U0-1130 QLC/RS232/AB Interface

Home , Group 2 (racing), Group 3 (racing)

QLC/RS232/AB Interface User’s Guide

Section Title Page Section 1. Introduction

1-1. Overview...... 1-1 1-2. Contents of this Document ...... 1-2 1-3. Additional Reference Documents...... 1-3

Section 2. Hardware Conﬁguration

2-1. Section Overview ...... 2-1 2-2. Interface Connections ...... 2-2 2-3. Cabling ...... 2-4 2-3.1. Cabling Requirements for QLC to KF2, RS-232-C...... 2-4 2-3.2. Cabling Requirements for QLC to KF2, RS-422-A ...... 2-5 2-3.3. Cabling Requirements for QLC to PLC-5, RS-232-C...... 2-6 2-3.4. Cabling Requirements for QLC to PLC-5, RS-422-A...... 2-7 2-3.5. Cabling Requirements for QLC to KF-3, RS-232-C ...... 2-7

Section 3. Software Conﬁguration

3-1. Section Overview ...... 3-1 3-2. Creating the Configuration File ...... 3-2 3-2.1. /FILE Attribute List ...... 3-3 3-2.2. /GROUP Attribute List ...... 3-6 3-2.3. /DATA Attribute List...... 3-7 3-3. Creating the AUTOEXEC.BAT File ...... 3-10 3-4. Configuring the QLC Card ...... 3-11 3-4.1. QLC LEDs ...... 3-11 3-5. Copying Required Files to the QLC Card...... 3-13

Section 4. Communication Problem Troubleshooting

4-1. Section Overview ...... 4-1 4-2. Displaying Error Messages on the External Host...... 4-1 4-3. Displaying Error Codes on the Operator Station ...... 4-2 4-4. Interpreting Allen-Bradley Reply Status Codes ...... 4-4

Glossary

Index

9/98 i U0-1130 Westinghouse Proprietary Class 2C Table of Contents, Cont’d List of Figures

Figure Title Page Section 2. Hardware Conﬁguration

2-1. QLC/AB KF2 Interface Connections...... 2-2 2-2. QLC/AB PLC-5 Connection ...... 2-3 2-3. QLC/AB SLC-500 Connection ...... 2-3 2-4. Cabling Scheme from SCOM to 1770-KF2, RS-232-C Interface ...... 2-4 2-5. Cabling Schedule from SCOM to 1770-KF2, RS-422-A Interface...... 2-5 2-6. Cabling Scheme from SCOM to PLC-5, RS-232-C Interface...... 2-6 2-7. Cabling Scheme from SCOM to PLC-5, RS-422-A Interface...... 2-7 2-8. Cabling Scheme from SCOM to KF-3, RS-232-C Interface ...... 2-7

Section 3. Software Conﬁguration

3-1. Sample PGROUPS Configuration File ...... 3-2 3-2. Sample /FILE Attribute List ...... 3-3 3-3. Sample /GROUP Attribute List ...... 3-6 3-4. Sample /DATA Attribute List ...... 3-7 3-5. Location of LEDs on QLC Card ...... 3-12

U0-1130 ii 9/98 Westinghouse Proprietary Class 2C Table of Contents, Cont’d List of Tables

Table Title Page Section 1. Introduction

1-1. Reference Documents ...... 1-3

Section 3. Software Conﬁguration

3-1. /FILE Attribute List ...... 3-3 3-2. /GROUP Attribute List ...... 3-6 3-3. /DATA Attribute List ...... 3-8 3-4. Valid AB PLC Addresses ...... 3-8

Section 4. Communication Problem Troubleshooting

4-1. Error Codes /Error Messages...... 4-3

9/98 iii U0-1130 Westinghouse Proprietary Class 2C Section 1. Introduction

1-1. Overview

This document describes the interface between the Q-Line Serial Link Controller (QLC) card and the Allen-Bradley Programmable Logic Controller (PLC®). This interface provides a link between the QLC card and Allen-Bradley PLC-2s, PLC- 5s, or SLC-500s.

This link may be established in several conﬁgurations. First, the QLC may be connected to the Allen-Bradley KF2 Interface Module, thereby giving it access to any or all the Allen-Bradley devices (PLCs) on the Data Highway. Another way is to connect the QLC directly to the programming port of an Allen Bradley PLC -5. (Note: This option is only available on the PLC-5: the PLC-2s do not have this capability.) Either of these connections may be made using either the RS-232-C or RS-422-A electrical interfaces. All these options are documented below.

This interface (hereafter referred to as the QLC/RS232/AB Interface) provides the communication necessary to integrate Allen Bradley PLC-controlled processes into the WDPF® control system.

PLC-2 communication utilizes the following commands: • Unprotected Read - Reads words of data from any area of PLC data table memory. • Protected Write - Writes words of data into limited areas of PLC data table memory (refer to the Allen-Bradley Manual “Data Highway/Data Highway Plus Protocol and Command Set” (1770-6.5.16) for more information on using PLC commands).

PLC-5 communication utilizes the following commands: • Typed Read - Reads a block of data from the processor (starting at PLC-5 system address plus the packet offset). • Typed Write - Writes a block of data to the processor (starting at PLC-5 system address plus the packet offset) (refer to the Allen-Bradley Manual “Data Highway/Data Highway Plus Protocol and Command Set” (1770-6.5.16) for more information on using PLC commands). • Read-Modify-Write - Writes digital bit data to the processor by first reading the data, modifying the specified bits, and writing the data back to the processor thereby avoiding the modification of unspecified bits.

9/98 1-1 U0-1130 Westinghouse Proprietary Class 2C 1-2. Contents of this Document

SLC-500 communication utilizes the following commands: • Unprotected Read - Reads words of data from any area of PLC data table memory. Low bytes are transferred ﬁrst. • Unprotected Write - Writes words of data to any area of PLC data table memory.

Note

This version of the interface software supersedes the software described in “QLC PCI User’s Guide” (U0-1110) that pertains to Allen-Bradley PLCs.

1-2. Contents of this Document

This document is organized into the following sections: • Section 1. Introduction provides an overview of the QLC Card to Allen- Bradley Programmable Logic Controller (PLC) Interface. • Section 2. Hardware Configuration provides information about the various ways the QLC can be connected to access Allen-Bradley equipment. Detailed cabling diagrams are provided for each possible connection and electrical interface. • Section 3. Software Configuration provides information needed to conﬁgure the applicable software for the QLC/RS232/AB Interface. • Section 4. Communication Problem Troubleshooting provides methods for solving QLC/RS232/AB Interface problems.

U0-1130 1-2 9/98 Westinghouse Proprietary Class 2C 1-3. Additional Reference Documents

1-3. Additional Reference Documents

Additional reference documents that will be helpful to the QLC/RS232/AB Interface user are listed in Table 1-1.

Table 1-1. Reference Documents Document Number Title Description M0-0003 Self-Test Diagnostics Describes the WDPF diagnostic tools and Fault Codes used to deﬁne errors and problems in the system. U0-0106 Standard Control Algorithm Describes algorithms available for use User’s Guide with the DPU. U0-1100 QLC User’s Guide Describes QLC card conﬁguration and operation. U0-1110 QLC PCI User’s Guide Describes QLC Programmable Controller Interface and its operation. Allen-Bradley Data Highway/Data Highway Describes protocol and commands Manual Plus Protocol and Command used in the operation of the Allen- 1770-6.5.16 Set Bradley PLC. Allen-Bradley Allen-Bradley Data Highway Describes the operation and use of the Manual or Data Highway Plus 1770-KF2 Interface Module, including 1770-6.5.13 Asynchronous (RS-232-C or cabling requirements. RS-422-A) Interface Module- User’s Manual Allen-Bradley DH-485 Communication Describes the operation and use of the Manual Interface 1770-KF3 Interface Module. 1770-6.5.18

9/98 1-3 U0-1130 Westinghouse Proprietary Class 2C Section 2. Hardware Conﬁguration

2-1. Section Overview

This section describes the hardware and cabling needed to connect the Westinghouse QLC Serial Link Controller card to Allen-Bradley equipment.

It covers connections between the QLC and the KF2, as well as to a single Allen- Bradley PLC-5 (for access to multiple Allen-Bradley devices via the Allen-Bradley Data Highway, refer to the “Allen-Bradley Interface Module - User’s Manual.”)

It also covers connection between the QLC and the KF3 (for access to Allen- Bradley SLC-500 controllers). Note that the identical communications protocol is used for communicating to the KF2, KF3 and to the PLC-5, so no changes in the QLC software are necessary for either installation. (Refer to “QLC User’s Guide” (U0-1100) for additional information on the use and operation of the QLC card).

9/98 2-1 U0-1130 Westinghouse Proprietary Class 2C 2-2. Interface Connections

2-2. Interface Connections

The QLC card uses an SCOM card to perform serial communications with Allen- Bradley devices. The SCOM card emulates the standard PC COM1 serial port. There are two types of SCOM cards available for the QLC: the “Group 01” card for the RS-232-C electrical interface (Westinghouse part number 4256A06G01) and the “Group 2” card for the RS-422-A electrical interface (Westinghouse part number 4256A06G02). These SCOM cards isolate the details of the electrical interface from the QLC card itself. This is why no programming changes are necessary to accommodate either electrical interface

Note that the RS-232-C interface is appropriate for installations where the distance between the QLC and the Allen-Bradley equipment is 50 feet (15 meters) or less. The RS-422-A interface can be used for distances up to 4000 feet (1220 meters).

The selected SCOM card may then be connected to the Allen-Bradley Data Highway/Data Highway Plus (tm) through the Allen-Bradley 1770-KF2 Interface Module. The purpose of this module is to provide access to the Data Highway through a serial (RS-232-C or RS-422-A) communications link. The KF2 Module can be conﬁgured to either electrical interface through several switch settings. (Refer to the Allen-Bradley Interface Module User’s Manual for details on selecting the desired interface).

The PLCs to be communicated with are connected to the Data Highway. (Refer to the Allen-Bradley manual 1770-6.5.16 for information on Allen-Bradley PLCs and the Data Highway.) Figure 2-1 illustrates an example of the connections in a typical QLC to an Allen-Bradley KF2 Interface Module.

Allen-Bradley Data Highway/Data Highway Plus Allen-Bradley 1770-KF2 SCOM Module QLC * Allen-Bradley Allen-Bradley PLC-5 PLC-2 * Group 01 or Group 02 card

Figure 2-1. QLC/AB KF2 Interface Connections

U0-1130 2-2 9/98 Westinghouse Proprietary Class 2C 2-2. Interface Connections

Alternatively, the SCOM card may be connected directly to a PLC-5’s programming port, utilizing either electrical interface. Unlike the KF2 interface conﬁguration above, this connection only allows communications between the QLC and a single Allen-Bradley PLC. However, very much like the KF2, the PLC-5 is switch-selectable between the RS-232-C and RS-422-A electrical interfaces. (Refer to the appropriate PLC-5 Hardware manual or the information printed on the side of the PLC-5 itself for details.) Figure 2-2 illustrates the conﬁguration of a QLC directly connected to a PLC-5.

SCOM Allen-Bradley QLC * PLC-5

* Group 01 or Group 02 card

Figure 2-2. QLC/AB PLC-5 Connection

The SCOM card may also be connected to the Allen-Bradley DH-485 Data Highway via the 1770-KF3 DH-485 interface module. This module is used to provide access to SLC-500 controllers on DH-485 to an RS-232 serial communication link. Figure 2-3 illustrates a typical connection between the QLC and SLC-500s.

Allen-Bradley DH-485 Allen-Bradley 1770-KF3 Module SCOM QLC * Allen-Bradley Allen-Bradley SLC-500 SLC-500

* Group 01card only

Figure 2-3. QLC/AB SLC-500 Connection

9/98 2-3 U0-1130 Westinghouse Proprietary Class 2C 2-3. Cabling

2-3. Cabling

2-3.1. Cabling Requirements for QLC to KF2, RS-232-C

Figure 2-4 illustrates the required cabling from the SCOM Group 01 card to a 1770- KF2 Interface Module.

9-Pin Female 25-Pin Female D Connector D Connector at SCOM Group 01card at 1770-KF2 Interface Module

Signal Pin Pin Signal Name Number Number Name RXD 2 2 TXD GND 5 7 GND

TXD 3 3 RXD

DCD 1 4 RTS DTR 4 5 CTS DSR 6 6 DSR RTS 7 8 DCD CTS 8 20 DTR

Figure 2-4. Cabling Scheme from SCOM to 1770-KF2, RS-232-C Interface

U0-1130 2-4 9/98 Westinghouse Proprietary Class 2C 2-3. Cabling

2-3.2. Cabling Requirements for QLC to KF2, RS-422-A

Figure 2-5 illustrates the required cabling from the SCOM Group 02 card to a 1770- KF2 Interface Module.

25-Pin Female 9-Pin Female D Connector D Connector at 1770-KF2 Interface Module at SCOM Group 02 card

Signal Pin Pin Signal Name Number Number Name - RXD 1 25 TDB + RXD 2 14 TDA

+ TXD 3 16 RDA - TXD 4 18 RDB 4 RTS 5 CTS 6 DSR 8 DCD 20 DTR

Figure 2-5. Cabling Schedule from SCOM to 1770-KF2, RS-422-A Interface

9/98 2-5 U0-1130 Westinghouse Proprietary Class 2C 2-3. Cabling

2-3.3. Cabling Requirements for QLC to PLC-5, RS-232-C

Figure 2-6 illustrates the required cabling from the SCOM Group 01 card to a PLC-5.

9-Pin Female 25-Pin Female D Connector D Connector at SCOM Group 01card at PLC-5 Interface Module

Signal Pin Pin Signal Name Number Number Name RXD 2 2 TXD GND 5 7 GND

TXD 3 3 RXD

DCD 1 4 RTS DTR 4 5 CTS DSR 6 6 DSR RTS 7 8 DCD CTS 8 20 DTR

Figure 2-6. Cabling Scheme from SCOM to PLC-5, RS-232-C Interface

U0-1130 2-6 9/98 Westinghouse Proprietary Class 2C 2-3. Cabling

2-3.4. Cabling Requirements for QLC to PLC-5, RS-422-A

Figure 2-7 illustrates the required cabling from the SCOM Group 02 card to a PLC-5.

25-Pin Male 9-Pin Female D Connector D Connector at PLC-5 Interface Module at SCOM Group 02 card

Signal Pin Pin Signal Name Number Number Name - RXD 1 2 TXD.OUT + RXD 2 14 TXD.OUT’

+ TXD 3 16 RXD.IN’ - TXD 4 3 RXD.IN

Figure 2-7. Cabling Scheme from SCOM to PLC-5, RS-422-A Interface

2-3.5. Cabling Requirements for QLC to KF-3, RS-232-C

Figure 2-6 illustrates the required cabling from the SCOM Group 01 card to a 1770-KF3 Interface Module.

9-Pin Female 25-Pin Female D Connector D Connector at SCOM Group 01card at 1770-KF3 Interface Module

Signal Pin Pin Signal Name Number Number Name RXD 2 2 TXD GND 5 7 GND

TXD 3 3 RXD

Figure 2-8. Cabling Scheme from SCOM to KF-3, RS-232-C Interface

9/98 2-7 U0-1130 Westinghouse Proprietary Class 2C Section 3. Software Conﬁguration

3-1. Section Overview

This section describes the software configuration needed for the interface between a QLC card and an Allen-Bradley PLC (QLC/RS232/AB Interface). The following procedures must be performed in order to use the QLC/RS232/AB Interface: • Create a configuration file (Section 3-2). • Create an AUTOEXEC.BAT file (Section 3-3). • Configure the QLC card (Section 3-4). • Copy the ABQLC.EXE program, the configuration file, and the AUTOEXEC.BAT file to the QLC card (Section 3-5).

9/98 3-1 U0-1130 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

3-2. Creating the Conﬁguration File

The first step is to create the configuration file. Once the configuration file has been created and verified, it must be loaded along with the driver executable file named ABQLC.EXE to the QLC. Please refer to the “QLC User's Guide” (U0-1100) for instructions on the operation of the QLC card.

The configuration file is made up of three parts, the /FILE, /GROUP, and /DATA attribute lists (a sample configuration file, PGROUPS, is provided with the system and is shown in Figure 3-3).

/FILE: title = “sample”, port = 1, baud = 19200, parity = N, databits = 8, stopbits = 1, sourceaddr = 12, looptime = 0.0, timeout = 2.0, numnaks = 3, numenqs = 3, watchdogtime = 5.0, switch = 1000, recoveryerrs = 3, quiettime = 5.0, statusreg = 2000 /GROUP: name = “group1”, direction = IN, type = PLC-2, station = 1, plc5file = 14 /DATA: AKJHKIC, N10:000, A0000 BLKYYLU, N10:001, A0002 CETKHGD, N10:002/00, D0004 SJHLKJH, N10:002/04, D0005 KJIUDFU, N10:008, G0007

Figure 3-1. Sample PGROUPS Conﬁguration File

The /FILE attribute list deﬁnes general attributes to be used for the interface. An example of a /FILE list follows in Section 3-2.1. Any attribute with a default can be left out of the list and maintain the default value. There must be a comma after every attribute except the last one in the list. The ﬁrst attribute without a comma following it is considered to be the last attribute.

U0-1130 3-2 9/98 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

/GROUP and /DATA attribute lists must be paired and each pair deﬁnes a single command to the PLC. After each /GROUP list there must be a /DATA list with at least one point deﬁned. Refer to Section 3-2.2 and Section 3-2.3 for information on creating /GROUP and /DATA attribute lists.

3-2.1. /FILE Attribute List

Figure 3-3 illustrates the /FILE portion of the sample PGROUPS configuration file and Table 3-1 defines the parameters.

Figure 3-2. Sample /FILE Attribute List

Table 3-1. /FILE Attribute List Parameter Range/Value Description title Any valid ﬁlename. Required in order to give the interface a name port 1 or 2. COM port, must be zero (1) for QLC. (Default = 1) baud 50 through 19200. Baud rate. (Default = 9600) parity None (N), Odd (O), or Parity. Even (E). (Default = N)

9/98 3-3 U0-1130 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

Table 3-1. /FILE Attribute List (Cont’d) Parameter Range/Value Description databits 5, 6, 7, or 8. Databits. (Default = 8) stopbits 1 or 2. Stopbits. (Default = 1) sourceaddr 0 through 254 Station Address of KF2. (Default = 0) looptime Equal to or greater than 0. Minimum time, in seconds, to execute a single loop of commands. 0 means as fast as possible. (Default = 0) timeout Equal to or greater than 0. Minimum time, in seconds, allowed to expire without receiving any bytes from the PLC. (Default = 0) numnaks Refer to Allen-Bradley Number of negative acknowledge messages manual. allowed before abandoning the command. (Default = 0) numenqs Refer to Allen-Bradley Number of enquiry messages allowed before manual. abandoning the command. (Default = 0) watchdogtime Equal to or greater than 0. Time, in seconds, it takes the watchdog timer to expire when not updated. (Default = 0) switch 0 through 2047. Register in the QLC that determines whether the QLC is in command or backup mode in a redundant pair of QLCs.

Parameter is not used if not included in FILE list. 0 means that QLC is not redundant. (Default = 0)

U0-1130 3-4 9/98 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

Table 3-1. /FILE Attribute List (Cont’d) Parameter Range/Value Description recoveryerrs Equal to or greater than 0. Number of consecutive errors allowed during communication with the PLC before entering a “recovery procedure” that synchronizes the QLC and PLC.

Parameter is not used if not included in FILE list. (Default = 0) quiettime Equal to or greater than 0. Time, in seconds, during which the line should be quiet while in the recovery procedure, before returning to normal processing.

Parameter is not used if not included in FILE list and should only be used with recoveryerrs parameter. (Default = 0) statusreg 0 through 2047. Register in the QLC where status information is stored for the QLCSTATalgorithm (refer to “Control Algorithms” (U0-0106) for information on the QLCSTAT algorithm).

Parameter is not used if not included in FILE list. (Default = 0). statusholdtime Equal to or greater than 0. Time, in seconds, that error information is held in statusreg location. Should be chosen to exceed the scan time of the control area containing the QLCSTAT algorithm.

(Default = 0).

9/98 3-5 U0-1130 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

3-2.2. /GROUP Attribute List

The /GROUP attributes deﬁne the group name, direction, PLC type, and station where the command is to be sent. Each group is handled as a single read or write command to the PLC. Therefore, when writing (OUT, OUT_E) data to a PLC, the points in the group should have contiguous addresses in the PLC.

Figure 3-3 illustrates the /GROUP portion of the sample PGROUPS configuration file and Table 3-2 defines the parameters.

/GROUP: name = “group1”, direction = IN, type = PLC-2, station = 1, plc5file = 14

Figure 3-3. Sample /GROUP Attribute List

Table 3-2. /GROUP Attribute List Parameter Range/Value Description name Any valid group name. Required in order to give the group of points a name direction IN = Read. Required to provide the direction of data. OUT = Write. OUT_E = Write by exception (only when a value has changed). OUT_B = Bit write. OUT_B_E = OUT_E_B = Bit write by exception. type PLC-2, PLC-5, or Required to identify the type of SLC-500. Programmable Logic Controller used.

U0-1130 3-6 9/98 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

Table 3-2. /GROUP Attribute List Parameter Range/Value Description station Any valid Allen- Required to identify the station number for Bradley station which the command is intended. number in the system. Note: This is ignored for direct PLC-5 connections. plc5ﬁle Any valid PLC ﬁle File number in PLC-5 that will be used for number. simulating PLC-2 communications (only required when talking to PLC-5 in PLC-2 mode with the -s command line parameter).

3-2.3. /DATA Attribute List

The /DATA attribute deﬁnes each point name, the Allen Bradley-PLC address, and the QLC address. The format is:

/DATA: pntname, AB-PLC address, QLC address Figure 3-3 illustrates the /DATA portion of the sample PGROUPS configuration file and Table 3-3 defines the parameters.

/DATA: AKJHKIC, N10:000, A0000 BLKYYLU, N10:001, A0002 CETKHGD, N10:002/00, D0004 SJHLKJH, N10:002/04, D0005 KJIUDFU, N10:008, G0007

Figure 3-4. Sample /DATA Attribute List

9/98 3-7 U0-1130 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

Table 3-3. /DATA Attribute List Parameter Range/Value Description pntname Any valid point name. Name of the WDPF point (not actually used by the QLC program and can therefore be a dummy string). AB-PLC address1 Any valid Allen- PLC address that corresponds to the point. Bradley PLC address QLC address A = Analog point. Letter that deﬁnes the point type, followed D = Digital point. by a register number in the QLC where this G = Packed Group point’s value will be written into shared point. memory (analog points occupy two consecutive registers in the QLC). 1 See Table 3-4 for information on valid AB PLC addresses.

Table 3-4. Valid AB PLC Addresses AB Data Type Address Format WDPF Data Type Integer Files Nxxx: yyy Analogs or groups Nxxx: yyy/zz Digitals Binary Files Bxxx: yyy Analogs or groups Bxxx: yyy/zz Digitals Floating Point Fxxx: yyy Analogs Input Regs I: yyy Digitals Output Regs O: yyy Digitals Timers Txxx: yyy Analogs or groups Counters Cxxx: yyy Analogs or groups Physical Address* PC yyyy Analogs or groups PC yyyy/zz Digitals xxx - ﬁle # yyy - data offset zz - bit # * Only valid data type for PLC-2, SLC-500

U0-1130 3-8 9/98 Westinghouse Proprietary Class 2C 3-2. Creating the Conﬁguration File

/DATA List Rules

1. The point name is not actually used by the QLC program and can therefore be a dummy string.

2. Analog points occupy two consecutive registers in the QLC.

3. All points in a /DATA list MUST be from the same ﬁle in the PLC-5.

4. Any gaps left in a point list will result in a value of zero being written to those addresses missing from the list (applicable only for OUT and OUT_E commands).

5. Do not attempt to read and write binary values from different bits in a single PLC register.

6. If using bit write or bit write by exception, only specified bits are written, those not specified are not modified.

9/98 3-9 U0-1130 Westinghouse Proprietary Class 2C 3-3. Creating the AUTOEXEC.BAT File

3-3. Creating the AUTOEXEC.BAT File

In order to enable the interface to start automatically when power is applied to the QLC or when the QLC is reset, create a QLC AUTOEXEC.BAT ﬁle containing the following line:

abqlc -f file [-s] [-l] [-d] [-e]

where:

file = Name of the point group configuration file. The file name cannot have any extensions. -s = Used to simulate PLC-2 communications to a PLC-5. (Optional) -l = Used to produce list file that details the configuration of the link. This can be run on a PC to verify that the configuration specified is correct. (Optional) -d = Used to debug link problems. This option lets the user view and modify the QLC registers from an external PC to verify link activity. (Optional: This option slows communication and should be turned off for normal operation) -e = Used to debug link problems. This option causes the QLC to display error messages on the external host PC if and when errors occur. (Optional: This option slows communication and should be turned off for normal operation)

U0-1130 3-10 9/98 Westinghouse Proprietary Class 2C 3-4. Conﬁguring the QLC Card

3-4. Conﬁguring the QLC Card

The QLC card provides the processing control for the QLC/RS232/AB Interface. Refer to “QLC User's Guide” (U0-1100) for instructions on the operation and use of the QLC card.

3-4.1. QLC LEDs

During execution of ABQLC.EXE, the row of LEDs on the QLC card (see Figure 3-5) have the following meaning:

LED 1 ON when QLC is powered up. LED 2 ON when a message is transmitting to the PLC. OFF when a message has been successfully transmitted. LED 3 ON when receiving a reply. OFF when a successful reply has been recevied from the PLC. LEDs 4 to 9 Undeﬁned, should always be OFF.

During normal operation, LEDs 2 and 3 should ﬂicker to indicate that messages are being transmitted and received by the QLC.

9/98 3-11 U0-1130 Westinghouse Proprietary Class 2C 3-4. Conﬁguring the QLC Card

PWR LE1 LE2 LE3 LE4 LE5 LE6 LE7 LE8 LE9

LEDs 1 (top) through 9 (bottom)

Figure 3-5. Location of LEDs on QLC Card

U0-1130 3-12 9/98 Westinghouse Proprietary Class 2C 3-5. Copying Required Files to the QLC Card

3-5. Copying Required Files to the QLC Card

After the QLC card has been formatted, perform the following procedure to install the required ﬁles on the QLC card (if necessary, refer to “QLC User's Guide” (U0-1100) for formatting instructions):

1. Copy the following files to the QLC card: • ABQLC.EXE file provided with the interface disk. • Configuration file as described in Section 3-2. • AUTOEXEC.BAT file as described in Section 3-3. 2. Run BAKFLASH as described in “QLC User's Guide” (U0-1100).

The Allen-Bradley QLC Interface is now ready to begin processing point data between a QLC card and an Allen-Bradley PLC.

9/98 3-13 U0-1130 Westinghouse Proprietary Class 2C Section 4. Communication Problem Troubleshooting

4-1. Section Overview

This section describes features of the QLC/RS232/AB Interface which facilitate troubleshooting of communication problems. Two methods of using this information are discussed here: • Using messages displayed on the external host PC. • Using the QLCSTAT algorithm and the Operator Station.

4-2. Displaying Error Messages on the External Host

Error messages which detail errors in communication between the QLC and the KF-2, KF-3, or PLC-5 are displayed on the external host PC if the command line parameter ‘-e’ is used in the AUTOEXEC.BAT ﬁle (as described in Section 3).

Once communication begins, error messages will be displayed when communication errors occur. The message indicates the error which occurred and the point group which was being processed when the error occurred.

If the error was a status return from the PLC, a KF-2, or a KF-3, then the status and optional extended status will be displayed as well. The signiﬁcance of these values can be found in Allen-Bradley Publication 1770-6.5.16 “Data Highway/Data Highway Plus Protocol and Command Set”.

The error messages, corresponding error number, and a likely cause can be found in Table 4-1.

9/98 4-1 U0-1130 Westinghouse Proprietary Class 2C 4-3. Displaying Error Codes on the Operator Station

4-3. Displaying Error Codes on the Operator Station

Displaying error codes on the Operator Station involves the use of the QLCSTAT algorithm. The algorithm is described in U0-0106 “Control Algorithms”.

Conﬁguring QLCSTAT

The first QLC register parameter used in the QLCSTAT algorithm should also be entered in the QLC/RS232/AB configuration file as the “statusreg” FILE attribute as described in Section 3. This register number should be selected as the first of a block of four unused registers in the QLC configuration.

The FILE attribute “statusholdtime” should be given a value in seconds which is greater than the scan time of the control area which contains the QLCSTAT algorithm.

Unique packed group points must be entered for the ﬁelds named PFID, PPR1, PPR2, PAUX, and PSTA. If a secondary QLC is used, unique packed group point names must also be entered for the ﬁelds named SFID, SPR1, SPR2, SAUX, and SSTA.

Once the QLCSTAT algorithm has been conﬁgured, QLC/RS232/AB errors will be indicated at the Operator Station.

Fault Codes

In operation, when the QLC program determines that an error has occurred, it places values in the QLC registers at the “statusreg” location. The QLCSTAT algorithm sees these values and puts the DPU in “QLC Drop Fault”. The System Status diagram displays this change (refer to “Self-Test Diagnostics” (M0-0003) for information on using this diagram).

The diagram will show numbers for the Fault Code, Fault ID, and Fault Parameters to indicate which error occurred: • Fault Code will be 129 (QLC fault), • Fault ID will be 22 (Allen-Bradley) • First Fault Parameter is the error code (found in Table 4-1). Its most signiﬁcant bit is set if this QLC is in control. • Second Fault Parameter tells which point group in the conﬁguration was being processed when the error occurred.

U0-1130 4-2 9/98 Westinghouse Proprietary Class 2C 4-3. Displaying Error Codes on the Operator Station

If the error code indicates that the error was a status return from the KF-2, KF-3, or PLC, then the status and optional extended status will be found in the packed group point which was entered in the QLCSTAT algorithm as PAUX, the auxiliary fault information.

The auxiliary fault information is not displayed on the drop fault display. When the drop fault appears and the ﬁrst Fault Parameter indicates a status return, the PAUX packed group point should be examined (using the point details display). The status will be in the high half of the word and the extended status will be in the low half of the word.

Table 4-1 lists the error code numbers in decimal and hexadecimal which will appear on the System Status diagram (if the QLCSTAT algorithm has been conﬁgured), and the description which will appear on the external host PC (if the ‘-e’ command line parameter has been entered). A suggested action is also listed.

Table 4-1. Error Codes /Error Messages Error Error Code Message Cause / Suggested Action 18 Timeout No response from KF-2 or PLC - 12H Check cabling and power. 19 UART Errors Parity Error, Framing Error, Overrun Error - 13H Check config file, KF-2 switches, cabling, and noise. 20 Checksum Checksums don’t match - 14H Ensure KF-2 switch is set for BCC, check parity and noise 21 Reply Too short Check that cabling is secure. 15H 22 Buffer Overflow Check cabling and noise. 16H 23 NAKs Exceeded KF-2 / PLC negative acknowledges - 17H Check config file, KF-2 switches, cabling, and noise. 24 ENQs Exceeded Virtually synonymous with Timeout - 18H Check cabling and power. 25 Reply Status KF-2 or PLC replies with status code - 19H Get status and extended status from error message on external host or from PAUX and interpret from Allen-Bradley publication 1770-6.5.16 “Data Highway Plus Protocol and Command Set”.

9/98 4-3 U0-1130 Westinghouse Proprietary Class 2C 4-4. Interpreting Allen-Bradley Reply Status Codes

4-4. Interpreting Allen-Bradley Reply Status Codes

Listed below are some troubleshooting suggestions for interpreting Allen-Bradley codes: • Listed in Table 4-1 is the error message “Reply Status.” This means that the KF-2, KF-3, or PLC has indicated in a reply message that a problem has occurred. The status and extended status codes returned from the device should be examined and interpreted. • Often, when ﬁrst starting the interface software, it appears that the QLC and KF-2, KF-3, or PLC are communicating with each other (evidenced by the rapidly ﬂashing LEDs) but that no valid data appears to be exchanged.

This means the two are communicating correctly, but that the KF-2 or PLC is indicating (via the reply status) that it cannot provide the requested information.

The reply status and extended status can be determined using either of the two methods detailed in Section 4-2 and Section 4-3. Once these are known, the status codes can be interpreted from the Allen-Bradley protocol document.

The two most common occurrences are:

1. The KF-2 reply status indicates that there is no PLC with the address the QLC indicated on the Allen-Bradley data highway.

In this case the status byte STS holds the value 02 which indicates “remote node speciﬁed does not acknowledge (ACK) the command message”

2. The QLC has asked for data from a PLC memory file which either has not been configured in the PLC or has asked for data from a location in a file beyond the size that has been configured.

In this case the status byte STS holds the value F0 which indicates “there is an error in the EXT STS byte” and the extended status byte will contain 7 “ﬁle is wrong size” or perhaps 4 “symbol not found”

U0-1130 4-4 9/98 Westinghouse Proprietary Class 2C Index

Symbols /DATA 3-8, 3-9 list rules 3-9 parameters 3-8 /FILE 3-2, 3-3, 3-4, 3-5 parameters 3-3, 3-4, 3-5 /GROUP 3-6 parameters 3-6 A ABQLC.EXE 3-2, 3-11, 3-13 attribute list /DATA 3-8 /FILE 3-2, 3-3, 3-4, 3-5 /GROUP 3-6 AUTOEXEC.BAT 3-10, 3-13 B BAKFLASH 3-13 C card PLC 1-3, 3-1, 3-8, 3-11, 3-13, 4-1 PLC-2 1-1 PLC-5 1-1, 2-1, 2-3, 3-9 cabling to 2-6, 2-7 QLC 1-1, 3-12 configuring 3-11 copying files to 3-13 creating configuration file 3-2 harware configuration 2-1 interface connections 2-2 software configuration 3-1, 3-10, 4-1 SCOM cabling 2-4, 2-5, 2-6, 2-7 interface connections 2-2, 2-3 SLC-500 2-3 configuration file /DATA 3-2 /FILE 3-2, 3-3 /GROUP 3-2, 3-6 E Error Codes Displaying on Operator Console 4-2 Error Messages Displaying on External Host 4-1

9/98 Index-1 U0-1130 Westinghouse Proprietary Class 2C Index

F QLCSTAT 4-2 file ABQLC.EXE 3-2, 3-11, 3-13 R AUTOEXEC.BAT 3-10, 3-13 Reply Status Codes Interpreting 4-4 I RS-232 1-2, 3-1, 4-1, 4-2 interface RS-232-C 1-1, 1-3, 2-2, 2-3, 2-4, 2-6, 2-7 KF2 1-1, 1-3, 2-1, 2-2 RS-422-A 1-1, 1-3, 2-2, 2-3, 2-5, 2-7 cabling to 2-4, 2-5 KF3 1-3, 2-1 S cabling to 2-7 SCOM PLC 1-2, 3-1, 3-8, 3-11, 3-13, 4-1 cabling 2-4, 2-5, 2-6, 2-7 RS-232 1-3, 3-1, 4-1, 4-2 interface connections 2-2, 2-3 RS-232-C 1-1, 2-2, 2-3, 2-4, 2-6, 2-7 SLC-500 2-3 RS-422-A 1-1, 2-2, 2-3, 2-5, 2-7 Unprotected Read 1-2 Unprotected Write 1-2 K KF2 1-1, 1-3, 2-1, 2-2, 4-1, 4-4 cabling to 2-4, 2-5 KF3 1-3, 2-1, 4-1, 4-4 cabling to 2-7 L LEDs 3-11, 3-12 P PLC 1-2, 3-1, 3-8, 3-11, 3-13, 4-1 valid addresses 3-8 PLC-2 1-1 Protected Write 1-1 Unprotected Read 1-1 PLC-5 1-1, 2-1, 2-3, 3-9 cabling to 2-6, 2-7 Read-Modify-Write 1-1 Typed Read 1-1 Typed Write 1-1 Q QLC 1-1, 2-1, 3-1, 3-12, 4-1, 4-2 AUTOEXEC.BAT 3-10 configuring 3-11 copying files to 3-13 creating configuration file 3-2 hardware configuration 2-1 interface connections 2-2 LEDs 3-11, 3-12 RS-232 1-3, 3-1, 4-1, 4-2 software configuration 3-1, 3-10, 4-1

U0-1130 Index-2 9/98 Westinghouse Proprietary Class 2C