Chapter 11

Introduction To ControlNet
Networks Popularity
Stand-alone PLCs fading fast
Older networks being upgraded
Faster more efficient networks
New networks offer deterministic and
repeatable data transfer

Network Advantages for
Maintenance Individuals
PLCs connected on network
Access any PLC from a single computer
anywhere on the network
Upload, download, on-line editing across
network to any device on network from a
central location

ControlNet
Open network managed by ControlNet International
Use for real-time data transfer of time-critical and
non-time-critical data between processors or I/O on
same link
Data transferred at a fixed rate of 5 million bits per
second
ControlNet basically a combination of Allen-
Bradleys Data Highway Plus and Remote I/O

ControlNet Nodes
Up to 99 nodes
No node 0
Actual number of nodes determined by how
efficiently the network bandwidth is set up
Network set up using RSNetWorx for
ControlNet software
Nodes on ControlNet
SLC 500, ControlLogix, PLC 5 processors
Third-party field devices
Operator interface
Variable frequency drives
ControlNet Applications
ControlLogix processor, SLC 500, or PLC 5
processor scheduled data exchange
Local PLC connection to remote chassis for
high-speed remote I/O connectivity

Interlocking or Synchronization
of Multiple Nodes
Synchronized starting of variable frequency
drives on ControlNet
Interlocking multiple processors
Network Bridging
Connect two Data Highway Plus networks
Connect multiple DeviceNet networks
Trunk Line Drop Line
Node
number
Termination
resistor
Control Net Tap
Trunk line
Drop line
Termination
resistor
PLC 5 as
node 7
SLC 500
as node 8
Variable
frequency drive
as node 4
Computer
Interface cards
Operator
interface
ControlLogix PLCs
ControlNet Taps
Straight T
Straight Y Right Angle Right Angle Y
Drop line length is fixed at 1 meter (39.5 inches).
SLC 500 ControlNet Interface
1747-SCNR
SLC 500 modular
PLCs
Scheduled and
unscheduled
messaging
ControlLogix ControlNet Interface
1756-CNB
Channel A only
1756-CNBR
Channel A and B for
redundant media
Module node address
set with side switches
Duplicate node
addresses not allowed
NAP for computer
connectivity

FlexLogix ControlNet Interface
FlexLogix processor
Two communication card slots
Two ControlNet interface cards
with redundancy
NAP
Set node address here
Redundant Media
Tap
Trunk
line
PLC 5
node
Personal computer
with ControlNet
interface
Redundant
cables
Drop
line
ControlLogix
Personal Computer Interface
Personal computer with ControlNet
interface card like 1784-KTCX15
Redundant
trunk line
KTCX15 ControlNet Interface
Status indicators
Network access port
Channel A
Channel B
Floppy with card driver
KTCX15 Interface to PLC 5
PLC 5 ControlNet
processor
NAP
Channel A
Channel B
Redundant
trunk line
Redundant
trunk line
Personal computer with
ControlNet interface
NAP connection
Personal Computer to NAP
ControlNet Cabling
ControlNet Segment
Cabling Terms
Segment
Trunk line cable section
Termination resistor
Link
Segment
Comprised of a number of sections of trunk
cable separated by taps
Maximum segment length 1,000 meters or
3,280 feet
Maximum 48 nodes per segment
Segment length determined by number of
nodes
Taps
Taps are required.
There is no minimum cable length between
taps.
Taps can be directly connected together.
Trunk Line Cable Section
Trunk line cable section connects one tap to
another.
Taps are required.
Standard light industrial quad shielded RG-6.
Special use cables are available.
Fiber optic cables are available.

Termination Resistor
One termination resistor is required on the
end of every segment.
ControlNet Segment
Termination
resistor
Termination
resistor
39.5
inches
Segment
Trunk
line
Drop
line
Tap
Segment Calculation
Formula to calculate segment length
1,000 meters [16.3 meters ( number of taps 2)]
Calculation Example:
Calculate maximum segment length using
standard light industrial RG-6 coax requiring
22 taps.
1,000 meters [16.3 meters ( 22 - 2)]
1,000 meters [16.3 meters ( 20 )]
1,000 meters 326 meters
Maximum segment length = 674 meters
ControlNet Link
If more than 48 nodes are required, an
additional segment is required.
Repeater connects segments.
Two segments connected by a repeater is a
link.
Three Segments Connected by a
Repeater to Create a Star
Four Segments Connected by
Repeaters to Create a Ring
ControlNet Repeaters
Required if additional nodes are required
after either maximum number of nodes or
cable length reached
Two modules required to build a repeater
Many copper and fiber repeaters to select
from depending on application
Building a Repeater Example
The two repeater modules can be DIN rail-
mounted as a pair to build a repeater.
1 - 1786-RPA (repeater adaptor module)
1 - 1786-RPCD (dual copper repeater)

Repeater Adapter Module
Dual Copper Repeater Module
Repeaters
ControlNet
PLC 5
Add Flex- I/O blocks
to this communication
for remote I/O points
Example of Fiber Repeater
Fiber repeaters
available as short,
medium, long, and very
long haul
Up to 18.5 miles
ControlNet network
using proper fiber
repeaters
Right-hand module in
previous slide
RSNetWorx Software
RSNetWorx
From Rockwell Software
Required to configure and schedule a
ControlNet network
RSNetWorx For ControlNet
Graphic view
of network
Go on-line
with network
RSNetWorx
for ControlNet
Enable
editing
Manual
network
configuration
Network
bandwidth
utilization
Trunk
line
Node
number
How Critical is this Data?
Separate data into two categories.
Is this information time critical?
Can this information be transferred on a non-
time critical basis?


What is Real-Time
for This Application?
How soon do you really need the
information?
Networks do not have unlimited bandwidth.
Cannot have everything instantly
Realistic Data Flow (1 of 2)
Assume you had a tank that takes four hours
to fill.
Why would you need a tank level every 10
milliseconds?
What is realistic?
Would every few seconds be acceptable?
Realistic Data Flow (2 of 2)
Assume you had a tank of water that takes
two hours to heat.
Why would you need a tank temperature
every 10 milliseconds?
What is realistic?
Would every few seconds be acceptable?
Scheduled / Unscheduled
Time critical data is scheduled data.
Requested packet interval (RPI) set up in
RSNetWorx
Non-time critical data is unscheduled data.
Message instruction programmed on PLC
ladder rung
Trigger to transfer only when needed
RPI
Requested packet interval
Scheduled network service
The requested interval time-critical data will
flow
ControlNet will meet or beat the RPI if network
installed and configured properly
Inefficient Network
Improper installation
Follow installation manual
Improper network modification
Follow installation manual
Poor design
Follow installation manual
Overdriving network
Unrealistic data flow expectations
ControlNet Bandwidth
Three pieces to bandwidth
Scheduled traffic
Unscheduled traffic
Maintenance or guard band
Scheduled Traffic
Unscheduled
Traffic
Network
Maintenance
Network Update Time
Network Update
One cycle of the network
Called NUT time
Set up on RSNetWorx
Data cannot transfer faster than the NUT
Scheduled Maximum Node
SMAX
This is the highest node number that will be
allowed to send scheduled data.
Any node address above SMAX that has
scheduled data to transfer will not be allowed
to transmit.
Unscheduled Maximum Node
UMAX
This is the highest node number that will be
allowed to send unscheduled data.
Any node address above UMAX that has
scheduled data to transfer will not be allowed
to transmit.
Node Can Send Both
A node can send scheduled as well as
unscheduled data/
The node number must be within SMAX.
Slot Time
Slot time is time the network spends waiting
for a node to respond when the node address
is either not used or the node is not
responding.
Unused node addresses should be kept to a
minimum for network efficiency.
NUT
SMAX
UMAX
Media and
channel information
RSNetWorx Parameters
Set-up Example
10 nodes scheduled traffic
2 spare nodes future scheduled traffic
14 unscheduled nodes
3 nodes for NAP connectivity
What will SMAX be?
What will UMAX be?
What about slot time?
Maximum cable length?
Maximum Segment Length
Assume RG-6 coax
How many taps?
Number of Taps
Number of taps does not include NAP
connections.
No node 0 in ControlNet.
To keep it simple, lets use taps as nodes 1 to
26.
NAP nodes 27, 28, 29
Total taps = 26
Segment Calculation
1,000 meters [16.3 meters( Number of taps
2)]
1,000 meters [16.3 meters( 26 2)]
1,000 meters [16.3 meters( 24 )]
1,000 meters 391.2 meters
Maximum segment length 608.8 meters
SMAX
Scheduled traffic nodes 1- 12
Nodes 1-10 currently used
Nodes 11 and 12 future scheduled
Unused nodes = slot time
SMAX set at 12
Determine UMAX
Nodes 13 - 26 unscheduled traffic
Nodes 27, 28, 29 for NAP
RSLinx drivers for personal computer node
addresses MUST be set at 27, 28, or 29.
RSLinx default for 1784-PCC personal
computer interface default = node 99.
UMAX must be set at a minimum of 29.
Efficient Network Configuration
1
99
UMAX =29 SMAX= 12
Node
10
Node 11 & 12
future scheduled
Node 27, 28, 29
for NAP
Future Network Expansion
Recalculate segment length?
Reconfigure SMAX?
Reconfigure UMAX?
Reschedule network using RSNetWorx if any
scheduled node is added or modified.
Reschedule Network
It must be done whenever a scheduled node
is modified or added to the network.
Network configuration is scheduled in
RSNetWorx for ControlNet.
Part of saving new network configuration
ALL processors on network in program mode
Referred to as optimizing and rewriting
network configuration
Rescheduling and the Keeper
The ControlNet communication module at the
lowest node number is called the keeper.
Should be node 1
For ControlLogix 1756-CNB(R)
Keeper like a traffic cop
Directs traffic on network and synchronizes nodes
Newer CNBs have multi-keeper capability
Multi-keeper
Older CNBs are single-keeper networks.
Newer CNBs support multi-keeper.
If there was a newer CNB at node 1 and also
at node 2, node 1 would be the keeper and
node 2 would be a back-up keeper.
If node 1 fails, node 2 would take over
network traffic control.
In single-keeper systems, if the keeper fails,
all network communications are lost.