Niobrara QUCM Instrucciones de montaje

QUCM Limitorque Valve Controller Application Manual

QUCM Limitorque Controller

Installation and Programming Manual

This Manual describes the QUCM application for interfacing Limitorque Valve Actuators to a Modicon Quantum

PLC system.

Effective: 18 March, 2008

Niobrara Research & Development Corporation

P.O. Box 3418 Joplin, MO 64803 USA

Telephone: (800) 235-6723 or (417) 624-8918

Facsimile: (417) 624-8920

www.niobrara.com

Modicon and Quantum are trademarks of Schneider Electric.

Limitorque is a trademark of Limitorque.

Subject to change without notice.

Contents

1 Introduction .........................................................................................................................5

2 Installation.............................................................................................................................7

QUCM Installation .........................................................................................................7

Serial Connections to the QUCM-OE ............................................................................7

Port 1 to DDC2I to Valves ......................................................................................7

Port 2 to DDC2I to Valves ......................................................................................7

DDC2I DIP Switch Settings....................................................................................8

Valve Configuration and Wiring.............................................................................8

Port 1 to the Personal Computer .............................................................................9

Loading the Applications into the QUCM .....................................................................9

FWLOAD QUCM Firmware Update....................................................................10

QLOAD Application 1 ..........................................................................................10

PLC Configuration .......................................................................................................11

PLC Local Rack Setup ..........................................................................................11

PLC Remote Rack Setup.......................................................................................14

4 Operation .............................................................................................................................19

Complete Ring Operation......................................................................................19

Non-responding Valve - Complete Ring...............................................................19

Incomplete Ring ....................................................................................................20

I/O Scanner Operation ..................................................................................................20

Example 1 - I/O Scanner ..............................................................................................21

Remote Rack I/O Operation .........................................................................................24

Example 2 - Remote Rack ............................................................................................24

5 Troubleshooting ..............................................................................................................27

LED Descriptions .........................................................................................................27

Web Server ...................................................................................................................28

Telnet Server ................................................................................................................28

Modbus/TCP Server .....................................................................................................28

Figures

Figure 2-1 DDC2I to "A1" port RS-485 2-wire cable...................................................................7

Figure 2-2 DDC2I to "A2" port RS-485 2-wire cable...................................................................8

Figure 2-3 PC Connection to QUCM-O serial port........................................................................9

Figure 2-4 QUCM-O to RS-232 PC Port (9-pin) (MM1 Cable) ..................................................9

Figure 2-5 FWLOAD of QUCM Firmware .................................................................................10

Figure 2-6 QLOAD of Application 1 ...........................................................................................11

Figure 4-1 Example 1 with QUCM in PLC Processor Rack.......................................................21

Figure 4-2 Example 1 with QUCM in Remote Rack ...................................................................25

Tables

Table 2-1 DDC2I DIP Switch Settings ..........................................................................................8

Table 2-2 QUCM Status Bit Descriptions....................................................................................12

Table 2-3 I/O Scanner Example ...................................................................................................14

Table 2-4 Valve Commands .........................................................................................................15

Table 2-5 I/O Register Map..........................................................................................................16

Table 2-6 Valve register 9 bitmap ................................................................................................17

Table 4-1 Valve Status Regsiters .................................................................................................20

Table 4-2 I/O Scanner Example ...................................................................................................22

Table 4-3 Possible Valve Status and PLC Values........................................................................22

Table 4-4 Health Registers with all devices online ......................................................................23

Table 4-5 Health Registers with Cable break between slaves 13 and 14 .....................................24

Table 4-6 Example 2 I/O Register Map with all slaves online.....................................................26

Table 5-1 Modbus/TCP Index List...............................................................................................28

QUCM Limitorque Valve Controller Application Manual 1Introduction 5

Introduction

The Niobrara QUCM is a TSX Quantum® compatible module that is capable of run-

ning multiple applications for performing communication translations between serial

protocols. This document covers an application provides a Modbus RTU serial ring

network for controlling Limitorque®valve actuators. Both serial ports of the QUCM-

OE are connected to a closed ring of actuators and the QUCM can determine if the

ring is complete and which valves are accessible from either port of the QUCM. This

ring network topology allows for the breaking of the network in one location and still

providing control of all of the actuators.

The QUCM-OE may be used in the local Quantum PLC processor rack and support up

to 127 actuators. The module is configured as an NOE-771-01 in the PLC and the I/O

Scanner table is used to define the actuators to be polled. The QUCM-OE may also be

used in a remote rack as an I/O module for communicating with up to 14 actuators. In

this case the QUCM is configured by Holding registers assigned to the QUCM’s slot.

The Ethernet port of the QUCM-OE provides a web server for troubleshooting of the

system.

The application, "qucm_limitorque_app1.qcm" is compiled and loaded into Applica-

tion 1 of the QUCM-OE. The application includes multiple threads for simultane-

ously servicing both serial ports.

Both serial ports of the QUCM are be used to connect to the actuator network. The

Niobrara DDC2I isolated RS-232<>RS-485 converter is recommended to connect the

QUCM to the 2-wire RS-485 network. This converter provides optical isolation be-

tween the Quantum PLC and the actuator network. A Niobrara MM1 cable is needed

to load the application into the QUCM.

QUCM Limitorque Valve Controller Application Manual 2Installation 7

Installation

QUCM Installation

Mount the QUCM in an available slot in the register rack. Secure the screw at the

bottom of the module.

Serial Connections to the QUCM-OE

Port 1 to DDC2I to Valves

The serial port of the QUCM-OE must be switched to RS-232. The Niobrara cable

MM0 is used to connect to the DDC2I. This cable is included with the DDC2I.

Limitorque wiring standard must be followed to ensure proper serial communication.

Belden 3074F, 3105A, or 9841 shielded 2-wire twisted pair cable is recommended

from the Green Connector on the DDC2I to the first Valve "A1" port. This cable

pinout is shown in Figure 2-1.

Figure 2-1 DDC2I to "A1" port RS-485 2-wire cable

Port 2 to DDC2I to Valves

The serial port of the QUCM-OE must be switched to RS-232. The Niobrara cable

MM0 is used to connect to the DDC2I. This cable is included with the DDC2I.

The Limitorque wiring standard must be followed to ensure proper serial communica-

tion. Belden 3074F, 3105A, or 9841 shielded 2-wire twisted pair cable is recom-

DDC2I Green Connector A1 Screw

TX+ 15 (-)

TX- 16 (+)

RX+

RX-

Shield Not Connected

8Installation 2QUCM Limitorque Valve Controller Application Manual

mended from the Green Connector on the DDC2I to the first Valve "A2" port. This

cable is shown in Figure 2-2.

Figure 2-2 DDC2I to "A2" port RS-485 2-wire cable

DDC2I DIP Switch Settings

The DDC2I DIP switches must be configured for 2-wire Slave with Termination but

no Bias. Only switch 6 will be OFF. The valve will provide the bias for the 2-wire

segment. The settings are the same for both DDC2Is.

Table 2-1 DDC2I DIP Switch Settings

Valve Configuration and Wiring

Refer to the appropriate Limitorque document for proper actuator configuration and

wiring diagrams.

Typical RS-485 wiring system setup

DDC2I Green Connector A2 Screw

TX+ 29 (-)

TX- 41 (+)

RX+

RX-

Shield No Connection

Switch Description Position

1 4/2 wire ON

2 4/2 wire ON

3 4/2 wire ON

4 Master/Slave ON

5 Termination ON

6 Bias OFF

MM0 Cable

140

QUCM

Niobrara

Active

Ready

Run

Col

Lnk

TXE

RXE

RN1

TX1

RX1

RN2

TX2

RX2

Fault DDC2I Valve 1

Valve 2 Valve 3

Valve 6 Valve 5 Valve 4

DDC2I

QUCM Limitorque Valve Controller Application Manual 2Installation 9

Port 1 to the Personal Computer

A physical connection must be made from the personal computer to the QUCM in or-

der load the QUCM application program. This link may be a serial connection from a

COM port on the personal computer to the RS-232 port on the QUCM-OE. The

Niobrara MM1 cable may be used for this connection. This cable pinout is shown in

Figure 2-4.

Figure 2-3 PC Connection to QUCM-O serial port

Figure 2-4 QUCM-O to RS-232 PC Port (9-pin) (MM1 Cable)

Loading the Applications into the QUCM

The QUCM-OE must use the qucmtcpl.fwl firmware included in the

QUCM_SETUP.EXE file. This firmware is dated 14Nov2006 or later.

MM1 Cable

140

QUCM

Niobrara

Active

Ready

Run

Col

Lnk

TXE

RXE

RN1

TX1

RX1

RN2

TX2

RX2

Fault

RJ45 DE9S (female)

10 Installation 2QUCM Limitorque Valve Controller Application Manual

FWLOAD QUCM Firmware Update.

Firmware upload is as follows:

1 Remove the module form the rack.

2 Move the RUN/LOAD switch on the back of the module to LOAD.

3 Replace the module in the rack and apply power.

4 Only the 3 light should be on. (The Link and RX E-net lights may be on if the

E-net port is connected and there is traffic.)

5 Connect the PC to QUCM Port 1 with a MM1 cable.. Make sure that Port 1 is set

to RS-232 mode with the slide switch below the port.

6 From the Windows’ Start button select:

"Start, Programs, Niobrara, QUCM, FWLOAD QUCM Firmware"

Verify that the file to load is qucmtcpl.fwl.

Also verify that the proper PC serial port is selected.

7 Press the "Start Download" button. The download will only take a few minutes

and it will notify the user when finished.

8 Remove the module from the rack and change the switch back to RUN.

Figure 2-5 FWLOAD of QUCM Firmware

QLOAD Application 1

1 Application 1 and 2 Switches must be in HALT.

2 Press "Start, Programs, Niobrara, QUCM, Apps, Limitorque, QLOAD Limitorque

Application 1"

3 Verify that the file to load is qucm_limitorque_app1.qcc

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