GIS GuardLogix Programming

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Project DocumentationDocument TN-0157Revision AGIS GuardLogix ProgrammingWith Sample CodeTim WilliamsControl SystemsOctober 26, 2012Advanced Technology Solar Telescope950 N. Cherry AvenuePhone 520-318-8102atst@nso.eduhttp://atst.nso.eduTucson, AZ 85719Fax 520-318-8500

GIS ControlLogix ProgrammingREVISION SUMMARY:1. Date:Revision:Changes:11/11/11DRAFT 1Rough draft for review and comments.2. Date:Revision:Changes:7/11/12DRAFT 2draft for FDR.3. Date:Revision:Changes:October 26, 2012Revision AInitial formal releaseTN-0157, Revision APage ii

GIS ControlLogix ProgrammingTable of ContentsPREFACE . V1.INTRODUCTION . 11.1PURPOSE . 11.2INTENDED AUDIENCE . 12.DOCUMENTS . 22.1RELATED DOCUMENTS . 22.2REFERENCED DOCUMENTS . 22.3SOFTWARE . 23.CONFIGURING THE NETWORK . 33.1INITIAL SETUP . 33.2SETTING UP PORTS . 43.3SETTING UP VLANS . 44.CONFIGURING THE GUARDLOGIX CONTROLLER. 74.1FIRMWARE. 74.2SAFETY NETWORK NUMBER. 74.3SAFETY LOCKING . 74.4I/O MODULES . 74.4.1Module Definitions . 75.5.16.6.16.27.7.17.27.3CONFIGURING REMOTE I/O MODULES . 8FIRMWARE . 8IP ADDRESSING . 9VIRTUAL LANS . 9HOST ADDRESS . 9TAGS. 11TAG SCOPE . 11PRODUCED AND CONSUMED TAGS . 11DATA ACCESS CONTROL . 117.3.17.3.2External Access.11Constant .118.8.18.2GENERAL NAMING CONVENTIONS . 12PROGRAMS AND ROUTINES . 12TAG NAMING . 128.2.18.2.28.2.38.2.48.2.5General Tag Name Guidelines .12Controller-Scoped Tag Names .12Program-Scoped Tag Names .12Aliases.13Descriptions.138.3I/O AND NETWORK MODULES . 138.3.18.3.2Description .13Examples .158.4USER DEFINED DATA TYPES (UDTS) . 188.5ADD-ON INSTRUCTIONS (AOIS) . 189.LADDER LOGIC . 1910. CONVENTIONS FOR REVISION NUMBERING . 2010.1 REVISION NUMBERING EXAMPLES . 20TN-0157, Revision APage iii

GIS ControlLogix Programming11. THE MAIN TASK . 2111.1 HEALTH AND STATUS . 2111.2 ALARMS . 2111.3 FAULT HANDLING . 2112. THE SAFETY TASK . 2212.1 SAFETYPROGRAM . 2213. EXAMPLE ROUTINES . 2313.1 MAIN ROUTINE . 2313.2 EMERGENCY STOP INPUT ROUTINE . 2413.3 EMERGENCY STOP ROUTINE . 2613.4 AXIS INTERLOCK . 2713.5 AXIS END-OF-TRAVEL ROUTINE . 2713.6 AXIS FINAL TRAVEL ROUTINE . 2913.7 AXIS ABSOLUTE ENCODER . 3113.8 AXIS ENABLE PENDANT . 3213.9 AXIS ENABLE OUTPUT ROUTINE . 3213.10 AXIS OVERSPEED . 3413.11 OVER TEMPERATURE . 3414. USER DEFINED TYPES . 3514.1 UDT SAFETYBOOL. 3515. PASSWORDS . 36TN-0157, Revision APage iv

GIS ControlLogix ProgrammingPREFACEIt is desirable to layout general guidelines for programming of various components of the GlobalInterlock System to produce a consistent and unified approach that will aid the end users in betterunderstanding the system. Development time should also be reduced by fostering the use of re-usablecode.For the most part, these guidelines reflect Rockwell Automation’s own guidelines for modularprogramming and sample code provided by Rockwell.TN-0157, Revision APage v

GIS ControlLogix Programming1. INTRODUCTION1.1PURPOSEThis document will build a foundation for consistency in programming the various components of theGlobal Interlock System (GIS). Nothing in the document is necessarily an absolute requirement orspecification. Consult the appropriate project document, specification, or interface controller documentfor actual system requirements.This document is based on standard practices that are found in Rockwell Automation’s documentation fortheir products, most notably Integrated Architecture: Foundations of Modular Programming.This document also gathers configuration details into one centralized location.This document should be a collaborative effort of all vendors, design teams, and the ATST project. It isnot the purpose of the document to restrict viable solutions. Comments and discussion of this documentare highly encouraged.1.2INTENDED AUDIENCEThis document is intended primarily to be used by the designers and programmers of the individual localinterlock controllers (LICs).TN-0157, Revision APage 1 of 38

GIS ControlLogix Programming2. DOCUMENTS2.1RELATED DOCUMENTS 2.2“Global Interlock System Design Definition”, ATST Project Document SPEC-0112.“Global Interlock System Specification”, ATST Project Document SPEC-0046.REFERENCED DOCUMENTS 2.3Rockwell Automation, “GuardLogix Controller Systems Safety Reference Manual”, Publication1756-RM093.Rockwell Automation, “GuardLogix Controllers”, Publication 1756-UM020.Rockwell Automation, “Integrated Architecture: Foundations of Modular Programming”,Publication IA-RM001.Rockwell Automation, “Logix5000 Controllers Common Procedures”, Publication 1756PM001.Rockwell Automation, “Logix5000 Controllers Ladder Diagram”, Publication 1756-PM008.Rockwell Automation, “Logix5000 Controllers Tasks, Programs, and Routines”, Publication1756-PM005.Rockwell Automation, “58814 - Smartport assignment guidelines for Stratix 8000”Rockwell Automation, “65491 - Resilient Ethernet Protocol Ring Using Stratix 8000/8300”Rockwell Automation, “65566 - Inter-VLAN routing using Stratix 8300 and Stratix 8000switches”SOFTWAREThe following software will be required for GIS Development RSLogix 5000, version 20.01 or higherRSLinx Classic, version 2.57.00 or higherThe following software is recommended in addition to the required software. Cisco Network Assistant, version 5.6 (3) or higherWireShark, version 1.6.5 or higherTN-0157, Revision APage 2 of 38

GIS ControlLogix Programming3. CONFIGURING THE NETWORK3.1INITIAL SETUPThe first step in getting the system up and running is configuring the network switch(es). Follow theprocedure given in 1783-UM003 to “initialize the Switch with Express Setup.”Configure as follows:Network SettingsManagement Interface (VLAN ID)IP Assignment ModeIP AddressSubnet MaskDefault GatewayPasswordConfirm PasswordCIP VLAN settingsCIP VLANIP AddressSubnet MaskOptional SettingsHost NameDefault -1StaticSeeTable 1 below255.255.255.010.4.0.200Default 1Blank255.255.255.0SeeTable 1 Switch IP AddressAssignmentsTable 1 belowSystem DateSystem TimeTN-0157, Revision APage 3 of 38

GIS ControlLogix ProgrammingFigure 1 Express SetupTable 1 Switch IP Address AssignmentsSystemGlobal Interlock ControllerTelescope Mount Drive AssemblyCoudé Rotator SystemOptical Support SystemInstruments SystemEnclosureFacility EquipmentFacility Thermal SystemDevelopment LIC1Development .20810.4.0.209HostnameGIS SwitchTel SwitchRot SwitchOSS SwitchInst SwitchEnc SwitchFac SwitchFTS SwitchLIC1 SwitchLIC2 SwitchSETTING UP PORTSThe Stratix 8300 has pre-configured settings (“Smartports”) that optimize the switch port for the type ofdevice that is connected. See Rockwell knowledge base article 58814 - Smartport assignment guidelinesfor Stratix 8000.DeviceA single 1734-AENTR moduleA single 1791ES-IB8XOBV4 or 1791ES-IB16 moduleDaisy-chained 1734-AENTRs (linear device network)1756-EN2TR, 1756-EN2FHMI terminalA single PC1783-RMS10T Stratix 8300 switch1783-ETAPTN-0157, Revision ASmartport RoleAutomation DeviceAutomation DevicenoneAutomation DeviceAutomation DeviceDesktop for AutomationSwitch for AutomationNonePage 4 of 38

GIS ControlLogix Programming3.3SETTING UP VLANSEach subsystem will exist in its own virtual LAN (VLAN). This will require that each switch beconfigured for each VLAN. In addition, there is a ‘Setup’ VLAN that will facilitate connection to devicesat the default IP addresses to enable configuration. Table 2 VLAN Assignments shows the VLANs thatshould be created on each switch.Figure 2 VLAN Setup ScreenTable 2 VLAN AssignmentsSystemGlobal Interlock ControllerTelescope Mount Drive AssemblyCoudé Rotator SystemOptical Support SystemInstruments SystemEnclosureFacility EquipmentTN-0157, Revision AVLAN 05VLAN0106VLAN ID100101102103104105106Page 5 of 38

GIS ControlLogix ProgrammingFacility Thermal SystemDevelopment LIC1Development 192Table 3 Subnet Address AssignmentsSystemGlobal Interlock ControllerTelescope Mount Drive AssemblyCoudé Rotator SystemOptical Support SystemInstruments SystemEnclosureFacility EquipmentFacility Thermal SystemDevelopment LIC1Development LIC2SetupTN-0157, Revision AAddress 5106107108109192Page 6 of 38

GIS ControlLogix Programming4. CONFIGURING THE GUARDLOGIX CONTROLLER4.1FIRMWAREAll controller will need to have version 20 of the appropriate firmware installed. The controller will shipwith minimal firmware to allow initial configuration and installation of a fully functional version of thefirmware.4.2SAFETY NETWORK NUMBERThe Safety Network Number (SNN) is a unique number that is generated for each network segment. It isused by the Safety CIP protocol to ensure that the communicating device is indeed the correct device, notjust a similar one.For the purposes of GIS, the automatic, time-based SNN should be sufficient. This should ensure that notwo devices share a unique SNN. However, there is a remote but non-zero chance that two units could beconfigured at different locations by different developers at the exact same moment. Prior tocommissioning the entire system, these numbers will need to be verified for their uniqueness.4.3SAFETY LOCKINGSafety-locking the controller helps protect safety control components from modification. This featurerequires two separate passwords, one for lock and one for unlock.See section 15 for password requirements.Typically, safety-locking will only be required once development is completed on a particular revisionand it is ready for verification and validation.4.44.4.1I/O MODULESModule DefinitionsI/O modules should be configured for providing combined status.Electronic Keying should be set for ‘Exact Match.’Requested Packet Interval (RPI) should be set for 20 milliseconds.‘Major Fault on Controller if Connection Fails While in Run Mode’ should not be set.Input configuration should be set for single. All inputs will use dual channel input instructions for safety.Test outputs should be configure as required by how the module is wired to the field devices. Typically,this will be set for pulse test.Output configuration should be set for single point operation type. Typically, this will be set for SafetyPulse test point mode.Since the controller and all remote I/O devices are part of the same network the safety network numbershould be the same as the safety network number of the controller.TN-0157, Revision APage 7 of 38

GIS ControlLogix Programming5. CONFIGURING REMOTE I/O MODULES5.1FIRMWAREAll remote I/O modules will need to have version 20 firmware installed.TN-0157, Revision APage 8 of 38

GIS ControlLogix Programming6. IP ADDRESSINGThe GIS is assigned the 10.4.0.0/16 subnet. Each subsystem of the GIS will receive its own /24 network.6.1VIRTUAL LANSEach of the subnets will be its own virtual LAN.Table 4 Subnet Address AssignmentsSystemGlobal Interlock ControllerTelescope Mount Drive AssemblyCoudé Rotator SystemOptical Support SystemInstruments SystemEnclosureFacility EquipmentFacility Thermal SystemDevelopment LIC1Development LIC2Setup6.2Address 5106107108109192HOST ADDRESSFor uniformity the following number scheme is suggested. Replace LIC1 with the appropriateabbreviation from Table 6 LIC Abbreviations. Replace x with the third octet from Table 4.Table 5 Host Address AssignmentsIP Address10.4.x.0/2410.4.x.1HostnameLIC GatewayDescriptionLocal Interlock Controller subnetLIC Stratix 8300 switch Gateway10.4.x.1010.4.x.11LIC R00 S02 ENETLIC R00 S03 ENETfirst Ethernet adaptersecond Ethernet adapter (if installed)10.4.x.20Second ControlLogix rack (if installed)10.4.x.80GIS PVPReserved for HMI10.4.x.9010.4.x.91GIS DevGIS MaintReserved for Development StationReserved for Maintenance Station10.4.x.10110.4.x.10210.4.x.103 10.4.x.199LIC R01 S00 ENETLIC R02 S00 ENETLIC R03 S00 ENET LIC R99 S00 ENETRemote I/O adapter (Rack #01)Remote I/O adapter (Rack#02)Remote I/O adapter (Rack #03) Remote I/O adapter (Rack #99)10.4.x.201LIC Switch201Embedded Switch #01TN-0157, Revision APage 9 of 38

GIS ControlLogix ProgrammingIP Address10.4.x.20210.4.x.203 10.4.x.254TN-0157, Revision AHostnameLIC Switch202LIC Switch203 LIC Switch254DescriptionEmbedded Switch #02Embedded Switch #03 Embedded Switch #54Page 10 of 38

GIS ControlLogix Programming7. TAGS7.1TAG SCOPEAll produced and consumed tags are controller-scoped tags. Controller-scoped tags represent informationthat must be passed between the GIC and the LIC. Program-scoped tags represent information that is onlyrequired at the LIC. Examples of controller-scoped tags would be emergency stop status signals.7.2PRODUCED AND CONSUMED TAGSThe entire Global Interlock System will produce and consume a large number of tags. Because of thelimited resources available to handle these connections it may be necessary to use user-defined types toaggregate the tags into larger structures.Tags that will be consumed by the individual LICs from the GIC include emergency stop, fire alarm, andseismic alarm.7.3DATA ACCESS CONTROLStarting with revision 18 of the RSLogix software, two new tag attributes are available: External Accessand Constant.7.3.1External AccessExternal Access attribute defines how an external application can access a tag. Options you can configurefor the External Access attribute include: Read/WriteRead OnlyNoneBy default, all tags external access attribute should be set to None. No tags in the Safety Task should beset to Read/Write.Program-scoped tags should typically be set to Read Only.7.3.2ConstantThe Constant attribute is used to protect the tag from being changed via the controller programmingapplication or logic in the controller.TN-0157, Revision APage 11 of 38

GIS ControlLogix Programming8. GENERAL NAMING CONVENTIONS8.1PROGRAMS AND ROUTINES 8.2Names should be meaningful to maintenance personnel.Keep names short by using abbreviations and acronyms.Spaces are not allowed, instead of using underscores (“ ”) use mixed case.Use standard industry abbreviations or abbreviations listed in this document.When using abbreviations be consistent, clear, and unambiguous.TAG NAMINGRSLogix enforces the following rules: A name may not exceed 40 characters.A name can contain only upper-case and lower-case letters, numbers and underscores.A name cannot begin with a number.A name cannot have adjacent underscores or end with an underscore.Underscores are significant.Case is not significant (lower-case letters match upper-case letters), and names are displayed with the caseentered when first created. The use of mixed case, sometimes referred to as camel case is desirable toincrease legibility.8.2.1General Tag Name GuidelinesCare should be taken when choosing names to avoid ambiguity. For example the tags DoorOpen andOpenDoor, each could alternately refer to a door being ajar or a command to open a door. Therefore, suchtags should be avoided in favor of tags such as DoorOpened and CmdOpenDoor.8.2.2Controller-Scoped Tag NamesController-scoped tags will take the format of major minor component signal.major indicates the major subsystem that the device is located in. This is the controller that“owns” the tag. This is the LIC abbreviation found in Table 6 LIC Abbreviations.minor indicates the subsystem that the device is associated with, such as Az or El for azimuth andelevation drive subsystems.component indicates the physical device which the tag is associated with. This could be anindividual drive in a subsystem, such as Drive1.signal is the particular status or information that the tag indicates, such as InputOK orDoorOpenedIt is often desirable for the data type to be included in the name. Because data types often contain severalpieces of information not just a BOOL value.8.2.3Program-Scoped Tag NamesProgram-scoped tags, because they are used only within a single LIC have no need of the elaboratestructure given in Controller-Scoped Tag Names above.TN-0157, Revision APage 12 of 38

GIS ControlLogix Programming8.2.4AliasesAliases allow individual tags to be referenced by various nomenclatures. In addition to the base tag, thesecan include functional names, and even references to schematic diagrams. Tags can even be doublealiased.For example: The first contact block on the emergency stop switch -SF116 is connected to input 0 on thePOINT I/O module in slot 01 of rack 01.LIC1 R01:2:I:PtData01 can be aliased as SF116 1 which can be further aliased as EStopPB1A. Thisway a technician referencing the ladder logic can know the actual I/O point, the connected componentthat the I/O is referencing, and also the logical name.8.2.5DescriptionsDescriptions should avoid simply repeating the tag name, but rather more fully describe what the tagrepresents in the logic. While tag names were chosen to be as clear and concise as possible, cleardescriptions will help remove any ambiguity for a technician who may be troubleshooting a problem.In the DoorOpened example from above, it could clearly indicate which door and that this is an input,“Access Door to Telescope Level is not fully closed and locked.”8.38.3.1I/O AND NETWORK MODULESDescriptionEach module in a RSLogix project requires a unique name. By default, I/O and network modules shouldbe named as follows:TN-0157, Revision APage 13 of 38

GIS ControlLogix ProgrammingLIC Rnn Snn functionWhere LIC represents the ATST system and LIC to which the component belongs. There areseven LICs in the GIS as listed in Table 6 below.Rnn is the chassis or remote adapter number. R00 is the local rack, R01 and R02 would be remoteadapters #1 and #2.Snn is the slot number. S00 is slot or module #0 (far left), S01 and S02 would be slot #1 and #2or module #1 and #2.function is an abbreviation for the type of module as listed in Table 8 (taken from “IntegratedArchitecture: Foundations of Modular Programming”).Strictly adhering to this scheme is not always desirable because it can make for some convoluted andpotentially confusing naming. For example, the second input module on a Point I/O chassis would beLIC2 R01 S00 ENET:2:I. In which case, it would be better to not use the slot number and function. Thiswould become LIC2 R01:2.I.For this reason it is suggested that ‘slot zero,’ the controller or communications adapter, in a chassis notuse slot number or function, but rather the logical location or communications adapter name, such asLIC2 GLX would be the GuardLogix controller in LIC2, while LIC1 R01 would be the first remote I/Ochassis in the LIC1 system. The rack designation, R01, might also be replaced with a more appropriateidentifier, such asTable 6 LIC AbbreviationsSystemGlobal Interlock ControllerTelescope Mount Drive AssemblyCoudé Rotator SystemOptical Support SystemInstruments SystemEnclosureFacility EquipmentFacility Thermal SystemAbbreviationGICTelRotOSSInstEncFacFTSTable 7 System AbbreviationsSystemGlobal Interlock ControllerTelescope Mount AssemblyM1 AssemblyTop End Optical AssemblyFeed OpticsWavefront CorrectionObservatory Control SystemTelescope Control SystemEnclosure Control SystemFacility EquipmentFacility Thermal SystemTN-0157, Revision AAbbreviationGICTMAM1TEOAFOWFCOCSTCSECSFacFTSPage 14 of 38

GIS ControlLogix ProgrammingTable 8 Function AbbreviationsFunctionAnalog InputAnalog OutputDiscrete InputDiscrete OutputAnalog Input/Output comboDiscrete Input/Output comboAnalog/Discrete Input/Output comboRemote I/OSerial data I/OMotion I/ODeviceNetControlNetEtherNet/IPProfibusHigh Speed CounterProgrammable Limit SwitchSequence Of EventsGuardLogix ProcessorControlLogix MIODNETCNETENETPFBHSCPLSSOEGLXCLXExample Module1734-IB8S1734-OB8S1791ES-IB8XOBV41734-AENTR, 1756-EN2TR1756-L62S1756-L55ExamplesGlobal Interlock Controller rack contains two Ethernet cards, one (in slot #2) for communication with theGIS and the other (in slot #3) for communication with the OCS, they would be calledGIC R00 S02 ENET and GIC R00 S03 ENET, respectively.TN-0157, Revision APage 15 of 38

GIS ControlLogix ProgrammingFigure 3 Global Interlock ControllerModule NameGIC GLXGIC R00 S02 ENETGIC R00 S03 ENETDescription1756-L63S Controller1756-EN2TR Ethernet adapter in GIC rack slot 21756-EN2TR Ethernet adapter in GIC rack slot 3Note that the controller does not specify a rack or slot position, regardless of where it is located ascontroller have a slightly different naming convention.Figure 4 Example LIC Remote Rack #01Module NameLIC R01Description1791ES-IB8XOBV4 CompactBlock Guard I/ONote even though there are no slots in this device, the Sxx portion of the name is retained forconsistency.TN-0157, Revision APage 16 of 38

GIS ControlLogix ProgrammingFigure 5 Example LIC Remote I/O Rack #02Module NameLIC R02LIC R02 S01 DILIC R02 S02 DILIC R02 S03 DOTN-0157, Revision ADescription1734-AENTR EtherNet/IP adapter (base module)1734-IB8S POINT I/O module (left-most)1734-IB8S POINT I/O module (second from the left)1734-OB8S POINT I/O module (third from the left)Page 17 of 38

GIS ControlLogix ProgrammingFigure 6 Example LIC Remote Rack #03Module NameLIC R03LIC R03 S01 DI8.4Description1734-AENTR EtherNet/IP adapter (base module)1734-IB8S POINT I/O module (left-most)USER DEFINED DATA TYPES (UDTS)All user-defined data types will begin with “UDT .”8.5ADD-ON INSTRUCTIONS (AOIS)All add-on instructions will begin with “AOI .”TN-0157, Revision APage 18 of 38

GIS ControlLogix Programming9. LADDER LOGICAll programming for the Global Interlock system will be Ladder Logic.Although output instructions can be placed in sequence on a single rung (serial), it is preferred that theyare placed in branches (parallel) to assist technicians viewing the ladder logic code. The same applies formixing input and output instructions on the same line. It is preferred to place the output instruction at theright-most side and create parallel branches as needed. These arrangements are commonly found inhardware relay logic.Possible OptionPreferred ( ) ( ) ( ) ( ) ] [ ( ) ] [ ( ) ] [ ( ) ] [ ( ) It is preferred that the instruction most likely to be FALSE be placed on the left and the instruction leastlikely to be FALSE be placed on the right. Typically instructions are executed faster when the rungcondition is FALSE.TN-0157, Revision APage 19 of 38

GIS ControlLogix Programming10. CONVENTIONS FOR REVISION NUMBERINGRevision number will apply to all software components as follows:Program Name M.n-TT.PPM, a major revision number, which changes when a major set of components is released as a set.n, a minor revision number, which changes when a when the interface to the component changes.TT a “tweak” revision number, which changes when any change at all is madeand PP any system specific revision number.PP is unlikely to change for the top level programs as there aren’t any system specific revisions (unless asecond ATST is built). Rather the PP suffix is useful when producing and sharing routines betweensubsystems, which require a change from the standard routine that is specific to the subsystem. PP willnormally be omitted10.1 REVISION NUMBERING EXAMPLESProgram NameGIC GLX 1.0-00.00GIC GLX 1.0-01.00GIC GLX 1.1-00.00TN-0157, Revision AFirst major release of the GIC codeFirst revision, which doesn’t change its interfacenext revision which affects its interface with other systemsPage 20 of 38

GIS ControlLogix Programming11. THE MAIN TASKThe main task does not run on Safety Partner. Safety-related tasks must not be run in the main task.The main task will handle general controller f

A single 1791ES -IB8XOBV4 or 1791ES -IB16 module Automation Device Daisy-chained 1734 -AENTRs (linear device network) none 1756 -EN2TR, 1756 -EN2F Automation Device HMI terminal Automation Device A single PC Desktop for Automation 1783 -RMS10T Stratix 8300 switch Switch for Automation 1783 -ETAP None Figure 1 Express Setup

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