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1Ć1

1.0 INTRODUCTION

The products described in this instruction manual are manufactured

by Reliance Electric Industrial Company. The Automax Processor

moduleplugs into thebackplaneof an AutoMax rack and executes

application programs which in turn control other AutoMax modules in

the system. The M/N 57C430A and 57C431 Processor modules are

based on the Motorola 68010 16Ćbit microprocessor. The M/N

57C435 Processor module is based on the Motorola 68020 32Ćbit

microprocessor. All three Processors are programmed using three

highĆlevel application languages: BASIC, Control Block and Ladder

Logic.
The Processor modules have the following memory/speed

configurations:

Model

CPU Speed

Memory

M/N 57C430A AutoMax

6010 Processor module

8 mHz

256K Parity RAM

M/N 57C431 AutoMax

6011 Processor module

8 mHz

512K Parity RAM

M/N 57C435 AutoMax

7010 Processor module

25 mHz

512K Parity RAM

Up to four AutoMax Processor modules can be used in a rack

(M/N 57C331, M/N 57C332 or M/N 57C334) to increase the

processing capability and the total memory available for application

tasks. M/N 57C430A, 57C431, and 57C435 Processors can be used

in thesamerack. M/N 57C430A Processors make135KĆ150K

available for application programs depending on which operating

system is loaded onto the Processor. M/N 57C431 and 57C435

Processors make 300K available for application programs, regardless

of which operating system is loaded onto the Processor. Multiple

Processors in a rack require the use of the Common Memory module

(M/N 57C413 or M/N 57C423) for bus arbitration and sharing of

systemĆwideinformation. TheCommon Memory modulecan also be

used with a singleProcessor moduleto makeavailablean additional

128K bytes of memory for common, i.e., systemĆwide, variables.
An onĆboard lithium battery and a superĆcapacitor protect the

Processor module from power failures. Should the system lose

power, the onĆboard battery of the M/N 57C430A or 57C431

Processor can maintain the contents of RAM for a minimum of 42

days. Theonboard battery of theM/N 57C435 Processor can

maintain thecontents of RAM for a minimum of 186 days.
The remainder of this manual describes the functions and

specifications of the module. It also includes a detailed overview of

installation and servicing procedures.

Thethick black bar shown at therightĆhand margin of this page

will be used throughout this instruction manual to signify new or

revised text or figures.

Содержание AutoMax 57C430A

Страница 1: ...Instruction Manual JĆ3650Ć6 AutoMax Processor Module M N 57C430A M N 57C431 M N 57C435 ...

Страница 2: ...RATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER MANUALS APPLICABLE TO YOUR INSTALLATION FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY WARNING INSERTING OR REMOVING THIS MODULE OR ITS CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION POWER TO THE MACHINE SHOULD BE TURNED OFF BEFORE INSERTING OR REMOVING THE MODULE OR ITS CONNECTING CABLES FAILURE ...

Страница 3: ...odule Diagnostics 3Ć5 3 5 1 PowerĆUp Diagnostics 3Ć5 3 5 2 RunĆTime Diagnostics 3Ć5 4 0 Programming 4Ć1 4 1 Loading the Operating System 4Ć1 4 2 Accessing Processor Ports 4Ć3 4 3 Programmable Tick Rate 4Ć4 4 4 Restrictions 4Ć5 4 4 1 Number of Processors in a Rack 4Ć5 4 4 2 Rack Slot Restrictions 4Ć5 4 4 3 Use with the DCS5000 M N 57C407 Processor Module or the 57C430 Processor Module 4Ć5 4 4 4 Eth...

Страница 4: ...ons AĆ1 Appendix B Module Block Diagram BĆ1 Appendix C Connecting the AutoMax Processor to the Personal Computer CĆ1 Appendix D Diagnostic LED Error Codes DĆ1 Appendix E Run Time LED Error Codes EĆ1 Appendix F Using Modems with AutoMax Systems FĆ1 ...

Страница 5: ... List of Figures Figure 2 1 Ć Processor Module Faceplate 2Ć2 Figure 2 2 Ć Typical RSĆ232C Circuit 2Ć3 Figure 3 1 Ć Rack Slot Numbers 3Ć2 Figure 4 1 Ć Specifying the SETUP Parameter in an OPEN Statement 4Ć4 ...

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Страница 7: ...s can be used in the same rack M N 57C430A Processors make 135KĆ150K available for application programs depending on which operating system is loaded onto the Processor M N 57C431 and 57C435 Processors make 300K available for application programs regardless of which operating system is loaded onto the Processor Multiple Processors in a rack require the use of the Common Memory module M N 57C413 or...

Страница 8: ...nfiguration 1 2 Related Hardware and Software M N 57C430A contains one 256K AutoMax Processor module M N 57C431 contains one 512K AutoMax Processor module M N 57C435 contains one 512K AutoMax Processor module The Processor module is used with the following hardware and software which can be purchased separately 1 IBMĆcompatible personal computer running DOS V3 1 or later 2 ReSource AutoMax Program...

Страница 9: ...utoMax Programming Executive software M N 57C435 requires Version 3 1 or later of the AutoMax Programming Executive software M N 57C430 cannot coĆexist in the same rack with M N 57C430A 57C431 or 57C435 AutoMax Programming Executive Software Compatible Processor Module Version 1 0 M N 57C304 57C305 M N 57C306 57C307 updates M N 57C430 M N 57C430 Version 2 0 M N 57C390 57C391 M N 57C392 57C393 upda...

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Страница 11: ...ule are two edge connectors that connect to the system backplane Module dimensions are listed in Appendix A The faceplate of the Processor module contains two independentlyĆisolated 25Ćpin D shell connectors for RSĆ232C serial I O links The upper port labeled PROGRAMMER PORT B of the leftmost Processor in the rack is reserved for connection to the personal computer only The personal computer can c...

Страница 12: ...M N 57C430A 6010 Processor 256K PROGRAMMER PORT B PORT A 2ND 1ST BAT OK OK AutoMax 7010 Processor 57C435 M N 57C435 7010 Processor 512K PROGRAMMER PORT B PORT A 2ND 1ST BAT OK OK AutoMax 6011 Processor 57C431 M N 57C431 6011 Processor 512K Figure 2 1 Ć Processor Module Faceplate ...

Страница 13: ...sor in slot 1 etc up to slot 4 See 3 5 1 and 3 5 2 for more information about the two sevenĆsegment LEDs on the Processor 2 2 Electrical Description The Processor module contains a local watchdog timer which must be reset within a specified interval or the Processor will shut down and all I O modules will be reset initialized to 0 FALSE or OFF Byte parity is supported for all backplane address and...

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Страница 15: ...sonal computer use shielded RSĆ232 cables Cable connectors must be equipped with EMI RFIĆshielded cable clamps attached to the cable shield The cable shield must be grounded at one end The cable length must be in accordance with the RSĆ232 specification Be sure to label the connector so that it can be easily reconnected later should it ever need to be removed A pin description can be found in Appe...

Страница 16: ... Typical 16 Slot Rack Figure 3 1 Ć Rack Slot Numbers Step 6 Using a screwdriver attach cable M N 61C127 or your own cable built according to directions in Appendix C to the port labeled PROGRAMMER PORT B on the leftmost Processor Attach the cable from step 2 above to ports being used to communicate with other devices Step 7 Turn on power to the system The module will automatically execute its powe...

Страница 17: ...connectors on the back of the module Place the module and the antiĆstatic bag in the cardboard shipping container Step 5 Take the new module out of the antiĆstatic bag being careful not to touch the connectors on the back of the module Step 6 Activate the battery by taking it out of its holder and removing the tape that covers it Replace the battery in its holder Make certain that the battery is f...

Страница 18: ...o the system All power to the rack as well as all power to the wiring leading to the module should be off Step 2 Use a screwdriver to loosen the screws holding the connectors to the module Remove the connectors from the module Step 3 Loosen the screws that hold the module in the rack Remove the module from the slot in the rack being careful not to touch the connectors on the back of the module Ste...

Страница 19: ...n addition to resetting their own watchdogs The Processor module will reset its own watchdog regardless of whether the operating system is loaded or not Should any watchdog be allowed to expire at any time after powerĆup diagnostics are complete all Processors in the rack will be shut down If application tasks are currently running in the rack they will be stopped The green LED labeled OK on the f...

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Страница 21: ...nterface module M N 47C440 must be installed in the rack and the Ethernet operating system must be used The Ethernet operating system is also required if any of the following functions are used in BASIC tasks READVAR WRITEVAR FINDVAR and CONVERT The 7010 Ć Standard operating system which supports all of the Ethernet functions must be used with the M N 57C435 Processor When you load the operating s...

Страница 22: ...eĆload the operating system only when enhancements become available when you change the password for the rack using the PWOS EXE utility or when a Processor module in the rack is replaced 3 If you have not already done so connect the personal computer to the leftmost processor in the rack following the directions in 4 4 4 Enter a CR at the initial screen If you are using AutoMax Version 2 select F...

Страница 23: ...exist in all Processors on all networks It will also require that you reĆload any tasks that exist on those Processors Note that this option requires the password to be entered Ć enter the slot number of the Network module representing the network you want to load over If you select this option you will also be able to choose to load the operating system to one drop all drops on this network where...

Страница 24: ...DELAY statement All of these scan rates can be specified in terms of ticks The programmable tick rate allows you to change the definition of the tick By changing the tick the time base for tasks is changed This change allows you to run a task at a scan rate other than the default of 5 5 msec It also allows you to execute application tasks at more easily understood scan times 5 0 msec or 10 0 msec ...

Страница 25: ...r Processor modules may be plugged into the rack M N 57C430A M N 57C431 and M N 57C435 can be used in the same rack 4 4 2 Rack Slot Restrictions A Processor module can occupy any slot from 0Ć4 in the 6 10 or 16Ćslot AutoMax rack If the rack will contain multiple Processors slot 0 must contain a Common Memory module and slots 1Ć4 can contain Processors 4 4 3 Use with the DCS5000 M N 57C407 Processo...

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Страница 27: ...NNECTOR ON THE FACEPLATE OF THE POWER SUPPLY IS AT LINE VOLTAGE WHEN AC POWER IS APPLIED DISCONNECT ALL POWER FROM THE POWER SUPPLY BEFORE HANDLING THE WIRING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE Step 1 Verify that the power supply is receiving 115V AC power If the power is on the POWER ON LED on the power supply faceplate should be lit indicating...

Страница 28: ...om the backplane is not active If the Power Supply FAULT LED is on use the following procedure to isolate the problem a Turn off power to the rack and all connections b Replace the Processor module whose OK LED was off c Turn on power to the rack If the Power Supply FAULT LED turns on the problem is with the Power Supply Step 3 Verify that the power supply output is sufficient to power all of the ...

Страница 29: ...edure to isolate a bus error Step 1 Determine where the bus error occurred Connect the personal computer to the rack and run the ReSource AutoMax Programming Executive Display the error log for the Processor that indicates the error The error log should indicate the address that caused the bus error or a line number in a BASIC or Control Block application task The address will be displayed in hexa...

Страница 30: ...EGISTER b 0 0 0 REMOTE RACK SLOT DROP A Network Communications Module M N 57C404 Least Significant 16 Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 BIT REGISTER b 0 0 0 DROP The bit number being accessed may be determined from word bit BYTE BIT 8 b If BYTE BIT and 8 b 0 address may have been accessed as a word integer or bit 0 of byte 0 The hexadecimal number represents the Multibus address of the er...

Страница 31: ...13 12 11 10 9 8 7 6 5 4 3 2 1 0 BIT R b where R is a local register address which may be used with the I O monitor Determine the AĆB register number from the following table R Decimal AĆB Register Decimal ăă64ă ă319 ă320ă ă575 ă576ă ă1599 1600ă ă2623 R 64 R 320 R 576 R 1600 AĆB File B0 B1 N0 N1 An AutoMate Interface Module M N 57C417 Least Significant 16 Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 ...

Страница 32: ...contain the statement number in the task where the error occurred If a Control Block or Ladder Logic task caused the error you will need to search the task for any instances where you wrote to an input Step 5 Verify that the hardware is working correctly Verify the hardware functionality by systematically swapping out the module in question the Processor module s or slave Remote I O module and the...

Страница 33: ...t may be running Use the I O Monitor function to display the individual I O points or registers on the module whichever is appropriate If the points can be monitored the problem lies in the application software refer to steps 4 and 5 If the points cannot be monitored the problem lies in the software go on to step 6 Step 4 For all modules in the rack verify that the configuration references the cor...

Страница 34: ... the remote I O system it probably involves the remote rack To test the remote rack systematically swap out the module being tested and the slave Remote I O module If the problem persists take all of the modules except the slave Remote I O module and the module being tested out of the rack If the problem is now corrected one of the other modules in the rack is malfunctioning ReĆconnect the other m...

Страница 35: ...ements D 5 Volts 3000 mA average D 12 Volts 100 mA average D 12 Volts 100 mA average Battery Specifications D Type Lithium D Size AA D Voltage 3 6 Volts D Amp Hrs 2 0 Memory Retention D Minimum holdĆup with battery 42 days D Typical holdĆup with battery 333 days D Minimum holdĆup without battery 10 minutes D Typical holdĆup without battery 10 hours D Maximum chargeĆup time 15 minutes Serial Port S...

Страница 36: ...equirements D 5 Volts 3000 mA average D 12 Volts 100 mA average D 12 Volts 100 mA average Battery Specifications D Type Lithium D Size AA D Voltage 3 6 Volts D Amp Hrs 2 0 Memory Retention D Minimum holdĆup with battery 42 days D Typical holdĆup with battery 333 days D Minimum holdĆup without battery 10 minutes D Typical holdĆup without battery 10 hours D Maximum chargeĆup time 15 minutes Serial P...

Страница 37: ...quirements D 5 Volts 3000 mA average D 12 Volts 100 mA average D 12 Volts 100 mA average Battery Specifications D Type Lithium D Size AA D Voltage 3 6 Volts D Amp Hrs 2 0 Memory Retention D Minimum holdĆup with battery 186 days D Typical holdĆup with battery 8 2 years D Minimum holdĆup without battery 10 minutes D Typical holdĆup without battery 10 hours D Maximum chargeĆup time 15 minutes Serial ...

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Страница 39: ...PARITY RAM WATCHDOG TIMER INTERRUPT CONTROLLER REAL TIME CLOCK BAUD RATES BATTERY OK OK SUPER CAPACITOR DATA ADDRESS BUS ADDRESS I O BUS B U S I N T E R F A C E ADDRESS DATA 5V 12V 12V X M I T R C V DC DC CONVERTER DC DC CONVERTER XMIT RTS DTR RECV CTS DSR COM XMIT RTS DTR RECV CTS DSR COM 2 4 20 3 5 6 2 4 20 3 5 6 X M I T R C V MULTIBUS ...

Страница 40: ... 16 PARITY RAM WATCHDOG TIMER INTERRUPT CONTROLLER REAL TIME CLOCK BAUD RATES BATTERY OK OK SUPER CAPACITOR DATA ADDRESS BUS ADDRESS I O BUS B U S I N T E R F A C E ADDRESS DATA 5V 12V 12V X M I T R C V DC DC CONVERTER DC DC CONVERTER XMIT RTS DTR RECV CTS DSR COM XMIT RTS DTR RECV CTS DSR COM 2 4 20 3 5 6 2 4 20 3 5 6 X M I T R C V MULTIBUS ...

Страница 41: ...28K X 32 PARITY RAM WATCHDOG TIMER INTERRUPT CONTROLLER REAL TIME CLOCK BATTERY OK OK SUPER CAPACITOR DATA ADDRESS BUS ADDRESS I O BUS B U S I N T E R F A C E ADDRESS DATA 5V 12V 12V X M I T R C V DC DC CONVERTER DC DC CONVERTER XMIT RTS DTR RECV CTS DSR COM XMIT RTS DTR RECV CTS DSR COM 2 4 20 3 5 6 2 4 20 3 5 6 X M I T R C V MULTIBUS ...

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Страница 43: ...PPLICABLE INSTRUCTION MANUALS PRIOR TO OPERATING THE EQUIPMENT FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY 1 Determine whether your programming terminal contains a 9Ć or 25Ćpin male connector 2 Cut a suitable length not to exceed 10 feet of 22Ćgauge multiĆconductor cable 3 Follow the connector manufacturer s instructions and make cable connections using figure 1 or 2 whichever...

Страница 44: ...transmit modem which requires an enable signal to output characters Refer to the OPEN statement in the Enhanced BASIC Language manual JĆ3675 for details concerning the operation of the modem enable signal RTS pin on connector 5 I This signal enables the transmitter It must be true for the transmitter to send a character This signal is typically used for hardware flow control It is meaningful only ...

Страница 45: ...x Processor 2 3 4 7 5 6 20 10 TXD RXD RTS CTS DSR 12V User Equipment NOTE CTS and DSR must be asserted when hardware handshaking has been enabled bit 15 in setup parameter of OPEN statement Cable Break Detect AutoMax Processor 2 3 4 7 5 6 20 10 2 to user Trans pin 3 to user Recv pin 7 to user Sig Com TXD RXD CTS DSR User Equipment must be asserted 5 to 12 volt level wire to pin 10 on AutoMax RSĆ23...

Страница 46: ...ost by the AutoMax task receiving characters 2 3 7 5 Transmit Enable TXD RXD DSR 12V DTR User Equipment BiĆDirectional Flow Control Hardware Handshaking AutoMax Processor 2 3 4 7 5 6 20 10 2 3 4 7 5 6 20 10 to user Trans pin to user Recv pin to user Sig Com Trans Enable Recv Buffer Status TXD RXD 12V CTS DSR DTR In this configure bin no characters are lost by the AutoMax task or user equipment rec...

Страница 47: ... interrupt failed 2 8 Local watchdog failed 3 0 Bad backplane 3 1 Multibus parity test failure 4 0 Ć 4 5 Common memory RAM failure 4 6 Common memory system watchdog failure 5 0 Processors with incompatible EPROMs in the rack Corrective action replace the Processor M N 57C430A 57C431 or 57C435 or replace the Common Memory module M N 57C413 if error codes 4 0 Ć 4 6 remain on Run Time Errors 02 Task ...

Страница 48: ...r codes cycle power and try to load the runbase again Loading the Runbase over the Network 8 0 Bad message length specified for network message 8 1 Bad destination drop 8 2 Transmitting drop inactive 8 3 Destination port unallocated 8 4 Destination port busy 8 5 Did not receive expected response 8 6 Spurious network interrupt received 8 7 Network message is being transmitted Corrective action 8 0 ...

Страница 49: ... running in the rack to stop 10 Event count underflow Ć too many WAITs max 32768 Ć not enough SETs BASIC tasks 11 Event count overflow Ć too many SETs max 32767 Ć not enough WAITs BASIC tasks 12 Hardware event timeĆout Ć interrupt time exceeded programmed timeĆout limit in a Control Block task 13 Runbase boot error Ć a check on the runbase failed 14 Processor overlap limit exceeded Ć ran out of pr...

Страница 50: ...u define bits in a register that is also defined as a register neither the bits nor the register can be forced For error code 38 examine the error logs for all UDC tasks in the rack Also error code 38 can be caused by enabling CCLK on more than one module in the rack Verify that CCLK is enabled on only one module For error code 39 cycle power to the rack and reĆload the configuration and applicati...

Страница 51: ...t After correcting the problem reset the Processor module to clear the error code 80 Instantaneous overcurrent fault Ć armature current exceeded IOC_THRESH value in CML task 81 Line sync loss fault 82 Tach loss fault Ć 40 armature voltage with less than 5 tach feedback 83 Overspeed overvoltage fault Ć CML task OSV_FDBK exceeded OSV_THRESH number 84 Hardware overspeed fault Ć drive analog module po...

Страница 52: ...n Processor Module Ed Error building task and error installing application task common symbol could not be resolved insufficient memory in Processor Module Invalid configuration not successfully downloaded EE Error building task and error installing application task common symbol could not be resolved insufficient memory in Processor Module I O referenced in configuration is missing EF Common vari...

Страница 53: ...0 Application task installation in progress d1 Waiting on synchronizing event in a rack with multiple processors d2 Waiting on mutual exclusion lock in a rack with multiple processors Corrective action for b0 and d0 that do not change or disappear reĆload configuration file and application tasks ...

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Страница 55: ...2 Run the AutoMax Programming Executive 3 Select the OnĆLine Programming menu 4 Select the Connect menu 5 Select Baud Rate 6 Using the up and down arrow keys choose the baud rate that matches the baud rate of the modem you will be using 7 Press CR to select the baud rate 8 Disconnect the cable between the Processor and the personal computer 9 Set the modem to autoĆanswer mode 10 Connect the modem ...

Страница 56: ...apable phone line where is the remote rack modem s phone number or AT DP pulseĆdial only line where is the remote rack modem s phone number 8 When the remote modem answers and the connection has been completed return to the AutoMax menu by typing the Ctrl and keys at the same time 9 Enter C 10 Enter Q CR 11 Select OnĆLine Programming This completes the connection between the local personal compute...

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