason the following is the description of the
values required in the configuration, using the DataLink standard configuration software “DL32-4000” (ver 2.05 or later), which
is supplied with the unit.
A. Start the configuration program and select the following:
1. On the Main Menu click on the DL4000 ALL MODELS button.
2. Choose the DL4000 Model used by clicking on the DL4000-BTI button.
3. Select which COM port on the PC the DL4000 is connected to by clicking on the appropriate ‘Radio’ button. COM1 is
most commonly used, however COM2, COM3 and COM4 are also available.
4. Select operation you want to perform and follow instructions further below:
a) For preparing a new configuration file click on the Configure/Open File button.
b) To download to the DL-4000 an existing configuration file on the PC click on the Download from FILE button.
c) To upload the existing DL-4000 configuration to a file on the PC click on the Upload to FILE button.
B. To configure a new configuration (button in 4.a. above) select the following:
1. Choose Newtork protocol for CHA by clicking on the appropriate ‘Radio’ button. DF1 (should be selected in this
case) or Modbus are available.
2. Select communication speed (Baud rate) and station number with the appropriate drop down menus. Speed should be the
same as set on the DF1 host. Station number should be 1, unless otherwise required.
3. View and change as appropriate the communication parameters to correspond to the DF1 host. Selections are made by
clicking on the appropriate ‘Radio’ button.
4. Select communication speed (Baud rate) for the Congrav S with the appropriate drop down menu. Speed can be only 9600.
5. Select Congrav type connected to the DL-4000. S in this case. Selection is made by clicking on the appropriate ‘Radio’
button.
6. View and change as appropriate the communication parameters. Selections are made by clicking on the appropriate ‘Radio’
button. Parameters should be as follows:
PARITY YES
PARITY EVEN
DATA BITS 8
STOP BITS 1
HANDSHAKING IGNORE
SERIAL CONNECTION RS422-4 Wire
7. Save the configuration with the following:
a) Click on the CONFIGURATION Settings button
b) Select Save DataLink Configuration Settings… from the pull down menu.
c) Use the ‘Save As’ explorer type window to select the folder and enter the desired file name.
8. Return to previous menu by clicking on the RETURN to Main Menu button.
C. To download an existing configuration (button in A.4.b. above) select the following:
1. Click on the DOWNLOAD CONFIGURATION FILE TO A DATALINK button.
2. Use the ‘Open’ explorer type window to select the folder and file name as entered in A.7.c. above or as previously saved.
3. Follow the on-screen prompt and press the ‘Configure’ pushbutton on the DataLink unit (only the CHA and CHC lights
should be red and the Power light green).
4. Follow the on-screen prompt and press the ‘Reset’ pushbutton on the DataLink unit to put it ON-LINE.
5. After verifying that the ‘STATUS’ line includes the A-OK message, return to previous menu by clicking on the RETURN
to Main Menu button.
D. To upload an existing configuration (button in A.4.c. above) select the following:
1. Click on the UPLOAD button.
2. Follow the on-screen prompt and press the ‘Configure’ pushbutton on the DataLink unit (only the CHA and CHC lights
should be red and the Power light green).
3. Use the ‘Save As’ explorer type window to select the folder and enter the desired file name.
4. Verify that the ‘STATUS’ line includes the A-OK message.
5. View and change as appropriate the configuration by clicking on the VIEW button and following instructions in B. above.
6. When done, return to previous menu by clicking on the RETURN to Main Menu button.