metasys integrator ge® fanuc™ application

Technical Bulletin/Application Note Issue Date September 11, 2003

Metasys Integrator® GE® Fanuc™ Application

lntroduction Page 2

• Application Details 2

• Component Requirements 4

• Vendor Contact Information 5

• Design Considerations 5

Cable Connections 7

• Cable Pinouts 7

• Connecting the Cable 9

Metasys Integrator Unit Setup 10

Point Mapping Tables 12

• GE Fanuc Series 90 PLCs 12

Metasys Network Setup 14

• Mapping to a CS Object 14

Custom Integration 15

© 2002 Johnson Controls, Inc. 1 Code No. LIT-6295300 www.johnsoncontrols.com Software Release 9.2

lntroduction

Application Details This document explains Metasys Integrator® GE® Fanuc™ Automation

PLC applications, which include the Series 90/70™ and Series 90/30™ Programmable Logic Controllers (PLCs). Use this document with the Metasys Integrator technical bulletins on the Johnson Controls Product Information site (http://cgproducts.johnsoncontrols.com System Manuals > Integration > Metasys Integrator), which provides information on installing and commissioning a Metasys Integrator unit. For information on vendor equipment, see GE documentation (obtainable from a GE representative), or call 1-800-843-3742.

Note: If you use a Universal Packaging Module (UPM) enclosure, you must install the Metasys Integrator Series 300 in a two high enclosure (EN—EWC25-0) rather than a one high enclosure (EN—EWC13-0) as shown in figures within this application note.

A Metasys Integrator unit allows GE Fanuc equipment to become an integral part of the Metasys and Metasys Companion Networks. After connecting the Fanuc Automation Series PLCs to a Metasys or Companion Network via the Metasys Integrator unit, their data is available to the full complement of Metasys Building Automation System (BAS) features, including Change-of-State (COS) monitoring, alarm notification, trend, and totalization. Up to 32 Series 90 PLCs can be connected to each Metasys Integrator port (if you are using an RS-232 configuration, then only one PLC may be connected to each Metasys Integrator port).

A Metasys Integrator unit scans blocks of 64 registers, discrete inputs, and discrete outputs. When commissioning the Metasys Integrator unit, the start address of each of these blocks is specified, allowing the programmer to choose the location of the registers used to provide Metasys Integrator unit with data. A Metasys Integrator unit also preserves any existing programs it does not use.

Figure 1 shows GE Series 90 PLC and Metasys Network integration. Figure 2 shows GE Series 90 PLC and Metasys Companion Network integration.

2 Metasys Integrator GE Fanuc Application Application Note

http://cgproducts.johnsoncontrols.com/

Standard NetworkControl Unit (NCU)

Unitary Controller (UNT)

RS-232

MetasysIntegrator

Unit

Horner ElectricIsolated

RS232/RS485adapter

Figure 1: GE Series 90 PLC and Metasys Network Integration

N2 Bus

UNT

Personal Computer (PC)-Version

or

Converter

MetasysIntegrator

RS-232Custom RS-422 Cable

90/70 90/70PLC

or

Series 90PLC

RS-422 Configuration

RS-232 Configuration

Panel Version /LTD

Horner ElectricIsolated

RS232/RS485adapter

Unit

Figure 2: GE Series 90 PLC and Metasys Companion Network Integration

Metasys Integrator GE Fanuc Application Application Note 3

Component Requirements GE Fanuc Automation System

To integrate the GE Fanuc Automation system, you need the following:

• properly installed GE Series 90 PLCs with a Communications Coprocessor Module (CMM)

• Horner Electric Isolated RS-232/485 Converter for multidrop application (HE485ISO232)

• RS-232 cable (for connecting the RS-232 to RS-485 converter to Metasys Integrator unit)

• custom RS-485 cable (for connecting the GE PLCs to the converter)

• Metasys Integrator unit

• N2 Bus (for connecting Metasys Integrator unit to the Metasys or Companion Network)

• portable PC for downloading vendor communication tables (.VCT files) and network setup information and for running diagnostics

• cable for connecting portable PC to Metasys Integrator unit

• the correct vendor communication table (.VCT file) to download into Metasys Integrator unit (supplied on CD-ROM)

This document describes the RS-232 cable, the RS-485 cable, and the vendor communication tables. GE documentation describes their equipment. The remaining components are described in the Metasys Integrator technical bulletins on the Johnson Controls Product Information site (http://cgproducts.johnsoncontrols.com System Manuals > Integration > Metasys Integrator).

To integrate the GE Fanuc Automation System into the Metasys Network, you need:

Metasys Release Requirements

• Metasys OWS software Release 6.0 or later

• Metasys Integrator software/firmware Release 5.0 or later

To integrate the GE Fanuc Automation System into the Metasys Companion Network, you need:

Metasys Companion Release Requirements • Metasys Companion Release 5.0 or later

• Metasys Integrator software/firmware Release 5.0 or later



Vendor Component Requirements

Integration between the Metasys Integrator unit and GE Fanuc equipment has been tested with the Fanuc Series 90 PLCs, models 90/70 and 90/30 (CMM Revision E). Changes made to this equipment or integration of GE products not discussed in this document requires additional software development and testing. For information on integrating other products, refer to the Custom Integration section of this document.

GE Fanuc Automation Rt. 29 @ Rt. 606 Charlottesville, VA 22901

Vendor Contact Information

Main Product Support Site Phone: (800) GE Fanuc (433-26820) FAX: (800) 432-3291

PLC Technical Support: www.gefanuc.com/support/plc

Horner Electric 640 North Sherman Drive Indianapolis, IN 46201 www.heapg.com

Customer Service Phone: (317) 916-4274 FAX: (317) 916-4286

To integrate the GE Fanuc equipment, consider the following: Design Considerations • Make sure GE Fanuc equipment is set up and running properly before

integrating with the Metasys or Companion Network. (The GE representative is responsible for operation of GE Fanuc equipment.)

• Make sure the equipment’s baud rate is set to 9600. (The GE representative is responsible for setting the baud rate.)

• RS-232 cable distance between the Metasys Integrator unit and the RS-485 converter or the PLC can be a maximum of 50 feet.

• If a PLC is not configured to report data for all of the points specified in the point mapping tables, those points that are not present have a value of 0 if defined in Metasys or Metasys Companion Network.

• In the 90/30 PLC, Port 1 only supports RS-232. Port 2 supports either RS-232 or RS-485.

• Make sure to use the configuration mode RTU ONLY when configuring the CMM. Set up the port with the following parameters.


Table 1: CMM Port Parameter Setup Parameter Setting RTU Enable Yes Interface RS-485 if RS-485 Connection

RS-232 if RS-232 Connection Data Rate 9600 Flow Control None Parity Odd Station Address <unique>


Cable Connections You can either connect to one GE Fanuc PLC using the cable in Figure 5 or to a network of PLCs using a Horner Electric RS-232 to RS-485 converter using the cables in Figure 4 and Figure 5.

Cable Pinouts

Use the following cable pinouts between the Metasys Integrator unit and Port 1 or 2 on the CMM.

DB-9 Female

Signal Pin

RDTDGNDCTSDCDDTR

235814

DB-25 Male

SignalPin

23745820

RS-232

Vendor Port A or Bon Metasys Integrator CCM Port 1 or 2

TDRDGNDRTSCTSDCDDTR

fanuc7(50 ft. maximum)

Figure 3: Cable Pinouts for RS 232 Connection between the Metasys Integrator Unit and Port 1 or 2 on the CMM


PinMake ConnectionsInside D-connectors

Note:* Terminate the HE485ISO232 by shorting Pin 9 to Pin 10 on the Horner PLC RS485 port. In multi-drop networks (more than one GE Fanuc controller on the same bus), only the last GE Fanuc controller on the bus needs to have the terminator resistor connected by shorting Pins 34 to 25. In the other GE Fanuc controllers on the same bus, Pin 24 is left unconnected.

** on the CMM311, only Port 2 can support RS-422/485

HornerElectric

HE485ISO232

SD (-)SD (+)RD (-)RD (+)

RTS (+)CTS (+)RTS (-)CTS (-)

TermGND

121310111486

15

97

*

RD (A’)RD (B’)SD (A)SD (B)

RTS (A)CTS (A’)RTS (B)CTS (B’)TermGNDSHLD

1325921101122232471

Figure 4: RS-485 Custom Cable Use the following cable pinouts for the RS-232 connection between the Metasys Integrator unit and the Horner Electric RS-485 Converter.

DB-9 Female

Signal Pin

23 35

SignalPin

Vendor Port A or Bon Metasys Integrator Converter

GNDGND

(50 ft Maximum)

CTS7RTS8 RTS

CTS8

RDSD

SDRD

RS-485

Figure 5: Cable Pinouts between the Metasys Integrator Unit and the RS-485 Converter


Connect the female end of the RS-232 cable to either Vendor Port A or Vendor Port B on the Metasys Integrator unit. Connect the other end to the RS-232 Port on the Converter or Port 1 or 2 on the CMM.

Connecting the Cable

Metasys Integrator

Unit

Vendor PortA or B

CCM or Horner Electric

RS-232 to RS-422Converter

RS-232 Port

Figure 6: Port to Port Connection


Metasys Integrator Unit Setup

Use a portable PC connected to the Metasys Integrator Terminal Port to set up the Metasys Integrator unit. Metasys Integrator unit setup involves:

• downloading the correct vendor communication table (.VCT file)

• setting up the ports

• setting up the network addressing

The following table provides information specific to the GE Series 90 PLC application. For detailed procedures, see the Metasys Integrator technical bulletins on the Johnson Controls Product Information site (http://cgproducts.johnsoncontrols.com System Manuals > Integration > Metasys Integrator).

Table 2: Metasys Integrator Unit Setup for GE Fanuc Applications Vendor Communication Table (.VCT File) AI and BI Points GEFAIBI.VCT AO and BO Points GEFAOBO.VCT ADI and BD Points GEFADIBD.VCT AI and ADI Points GEFAIADI.VCT BI and BD Points GEFBIBD.VCT Port Setup Baud Rate 9600 Word Length 8 Stop Bits 1 Parity Odd Interface RS-232 Network Setup Vendor Address VVVVAAAABBBB, where:

VVVV = PLC Address (0001-00F7) AAAA = Start of Register Block 1 (AI,AO,ADI,BI) BBBB = Start of Register Block 2 (BI,BO,BD,ADI) All parameters must be specified, and are specified in hex. See Table 3 for the maximum register values associated with each CMM model. Ex: 000A00010100 for GEFAIBI table: Vendor Address 10 (000A) AI Start Register 1 (0001) BI Start Discrete Input 256 (0100)

Timeout Value 3000 ms Poll Delay 55 ms Performance Guide Approximate Scan Time (For a single N2 address) Series 90 Fanuc PLC

1 second



The Series 90 PLCs contain one of a number of compatible Central Processing Unit (CPU) cards. Each CPU has a different capacity for each point table. The CPU types and the maximum start table values associated with each CPU are given in Figure 3. As a rule, the maximum allowable starting register value is 63 less than the number of registers in the PLC for each point type. Specifying a start register value larger than the maximum values listed in Table 3 causes the PLC to be offline to the Metasys Integrator unit.

Table 3: Maximum Start Register Values for CPUs PLC CPU Type Maximum Start Table Values

%I (Discrete Inputs) and%Q (Discrete Outputs)

%R (Registers)

Hex Decimal Hex Decimal 331 01C1 449 07C1 1985

90/30 340 01C1 449 26D0 9936 341 01C1 449 26D0 9936 351 01C1 449 26D0 9936 364 07C1 1985 03C1-3FC1 961-16321** 731, 732 01C1 449 03C1-3FC1 961-16321** 771, 772 07C1 1985 03C1-3FC1 961-16321**

90/70 781, 782 2F85 12165 03C1-3FC1 961-16321** 914 2F85 12165 03C1-3FC1 961-16321** 924 2F85 12165 03C1-3FC1 961-16321**

** Based on available memory in the CPU.


Point Mapping Tables

GE Fanuc Series 90 PLCs The following tables show the points available for mapping in the

GE Fanuc Series 90 PLCs.

Table 4: GE Fanuc Series 90 PLCs (AI and BI Points) To obtain the hardware reference for mapping points to a CS object (via the software model), combine the Network Point Type (NPT) and Network Point Address (NPA). For example, the hardware reference for Read Register is AI1-AI64.

NPT1 NPA2 Unit Description Analog Input (AI)

1-64 %R Read Register (NPA + addr. of start of block -1)

Binary Input (BI)

1-64 %I Read Discrete Input (NPA + addr. of start of block -1)

1 Network Point Type 2 Network Point Address

Table 5: GE Fanuc Series 90 PLCs (AO and BO Points) To obtain the hardware reference for mapping points to a CS object (via the software model), combine the Network Point Type (NPT) and Network Point Address (NPA). For example, the hardware reference for Write Register is AO1-AO64.

NPT1 NPA2 Unit Description Analog Output

(AO)

1-64 %R Write Register (NPA + addr. of start of block -1) (-32, 768 - 32, 767)

Binary Output

(BO)

1-64 %Q Write Discrete Output (NPA + addr. of start of block -1)



Table 6: GE Fanuc Series 90 PLCs (ADI and BD Points) To obtain the hardware reference for mapping points to a CS object (via the software model), combine the Network Point Type (NPT) and Network Point Address (NPA). For example, the hardware reference for Read Register is ADI1-ADI64.

NPT1 NPA2 Unit Description Analog

Data Integer(ADI)


Binary Data (BD)



Table 7: GE Fanuc Series 90 PLCs (AI and ADI Points) To obtain the hardware reference for mapping points to a CS object (via the software model), combine the Network Point Type (NPT) and Network Point Address (NPA). For example, the hardware reference for Read Register is AI1-AI64 or ADI1-ADI64.

NPT1 NPA2 Unit Description Analog Input (AI)


Analog Data (ADI)



Table 8: GE Fanuc Series 90 PLCs (BI and BD Points) To obtain the hardware reference for mapping points to a CS object (via the software model), combine the Network Point Type (NPT) and Network Point Address (NPA). For example, the hardware reference for Read Discrete Input is BI1-BI64 or BD1-BD64.

NPT1 NPA2 Unit Description Binary Input (BI)


Binary Data (BD)




Metasys Network Setup

Metasys Network Setup is described in the Metasys Integrator technical bulletins on the Johnson Controls Product Information site (http://cgproducts.johnsoncontrols.com System Manuals > Integration > Metasys Integrator). This section contains details specific to the GE Fanuc applications.

Table 9: Software Model and CS Object Details Mapping to a CS Object Application Software Model

(on Models Disk) Display

Attribute (Recommended)

NT Command Attribute

(Recommended) GE Series 90 PLC GE_FNPLC.DDL Any Any

The model file GE_FNPLC.DDL contains CS object models for all point types in all of the GE Fanuc Series 90 vendor communication tables. Use the appropriate CS object models to build a model file that fits the application.




Custom Integration

For information on integrating products that are not discussed in this document, first refer to the Metasys Compatible Products online list of released connectivity products. If this list does not provide the information you require, consider using the Systems Integration Services (SIS) Request Custom Engineered Solutions process to request a custom contract from the System Integration Team.

Access both the Metasys Compatible Products and the Request Custom Engineered Solutions process from The Advisor by performing the following steps:

1. Click on the Products Focus link, located at the top of The Advisor home page.

2. Under Products, click on the Systems Integration Services link.

3. Under Popular Pages, click on Metasys Compatible Products for a searchable database of Metasys compatible products.

4. Return to the System Integration Services home page.

5. Under What’s New, click on Request Custom Engineered Solutions to view the process used for requesting all types of SIS engineered solutions and services.

If you need further assistance, contact the Johnson Controls Field Support Center.

Controls Group 507 E. Michigan Street P.O. Box 423 www.johnsoncontrols.comMilwaukee, WI 53201 Published in U.S.A.

metasys integrator ge® fanuc™ application

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