Insert No. DLCD-B Drawing No. LP0535 Released 3/02 Tel +1 (717) 767-6511 Fax +1 (717) 764-0839 www.redlion-controls.com MODEL DLCD – DUAL LOOP CONTROLLER w/ DH-485 GENERAL DESCRIPTION The Model DLCD, Dual Loop Controller with DH-485, has a similar feature set and specifications as the standard Dual Loop Controller. The DLCD provides a connection into an Allen Bradley DH-485 network allowing a fully featured dual loop PID controller to be controlled and monitored by an Allen Bradley PLC (SLC 500 controller, or similar), over a DH-485 network. The DLCD communications port may be configured for DH-485, or as a programming port allowing complete programming by our Windows based RLCPro configuration software. ORDERING INFORMATION MODEL NO. DLCD CBJ DRRJ11 USING THIS DOCUMENT DESCRIPTION PART NUMBER Dual Loop Controller w/ DH-485 DLCD0001 Dual Loop Controller w/ 2 Analog Outputs w/ DH-485 DLCD1001 SLC 500 (RJ45) to RJ11 Cable CBJ11C07 RJ11 Connector to Terminal Adapter DRRJ11T6 This document is an addendum to the bulletin describing the standard DLC and describes the use of the DH-485 connection of the DLCD. This document should be read in conjunction with the DLC Bulletin. 1.0 Using the DLCD on a DH-485 Network Overview The DLCD rapidly exchanges blocks of control and status information for each PID loop with an Integer File that has been allocated in the PLC. Each DLCD is assigned an Integer File by setting the appropriate DIP Switches on the DLCD. By accessing this Integer File, the PLC is able to control and monitor the operation of each PID loop within each DLCD. Most applications will only require information contained in these Control and Status blocks. The ability has been included to upload and download Parameter and Configuration blocks on demand for each PID loop. Integer File Structure The Integer File for each DLCD is structured to include Control, Status, Parameter and Configuration blocks for each PID Loop. Control and Status blocks contain data that is transferred automatically by the DLCD on alternate communication scans. Parameter Blocks contain DLCD operating parameters and may be occasionally changed. Configuration Blocks contain system configuration parameters and are rarely changed. Table 1 gives the overall structure of the Integer File giving the location of the various blocks for each PID loop or channel. The tables in the following sections show the structure of each block and provide a cross-reference from the Allen Bradley Integer File register to the equivalent MODBUS Holding Register in the DLCD. When using the Integer File tables in the following sections, refer to the Register Table in the DLC Bulletin for register details such as factory setting, limits and description. Note: Modbus registers provided for reference only. Nx: Block Reference 0..3 Control Block – Channel A Table 2 4..7 Control Block – Channel B Table 2 8..11 Status Block – Channel A Table 5 12..15 Status Block – Channel B Table 5 16..23 Parameter Block – Channel A Table 8 24..31 Parameter Block – Channel B Table 9 32..63 Configuration Block – Channel A Table 10 64..95 Configuration Block – Channel B Table 13 Table 1 - Overview of Integer File Structure 1 Control Block Status Block The Control block contains control values and commands, such as Set Point and Control Mode. The DLCD continually reads the Control Blocks for each PID loop from the PLC providing a means whereby the PLC program can control the DLCD. The Status block contains current operating values and status such as Process Value and Input Status. The DLCD continually writes the Status Block for each PID channel providing a means whereby the PLC can monitor the operating status of the DLCD. BIT POSITION Nx: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 BIT POSITION REFERENCE/ MODBUS REGISTER Nx: 15 14 13 12 11 10 9 8 0 Setpoint Channel A 40002 8 Process Value Channel A 1 Output Power Channel A 40005 9 Output Power Channel A 2 15 14 13 7 10 1 0 Table 3 6..5 3 2 1 0 Table 4 3 11 15 12 Process Value Channel B 5 Output Power Channel B 40021 13 Output Power Channel B 7 14 1 0 Table 3 6..5 4 CH. B 3 2 1 0 Table 7 40017 40021 7..5 4 3 2 1 0 Table 6 7 6 CH. A CH. B Input Error Status Register 40504 40504 Auto-Tune Phase 40012 40028 Control Output OP2 40016 40032 3 Control Output OP1 40014 40030 - 2 Set Point Ramping In Progress 40043 40051 - 1 Alarm Output AL2 40016 40032 0 Alarm Output AL1 40015 40031 40041 40049 15..8 14 Disable Integral Action 40044 40052 7..5 13 Disable Setpoint Ramping 40042 40050 4 12 Not Used - - 11 Not Used - 10 Not Used - 9 Not Used - - 8 Not Used - - 7 Auto-tune Request (See Note 2) - - 40013 40029 4 Not Used - - 3 Not Used - - 2 Not Used - - 1 Alarm Output AL2 (See Note 1) 40016 40032 0 Alarm Output AL1 (See Note 1) 40015 40031 Table 6 - Status Block for Nx:10 and Nx:14 Flags MODBUS REGISTER BITS Table 3 - Control Block for Nx:2 and Nx:6 Flags MODBUS REGISTER BITS 3 2 1 0 Table 7 REGISTER NAME Control Mode Auto-tune Code REFERENCE/ MODBUS REGISTER 0 MODBUS REGISTER BITS 15 6..5 1 4 3 2 1 0 Table 6 MODBUS REGISTER REGISTER NAME CH. A 2 Table 5 - Status Block - Channel A and B Table 2 - Control Block - Channel A and B BITS 3 40005 7..5 15..8 15 15 3 2 1 0 Table 4 5 7 6 40018 7 6 40001 15..8 4 Setpoint Channel B 6 15 14 13 7 REGISTER NAME CH. A CH. B 15 Not Used - - 14 Not Used - - 13 Not Used - - 12 Not Used - - 11 Not Used - - 10 Not Used - - 9 Not Used - - 8 Not Used - - 7 Not Used - - 6 Not Used - - 5 Not Used - - 4 Not Used - - 3 Parameter Read Strobe (See Note 3) - - 2 Configuration Read Strobe (See Note 3) - - 1 Parameter Write Strobe (See Note 3) - - 0 Configuration Write Strobe (See Note 3) - - REGISTER NAME CH. A CH. B 15 Bus Active (See Note 5) - - 14 Not Used - - 13 Not Used - - 12 Not Used - - 11 Not Used - - 10 Not Used - - 9 Not Used - - 8 Not Used - - 7 Auto-Tune In Progress (See Note 4) - - 6 Auto-Tune Done (See Note 4) - - 5 Not Used - - 4 Not Used - - 3 Parameter Block Read Acknowledge (See Note 6) - - 2 Configuration Block Read Acknowledge (See Note 6) - - 1 Parameter Block Write Acknowledge (See Note 6) - - 0 Configuration Block Write Acknowledge (See Note 6) - - Table 7 - Status Block for Nx:11 and Nx:15 Flags Table 4 - Control Block for Nx:3 and Nx:7 Flags 2 Notes: 1. Alarm Output Control The Control flags Alarm Output AL1 and AL2 must set TRUE (1) for correct Alarm operation when Control Mode is Automatic (0). Set to 0 to reset an Alarm. 2. Auto-tune Request Setting the Auto-tune Request flag forces the DLCD to start the auto-tune process. Refer to section Auto-tune Request for more detail on how the PLC program may auto-tune a PID loop in the DLCD. 3. Read/Write Strobes Setting the Read/Write Strobe flags forces the DLCD to upload or download the appropriate Parameter or Configuration block. Refer to section Transferring Parameter and Configuration Data for more detail on how to transfer these blocks between the PLC and the DLCD. 4. Auto-tune Status Monitoring the Auto-Tune Done and Auto-Tune In Progress flags allows the PLC program to detect the completion of the Auto-tune process in the DLCD. Refer to section Auto-tune Request for more detail on how the PLC program may auto-tune a PID loop in the DLCD. 5. Bus Active Each DLCD toggles the Bus Active flag on each communication scan. 6. Read/Write Acknowledge The DLCD sets the appropriate acknowledge flag once the requested upload or download of the Parameter or Configuration block is complete. Refer to section Transferring Parameter and Configuration Data for more detail on how to transfer these blocks between the PLC and the DLCD. 7. Data flow is described with respect to the DLCD in exchanges with the PLC. Thus, Read data is data transferred from the PLC to the DLCD and Write data is data transferred from the DLCD to the PLC. Parameter Block The Parameter blocks contain values that may need to be changed while the DLCD is operating, such as PID parameters. Each Parameter Block may be uploaded to or downloaded from the PLC on demand by setting the appropriate request bit in the Control Block. Refer to section Transferring Parameter and Configuration Data to see how this is done. BIT POSITION Nx: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 BIT POSITION REFERENCE/ MODBUS REGISTER Nx: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 REFERENCE/ MODBUS REGISTER 16 Proportional Band 40007 24 Proportional Band 40023 17 Integral Time 40008 25 Integral Time 40024 18 Derivative Time 40009 26 Derivative Time 19 Cycle Time (Cooling) Relative Gain (Cooling) 40141 27 Cycle Time (Cooling) 40142 40025 Relative Gain (Cooling) 40241 20 Deadband (Cooling) 40143 28 Deadband (Cooling) 40243 21 Alarm 1 Value 40003 29 Alarm 1 Value 40019 22 Alarm 2 Value 40004 30 Alarm 2 Value 40020 23 Not Used - 31 Not Used - Table 8 - Parameter Block – Channel A Table 9 - Parameter Block – Channel B 3 40242 Configuration Block The Configuration blocks contain values that describe the DLCD setup such as Input configuration and as such will not need to be changed during normal operation. These blocks may be uploaded to and downloaded from the PLC on demand by setting the appropriate request bit in the Control Block. Refer to section Transferring Parameter and Configuration Data to see how this is done. BIT POSITION Nx: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 REFERENCE/ MODBUS REGISTER BIT POSITION Nx: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 REFERENCE/ MODBUS REGISTER 32 Offset Power 40010 64 Offset Power 40026 33 Span Correction 40106 65 Span Correction / Remote Setpoint Ratio Multiplier 40206 34 Offset Correction 40107 66 Offset Correction / Remote Setpoint Bias Offset 40207 35 Low Limit (Setpoint) 40108 67 Low Limit (Setpoint) 40208 36 High Limit (Setpoint) 40109 68 High Limit (Setpoint) 40209 37 Ramp Rate (Setpoint) 40110 69 Ramp Rate (Setpoint) 40210 38 Process Low (Scaling Points) 40111 70 Process Low (Scaling Points) 40211 39 Process High (Scaling Points) 40112 71 Process High (Scaling Points) 40212 40 Input Low (Scaling Points) 40113 72 Input Low (Scaling Points) 40213 41 Input High (Scaling Points) 40114 73 Input High (Scaling Points) 40214 42 Cycle Time (OP1) 40116 74 Cycle Time (OP1) 40216 43 On Delay (AL1) 40135 75 On Delay (AL1) 40235 44 On Delay (AL2) 40140 76 On Delay (AL2) 40240 45 Scaling Value Low (Analog Output) 40303 77 Scaling Value Low (Analog Output) 40311 46 Scaling Value High (Analog Output) 40304 78 Scaling Value High (Analog Output) 40312 47 Direct Entry Value (Analog Output) 40307 79 Direct Entry Value (Analog Output) 40315 48 Ramping Setpoint Value 40045 80 Ramping Setpoint Value 40053 49 15 Table 11 81 15 Table 11 50 Sensor Failure Power Preset (OP1) 40120 82 Sensor Failure Power Preset (OP1) 40220 51 Power Low Limit (OP1) 40118 83 Power Low Limit (OP1) 40218 52 Power High Limit (OP1) 40119 84 Power High Limit (OP1) 14..8 14..8 40219 53 Dampening Time (OP1) On/Off Control Hysteresis (OP1) 40121 40122 85 Dampening Time (OP1) On/Off Control Hysteresis (OP1) 40221 40222 54 Hysteresis (AL1) Hysteresis (AL2) 40134 40139 86 Hysteresis (AL1) Hysteresis (AL2) 40305 40306 87 Deadband (Analog Output) Update Time (Analog Output) Table 12 88 15 14 13 12 Table 14 89 15..14 Table 15 90 15 40131 40136 91 Action (AL1) 60 Not Used - 92 Not Used - 61 Not Used - 93 Not Used - 62 Not Used - 94 Not Used - 63 Not Used - 95 Not Used - 55 Deadband (Analog Output) Update Time (Analog Output) 56 15 14 13 12 7 11..8 6 57 15..14 13..11 5 4..0 10..0 58 15 14..0 59 Action (AL1) Action (AL2) Table 10 - Configuration Block – Channel A 11..8 7 6 13..11 5 40234 40239 15 Channel B Assignment (Input) 14..8 Rounding (Input) Table 14 14..0 Table 15 40231 40236 Action (AL2) Table 13 - Configuration Block – Channel B MODBUS REGISTER REGISTER NAME Remote/Local Setpoint Select Table 12 10..0 MODBUS REGISTER BITS 40313 40314 4..0 BITS CH. A CH. B 40046 - - 40198 40104 40204 REGISTER NAME 15..14 Local/Remote Set Point Transfer Mode (Input) 13..11 Mode (Analog Output) 10..0 Assignment (Analog Output) Table 11 - Configuration Block for Nx:49 and Nx:81 Flags CH. A CH. B - 40199 40302 40310 40301 40309 Table 14 - Configuration Block for Nx:57 and Nx:89 Flags MODBUS REGISTER BITS REGISTER NAME Ch. A Ch. B 15 Reset (AL2) 40137 40237 CH. A CH. B 14 Reset (AL1) 40132 40232 15 Resolution (Input) 40103 40203 13 Enable Standby (AL2) 40138 40238 14..0 Input Type (Input) 40101 40201 12 Enable Standby (AL1) 40133 40233 11..8 Digital Input Filter (Input) 40105 40205 7 Temperature Scale (Input) 40102 40202 6 Control Action (OP1) 40117 40217 5 Filter (Analog Output) 40308 40316 40115 40215 4..0 Process Decimal Point (Scaling Points) MODBUS REGISTER BITS REGISTER NAME Table 15 - Configuration Block for Nx:58 and Nx:90 Flags Table 12 - Configuration Block for Nx:56 and Nx:88 Flags 4 2.0 Setting the DIP Switches Overview The DIP Switches and the Default Serial Terminal set the DLCD serial communication operating mode to either DH-485 mode or MODBUS mode. DH-485 mode allows the DLCD to be connected to a DH-485 network. MODBUS mode allows programming of the DLCD using RLCPro. PLC Address The DLCD transfers data with a target PLC. Switch B (SWB) allows the address of the target PLC on the DH-485 network to be set in the range 0..7. DH-485 Mode PLC ADDRESS Integer File Each DLCD is assigned a unique Integer File in the PLC that the DLCD uses to transfer data. Switch A (SWA) sets the target Integer file in the range N7..N70. Note N8 and N9 are invalid Integer File numbers and therefore cannot be used. SWITCH POSITION 1 2 3 4 5 6 N7 DN DN DN DN DN DN Valid File Number N8 DN DN DN DN DN UP Invalid File Number N9 DN DN DN DN UP DN Invalid File Number N10 DN DN DN DN UP UP Valid File Number N11 DN DN DN UP DN DN Valid File Number UP UP UP UP UP UP COMMENT .. 7 8 DN DN DN 1 DN DN UP 2 DN UP DN UP UP UP 7 Table 18 - Selections for PLC Address using DIP Switch B Example 1 This example shows the DIP Switch settings for a DLCD operating in DH485 mode with the following configuration. PLC Address :1 DLCD Address :8 Integer File : 10 (N10) Valid File Number Valid File Number Table 16 - Integer File settings using DIP Switch A 1 2 3 4 5 6 1 UP UP DLCD Address Each device on a DH-485 network must have a unique address. Switch B (SWB) allows the DLCD address to be set in the range 0..31. DN DN DN DN 2 3 4 5 6 7 UP DN 8 UP DN DN DN DN DN Switch Position DLCD Address 1 2 3 4 5 0 DN DN DN DN DN 1 DN DN DN DN UP 2 DN DN DN UP DN 3 DN DN DN UP UP UP UP UP UP UP Communication Settings .. 31 6 0 .. INTEGER FILE N70 SWITCH POSITION The DLCD has a fixed baud rate of 19200 when used in DH-485 mode. Table 17 - Selections for DLCD Address using DIP Switch B MODBUS Mode Alternatively, set all DIP switches Down as shown in Example 2. The DLCD leaves the factory in this state, and is therefore ready to be programmed using RLCPro. In MODBUS mode, the DLCD responds to MODBUS RTU frames and therefore allows programming using RLCPro (refer to DLC Bulletin for detailed information on using RLCPro with the DLCD). To configure the DLCD for MODBUS without changing the DIP switches, use the Default Serial Setting Terminal. Example 2 This example shows the DIP Switch settings for a DLCD operating in MODBUS mode with the default serial settings. DEFAULT SERIAL SETTING CONNECTIONS If using software selectable serial settings and the serial settings are unknown or forgotten, they can be temporarily reset to the defaults by connecting the “Default Serial Setting” terminal 7 to “Output Common” terminal 4 with a jumper. 1 3 4 5 6 DN DN DN DN DN DN Serial Communication Defaults: Protocol: RTU Address: 247 Baud Rate:9600 2 Data Bits: 8 Parity: none 5 1 2 3 4 5 6 7 8 DN DN DN DN DN DN DN DN EXAMPLE APPLICATIONS Transferring Parameter and Configuration Data Auto-tune Request Parameter and Configuration blocks can be uploaded to and downloaded from the PLC Integer File by setting the appropriate read/write strobe in the relevant Control block. On completion of the data transfer the DLCD sets the corresponding acknowledge bit in the Status block. Figure 1 shows a fragment of a Program File, captured from Rockwell’s RSLogix 500 that shows how the strobe and acknowledge flags may be used to download a configuration block to the DLCD. The Auto-tune Request flag allows the PLC program to start the auto-tune process in the DLCD. While auto-tuning, the DLCD sets the Auto-tune In Progress bit and when complete, sets the Auto-tune Done bit. By monitoring this bit, the PLC program is able to detect when the auto-tune process is complete. Figure 3 shows a fragment of a program file, captured from RSLogix 500 that shows how the request flag and done flag may be used to start the auto-tune process in the DLCD. Figure 3 - Auto-tune Request Figure 1 - Configuration Block Download Figure 2 shows a fragment of a program file, captured from RSLogix 500 that shows how the strobe and acknowledge flags may be used to upload a configuration block from the DLCD. Figure 2 - Configuration Block Upload 6 APPLICATION 1: SLC 5/03 AND DLCD Example showing direct connection of multiple DLCD units and a SLC 5/03, using Red Lion Cable Jumper (CBJ11BD5) and SLC 500 to RJ11 Cable (CBJ11C07). APPLICATION 2: DLCD with AIC MODULE Example showing direct connection of multiple DLCD units to Red Lion DIN Rail Mounted Terminal Connector (DRJ11T6) allowing a variety of connection options using the AIC Module from Allen Bradley. 7 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option. The Company disclaims all liability for any affirmation, promise or representation with respect to the products. The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries, deaths, property damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be to any extent liable, including without limitation penalties imposed by the Consumer Product Safety Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter. No warranties expressed or implied are created with respect to The Company’s products except those expressly contained herein. The Customer acknowledges the disclaimers and limitations contained herein and relies on no other warranties or affirmations. Red Lion Controls 20 Willow Springs Circle York PA 17402 Red Lion Controls France 56 Boulevard du Courcerin, Batiment 21, ZI Pariest F-77183 Croissy Beaubourg Red Lion Controls BV Databankweg 6C NL - 3821 AL Amersfoort Tel +1 (717) 767-6511 Tel +33 (64) 80 12 12 Tel +31 (33) 472 32 25 Fax +1 (717) 764-0839 Fax +33 (64) 80 12 13 Fax +31 (33) 489 37 93