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Emerson PaCSystems VersaMax Series, User Manual

The Emerson PaCSystems VersaMax Series is a state-of-the-art automation solution designed for streamlined industrial operations. To help users unlock its full potential, a comprehensive User Manual is available for free download from manualshive.com. This manual provides in-depth instructions and insights, ensuring seamless use and maximum efficiency.

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User Manual 

GFK-1503F 

Jan 2020 

 

 

PACSystems

TM

 VersaMax 

PLC USER MANUAL 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for PaCSystems VersaMax Series

Page 1: ...User Manual GFK 1503F Jan 2020 PACSystemsTM VersaMax PLC USER MANUAL ...

Page 2: ...10 1 6 1 VersaMax Modules for Expansion Racks 11 1 6 2 Available Expansion Modules 11 1 7 Communications Modules 12 1 7 1 Available VersaMax PLC Communications Modules 12 1 7 2 Profibus DP Network Slave Module 12 1 7 3 DeviceNet Network Control Module 13 1 7 4 Asi Network Master Module 13 1 7 5 Serial Communications Module 13 Chapter 2 CPU Module Datasheets CPU001 CPU002 CPU00514 2 1 Features 15 2...

Page 3: ...Installing an Expansion Transmitter Module 33 4 2 1 Removing an Expansion Transmitter Module 33 4 3 Installing an Expansion Receiver Module 34 4 3 1 Removing an Expansion Receiver Module 34 4 3 2 Expansion Rack Power Sources 35 4 3 3 Connecting the Expansion Cable RS 485 Differential 35 4 3 4 RS 485 Differential Inter Rack Connection IC200CBL601 602 615 36 4 3 5 Building a Custom Expansion Cable 3...

Page 4: ... Parameters 51 5 3 2 Configurable Memory for CPU Module IC200CPU001 CPU002 CPU005 53 5 3 3 Configurable Memory for CPU Module IC200CPUE05 53 5 3 4 Configuring Serial Port Parameters 54 5 3 5 RTU and Serial IO Delays 55 5 3 6 Configuration Required to use Winloader 56 5 3 7 Note for RTU Communications 56 5 3 8 Storing a Configuration from a Programmer 56 5 4 Autoconfiguration 57 5 4 1 Autoconfigura...

Page 5: ...outine Block 76 7 5 2 Creating a Temporary End of Logic 76 7 5 3 Executing Rungs of Logic without Logical Power Flow 76 7 5 4 Jumping to Another Part of the Program 76 7 6 Run Stop Mode Switch Operation 77 7 6 1 Configurable Run Stop Mode Operation 77 7 6 2 Configurable Memory Protection 77 7 6 3 Summary of CPU Switch Run Stop Operation 77 7 7 Privilege Levels and Passwords 78 7 7 1 Protection Lev...

Page 6: ... 2 S References 94 9 3 3 SA SB and SC References 95 9 4 How Program Functions Handle Numerical Data 96 9 4 1 Real Numbers 98 9 4 2 Errors in Real Numbers and Operations 98 9 5 Time tick Contacts 98 Chapter 10 Instruction Set Reference 100 10 1 Bit Operation Functions 101 10 1 1Data Lengths for the Bit Operation Functions 101 10 1 2Bit Operation Functions Logical AND Logical OR 101 10 1 3Bit Operat...

Page 7: ...ersion Functions Convert Signed Integer Data to BCD 4 134 10 4 2Data Type Conversion Functions Convert to Signed Integer 135 10 4 3Data Type Conversion Functions Convert to Double Precision Signed Integer 136 10 4 4Data Type Conversion Functions Convert to Real Data 137 10 4 5Data Type Conversion Functions Convert Real Data to Word Data 138 10 4 6Data Type Conversion Functions Truncate Real Number...

Page 8: ... the SVCREQ Function 178 11 3 SVCREQ 1 Change Read Constant Sweep Timer 178 11 3 1Input Parameter Block for SCVREQ 1 178 11 4 SVCREQ 2 Read Window Times 180 11 4 1Output Parameter Block for SVCREQ 2 181 11 5 SVCREQ 3 Change Programmer Communications Window Mode 181 11 5 1Changing the Programmer Communications Window Mode 181 11 6 SVCREQ 4 Change System Communications Window Mode 182 11 6 1Changing...

Page 9: ... SVCREQ 15 194 11 16 SVCREQ 16 Read Elapsed Time Clock 195 11 16 1 Output Parameter Block for SVCREQ 16 195 11 16 2 Example of SVCREQ 16 195 11 17 SVCREQ 18 Read I O Override Status 196 11 17 1 Output Parameter Block for SVCREQ 18 196 11 17 2 Example of SVCREQ 18 196 11 18 SVCREQ 23 Read Master Checksum 197 11 18 1 Output Parameter Block for SVCREQ 23 197 11 18 2 Example of SVCREQ 23 197 11 19 SVC...

Page 10: ... Commands 212 12 4 1Overlapping COMMREQs 213 12 4 2COMMREQS that Must Complete Execution 213 12 4 3COMMREQs that Can be Pending While Others Execute 213 12 4 4Initialize Port Function 4300 213 12 4 5Set Up Input Buffer Function 4301 214 12 4 6Flush Input Buffer Function 4302 215 12 4 7Read Port Status Function 4303 216 12 4 8Write Port Control Function 4304 217 12 4 9Cancel Commreq Function 4399 2...

Page 11: ...3 5 5Checking the Status of an Ethernet Global Data Exchange 243 13 5 6Using the Ethernet Station Manager Function 244 13 6 Troubleshooting Common Ethernet Difficulties 244 13 6 1PLC Timeout Errors 245 13 6 2Unexpected Ethernet Restart or Runtime Errors 245 13 6 3EGD Configuration Mismatch Errors 246 13 6 4Receive Resource Exhaustion Errors 247 13 6 5Station Manager Lockout under Heavy Load 247 13...

Page 12: ... 273 15 1 4Writing Data to RAM or Flash 273 15 1 5Using the EZ Program Store Device with the Programmer 274 15 2 Update a PLC CPU without a Programmer Present 275 15 2 1Error During Update 278 Appendix A Performance Data 279 A 1 Base Sweep Time 279 A 2 Boolean Instruction Time 279 A 3 Function Block Timing 279 A 3 1 Sweep Impact Times 279 A 3 2 Sizes of Timers Counters Math Functions Trig Function...

Page 13: ... Contents xiii A 4 5 Modules Located in Single ended Isolated Expansion Rack 291 A 5 Ethernet Global Data Sweep Impact 292 A 5 1 Exchange Overhead 292 A 5 2 Byte Transfer Time 292 A 6 Support for Large Ethernet Global Data Configurations 293 ...

Page 14: ...maintenance The information is supplied for informational purposes only and Emerson makes no warranty as to the accuracy of the information included herein Changes modifications and or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein It is understood that Emerson may make changes modifications or improvements to the equipment r...

Page 15: ...t Communications for CPU model IC200CPUE05 is described in Chapter 13 The rest of the manual describes many programming features Elements of an Application Program chapter 8 Program Data Chapter 9 Instruction Set Reference Chapter10 The Service Request Function Chapter11 The PID Function Chapter14 Instruction Timing AppendixA Other VersaMax Manuals VersaMax Modules Power Supplies and Carriers User...

Page 16: ...ss1 Zone 2 and Class I Division 2 requirements As a scaleable automation solution VersaMax I O combines compactness and modularity for greater ease of use The 70 mm depth and small footprint of VersaMax I O enables easy convenient mounting as well as space saving benefits Modules can accommodate up to 32 points of I O each The compact modular VersaMax products feature DIN rail mounting with up to ...

Page 17: ...ns CPU model IC200CPUE05 provides a built in Ethernet port 1 2 1 Basic CPU Features Programming in Ladder Diagram Sequential Function Chart and Instruction List Floating point real data functions Non volatile flash memory for program storage Run Stop switch Embedded RS 232 and RS 485 communications Compatible with EZ Program Store device 1 2 2 Available VersaMax CPUs CPU with Two Serial Ports 34kB...

Page 18: ...re 2 1 2 3 EZ Program Store The EZ Program Store device IC200ACC003 can be used to store and update the configuration application program and reference table data of a VersaMax PLC A programmer and PLC CPU are used to initially write data to the device Figure 3 ...

Page 19: ...external power source CPU models IC200CPU005 and IC200CPUE05 require the use of an expanded 3 3V power supply See the table below Figure 4 1 3 1 Available Power Supplies and Carrier The following VersaMax power supplies and carrier are available 24VDC Power Supply IC200PWR001 24VDC Expanded 3 3V Power Supply IC200PWR002 120 240VAC Power Supply IC200PWR101 120 240VAC Expanded 3 3V Power Supply IC20...

Page 20: ...oint Grouped Module IC200MDL141 Input 120VAC 8 Point Isolated Module IC200MDL143 Input 240VAC 4 Point Isolated Module IC200MDL144 Input 120VAC 2 Groups of 8 16 Point Module IC200MDL240 Input 240VAC 2 Groups of 8 16 Point Module IC200MDL241 Input 120VAC 16 Point Isolated Module IC200MDL243 Input 240VAC 8 Point Isolated Module IC200MDL244 Input 125VDC Positive Negative Logic Grouped 8 Point Module I...

Page 21: ... Modules Mixed 24VDC Positive Logic Input Grouped 20 Point Output Relay 2 0A per Point Grouped 12 Point Module IC200MDD840 Mixed 24VDC Positive Logic Input 20 Point Output 12 Point 4 High Speed Counter PWM or Pulse Train Configurable Points IC200MDD841 Mixed 16 Point Grouped Input 24VDC Pos Neg Logic 16 Pt Grouped Output 24VDC Pos Logic 0 5A w ESCP IC200MDD842 Mixed 24VDC Positive Logic Input Grou...

Page 22: ... 4 Channels IC200ALG331 Analog Mixed I O Modules Analog Mixed Module Input Current 4 Channels Output Current 2 Channels IC200ALG430 Analog Mixed Module 0 to 10VDC Input 4 Channels Output 0 to 10VDC 2 Channels IC200ALG431 Analog Mixed Module 12 Bit 10 to 10VDC Input 4 Channels Output 10 to 10VDC 2 Channels IC200ALG432 1 5 Carriers Carriers provide mounting backplane communications and field wiring ...

Page 23: ...rrier IC200CHS003 Interposing Terminals for use with Connector Style Carrier Barrier Style Interposing I O Terminals IC200CHS011 Box Style Interposing I O Terminals IC200CHS012 Thermocouple Style Interposing I O Terminals IC200CHS014 Spring Style Interposing I O Terminals IC200CHS015 Disconnect Style Interposing I O Terminals Main Base Disconnect Style Interposing I O Terminals Expansion Base IC20...

Page 24: ...ster Carrier IC200PWB001 1 6 Expansion Modules There are two basic types of VersaMax I O expansion systems Multi Rack and Single ended Multi Rack A VersaMax PLC or NIU I O Station with an Expansion Transmitter Module IC200ETM001 and one to seven expansion racks each with an Expansion Receiver Module IC200ERM001 or IC200ERM002 If all the Expansion Receivers are the Isolated type IC200ERM001 the max...

Page 25: ... 1 6 2 Available Expansion Modules The following Expansion Modules and related products are available Expansion Modules Expansion Transmitter Module IC200ETM001 Expansion Receiver Module Isolated IC200ERM001 Expansion Receiver Module Non isolated IC200ERM002 Cables Expansion Cable Shielded 1 meter IC200CBL601 Expansion Cable Shielded 2 meters IC200CBL602 Expansion Cable Shielded 15 meters IC200CBL...

Page 26: ...00CMM020 Communications Carrier IC200CHS006 For information about the Communications Carrier please see the VersaMax Modules Power Supplies and Carriers User s Manual GFK 1504 1 7 2 Profibus DP Network Slave Module The Profibus DP Network Slave Module IC200BEM002 is a communications module that exchanges PLC reference table data on the Profibus network The VersaMax PLC CPU can read and write this ...

Page 27: ...Net Network Control Module refer to the VersaMax System DeviceNet Network Communications User s Manual GFK 1533 1 7 4 Asi Network Master Module The VersaMax AS Interface Network Master IC200BEM104 conforms to the AS Interface Specification for the master AS Interface protocol It can be used to connect a VersaMax PLC or I O station NIU to an Actuator Sensor network The AS Interface module supports ...

Page 28: ...CPU001 CPU with 34kB Configurable Memory IC200CPU002 CPU with 42kB Configurable Memory IC200CPU005 CPU with 128kB Configurable Memory VersaMaxTM PLC CPUs IC200CPU001 CPU002 and CPU005 provide powerful PLC functionality in a small versatile system They are designed to serve as the system controller for up to 64 modules with up to 2048 I O points Two serial ports provide RS 232 and RS 485 interfaces...

Page 29: ...memory for 1 hour Over 1 hour backup battery protects memory contents up to 6 months Backup battery has shelf life of 5 years when not in use Backplane current consumption IC200CPU001 IC200CPU002 no serial port converter or EZ Program Store device 5V output 40mA 3 3V output 100mA with serial port converter or EZ Program Store device 5V output 140mA Backplane current consumption IC200CPU005 no seri...

Page 30: ...ndustrial Scientific Medical Equipment Group 1 Class A CISPR 22 EN 55022 Information Technology Equipment Class A FCC 47 CFR 15 referred to as FCC part 15 Radio Devices Class A EMC Immunity Electrostatic Discharge EN 61000 4 2 8KV Air 4KV Contact RF Susceptibility EN 61000 4 3 10Vrms m 80Mhz to 1000Mhz 80 AM ENV 50140 ENV 50204 10Vrms m 900MHz 5MHZ 100 AM with 200Hz square wave Fast Transient Burs...

Page 31: ...ial I O Either port can be software configured to set up communications between the CPU and various serial devices An external device can obtain power from Port 2 if it requires 100mA or less at 5VDC Port 1 is an RS 232 port with a 9 pin female D sub connector The pinout of Port 1 allows a simple straight through cable to connect with a standard AT style RS 232 port Maximum cable lengths from the ...

Page 32: ... 9600 19 2K 38 4K 57 6K 115 2K Only on one port at a time not available on older CPU001 and CPU002 hardware revisions Some versions of VersaPro software allow configuration of RTU and Serial I O at 115 2K baud for CPU005 However this baud rate is not supported by the CPU If a configuration using this baud rate is stored to the PLC 1 For RTU an Unsupported Feature in Configuration fault is logged a...

Page 33: ...PU has passed its powerup diagnostics and is functioning properly OFF indicates a CPU problem Fast blinking indicates that the CPU is running its powerup diagnostics Slow blinking indicates the CPU is configuring I O modules Simultaneous blinking of this LED and the green Run LED indicates that the CPU is in boot mode and is waiting for a firmware update through port 1 RUN Green when the CPU is in...

Page 34: ...y required for the application program hardware configuration registers R analog inputs AI and analog outputs AQ The amount of memory allocated to the application program and hardware configuration are automatically determined by the actual program and configuration entered from the programmer The rest of the configurable memory can be easily allocated to suit the application Configurable memory C...

Page 35: ...ides a built in Ethernet Interface The RS 232 serial port can be configured for Local Station manager operation to provide access to diagnostic information about the Ethernet interface CPUE05 has 128kB of configurable memory In addition CPUE05 is compatible with the EZ Program Store device which can be used to write read update and verify programs configuration and reference tables data without a ...

Page 36: ...0 5ms K typical Realtime clock accuracy for timer functions 100ppm 0 01 or 9sec day Time of day clock accuracy 23ppm 0 0023 or 2sec day 30C 100 ppm 0 01 or 9sec day full temperature range Embedded communications RS 232 RS 485 Ethernet interface Configurable memory 128K bytes maximum Ethernet Interface Specifications Number of SRTP server connections 8 Ethernet data rate 10Mbps Physical interface 1...

Page 37: ... cabinet per IP54 protection from dust splashing water EMC Emission Radiated Conducted CISPR 11 EN 55011 Industrial Scientific Medical Equipment Group 1 Class A CISPR 22 EN 55022 Information Technology Equipment Class A FCC 47 CFR 15 referred to as FCC part 15 Radio Devices Class A EMC Immunity Electrostatic Discharge EN 61000 4 2 8KV Air 4KV Contact RF Susceptibility EN 61000 4 3 10Vrms m 80Mhz t...

Page 38: ...the CPU and various serial devices An external device can obtain power from Port 2 if it requires 100mA or less at 5VDC Figure 15 Port 1 is an RS 232 port with a 9 pin female D sub connector The pinout of Port 1 allows a simple straight through cable to connect with a standard AT style RS 232 port Port 1 can be configured foreither CPU serial communications SNP RTU Serial I O or local Station Mana...

Page 39: ... Stop No IO mode 3 4 1 Cable Lengths Maximum cable lengths from the CPU to the last device attached to the cable are Port 1 RS 232 Baud Rate Maximum Cable Length 19 2 K and below 15 meters 50 ft 38 4K 7 5 meters 25 ft 57 6K 5 meters 16 ft 115 2K 2 5 meters 8 ft Port 2 RS 485 1200 meters 4000 ft 3 4 2 Serial Port Baud Rates Port 1 Port 2 RTU protocol 1200 2400 4800 9600 19 2K 38 4K 57 6K 1200 2400 ...

Page 40: ...AN port supports SRTP Server and Ethernet Global Data This port connects directly to a 10BaseT twisted pair shielded network without an external transceiver The 10BaseT twisted pair shielded cables must meet applicable IEEE 802 standards CPUE05 automatically selects either half duplex or full duplex operation as sensed from the network connection A space is provided on the front of the CPUE05 modu...

Page 41: ...power output Figure 18 OK ON indicates the CPU has passed its powerup diagnostics and is functioning properly OFF indicates a CPU problem Fast blinking indicates that the CPU is running its powerup diagnostics Slow blinking indicates the CPU is configuring I O modules Simultaneous blinking of this LED and the green Run LED indicates that the CPU is in boot mode and is waiting for a firmware update...

Page 42: ...led by the CPU 3 8 Ethernet Restart Pushbutton The Ethernet Restart pushbutton is located on the right side of the module Figure 19 The Ethernet Restart pushbutton has two functions When pressed for less than 5 seconds it resets the Ethernet hardware tests the Ethernet LEDs and restarts the Ethernet firmware This disrupts any Ethernet communications that are presently underway When pressed for at ...

Page 43: ...en a restart is performed in the Operational state by pressing and releasing the Restart pushbutton This verifies that the Ethernet LEDs are operational All three LEDs blink green in unison when a software load is in progress 3 10 Configurable Memory CPUE05 provides a total of 128K bytes of configurable user memory This 64K of memory is use for the application program hardware configuration regist...

Page 44: ... configured using the PLC programming software then stored to the PLC Both Produced and Consumed exchanges may be configured CPUE05 supports up to 1200 variables across all Ethernet Global Data exchanges and supports selective consumption of Ethernet Global Data exchanges See chapter 13 for information about Ethernet Global Data 3 11 3 Station Manager Functionality CPUE05 has built in Station Mana...

Page 45: ...rriers in the same PLC rack must be installed on a single section of 7 5mm X 35mm DIN rail 1mm thick Steel DIN rail is recommended The DIN rail must be electrically grounded to provide EMC protection The rail must have a conductive unpainted corrosion resistant finish DIN rails compliant with DIN EN50022 are preferred For vibration resistance the DIN rail should be installed on a panel using screw...

Page 46: ...st also be installed on a panel Using the module as a template mark the location of the module s panel mount hole on the panel Drill the hole in the panel Install the module using an M3 5 6 screw in the panel mount hole Figure 21 Note 1 Tolerances on all dimensions are 0 13mm 0 005in non cumulative 2 1 1 to 1 4Nm 10 to 12 in lbs of torque should be applied to M3 5 6 32 steel screw threaded into ma...

Page 47: ...e rest of the modules in the main rack rack 0 Figure 23 VersaMax PLC Main Rack 0 1 Make sure rack power is off 2 Attach the Expansion Transmitter to DIN rail to the left of the CPU position 3 Install the CPU Connect the modules and press them together until the connectors are mated 4 After completing any additional system installation steps apply power and observe the module LEDs Figure 24 4 2 1 R...

Page 48: ...n rack only set the Rack ID to 1 Figure 25 4 Install a VersaMax Power Supply module on top of the Expansion Receiver See Installing Power Supply Modules in this chapter for details 5 Attach the cables If the system includes an Expansion Transmitter Module attach the terminator plug to the EXP2 port on the last Expansion Receiver Module 6 After completing any additional system installation steps ap...

Page 49: ... Differential For a multiple rack expansion system connect the cable from the expansion port on the Expansion Transmitter to the Expansion Receivers as shown below If all the Expansion Receivers are the Isolated type IC200ERM001 the maximum overall cable length is 750 meters If the expansion bus includes any non isolated Expansion Receivers IC200ERM002 the maximum overall cable length is 15 meters...

Page 50: ... 0 089mm2 cable 4 3 6 Connecting the Expansion Cable Single ended For a system with one non isolated expansion rack IC200ERM002 and NO Expansion Transmitter connect the expansion cable from the serial port on the VersaMax CPU to the Expansion Receiver as shown below The maximum cable length is one meter Cables cannot be fabricated for this type of installation cable IC200CBL600 must be ordered sep...

Page 51: ...t must be tied to the same source as the Power Supply on the Expansion Receiver Module 4 4 Installing Power Supply Modules Power Supply modules install directly onto the CPU module Expansion Receiver Modules and supplementary power supply carriers The Power Supply on the CPU or Expansion Receiver Module supplies 5V and 3 3V to downstream modules through the mating connector The number of modules t...

Page 52: ...nserted in the holes in bottom edge of the CPU ERM or carrier 3 Turn the latch to the locked position to secure the power supply 4 4 1 Removing the Power Supply Exercise care when working around operating equipment Devices may become very hot and could cause injury Figure 32 1 Remove power 2 urn the latch to the unlocked position as illustrated 3 Press the flexible panel on the lower edge of the p...

Page 53: ... not discard this cover you will need to install it on the last carrier It protects the connector pins from damage and ESD during handling and use Do not remove the connector cover on the lefthand side Figure 33 Install each carrier close to the previously installed carrier then slide the properly aligned carriers together to join the mating connectors To avoid damaging the connector pins do not f...

Page 54: ...tivate the battery by pulling and removing the insulator tab Figure 35 4 6 1 Lithium Battery Replacement To replace the battery use a small screwdriver to gently pry open the battery holder Replace battery only with one of the following Emerson IC200ACC001 Panasonic BR2032 Use of another battery may present a risk of fire or explosion CAUTION Battery may explode if mistreated Do not recharge disas...

Page 55: ...e cable are Port 1 RS 232 15 meters 50 ft Port 2 RS 485 1200 meters 4000 ft Both ports support configurable baud rates as listed in the CPU descriptions in this manual The following pre assembled cables are available IC200CBL001 CPU Programming Cable RS232 IC200CBL002 Expansion Firmware Upgrade Cable 4 7 3 Port 1 RS 232 Pin Assignments for Port 1 Port 1 is an RS 232 port with a 9 pin female D sub ...

Page 56: ...put 9 n c Shell SHLD Cable Shield wire connection 100 Continuous shielding cable shield connection RS 232 Point to Point Connection In point to point configuration two devices are connected to the same communication line For RS 232 the maximum length is 15 meters 50ft Figure 37 The shield must connect to shell of connectors on both ends of the cable PC 9 Pin Serial Port CPU Port1 9 pin female 9 pi...

Page 57: ...ntain low profile installation Plus ITT Cannon 250 8501 010 Extended Jackscrew Threaded with 4 40 for secure attachment to CPU001 port Order Qty 2 for each cable shell ordered Critical Information any other part selected should meet or exceed this requirement Use of this kit maintains the 70mm installed depth 4 7 4 Port 2 RS 485 Pin Assignments for Port 2 Port 2 is an RS 485 port with a 15 pin fem...

Page 58: ...Nominal Impedance 100Ω 15 Pin Male Connector Type Crimp Vendor ITT Cannon AMP Plug DAA15PK87F0 205206 1 Pin 030 2487 017 66506 9 Solder ITT Cannon AMP ZDA15P 747908 2 Connector Shell Kit ITT Cannon DA121073 50 15 pin size backshell kit Metal Plated Plastic Plastic with Nickel over Copper Cable Grounding Clamp included 40 cable exit design to maintain low profile installation Plus ITT Cannon 250 85...

Page 59: ...mes good quality cables and a moderately noisy environment A maximum of 8 slaves can be connected using RS 485 in a daisy chain or multidrop configuration The RS 485 line must include handshaking and use wire type as specified earlier Figure 39 When wiring RS 485 multidrop cables reflections on the transmission line can be reduced by daisy chaining the cable as shown below Make connections inside ...

Page 60: ...er operation of the system 4 8 Ethernet Connection for CPUE05 The Ethernet port on PLC module IC200CPUE05 connects directly to a 10BaseT twisted pair shielded network without an external transceiver Connect the port to an external 10BaseT hub or switch or a hub or repeater with auto sense of 10 100 using a twisted pair cable Cables are readily available from commercial distributors Emerson recomme...

Page 61: ...environment that contains static material such as carpets personnel should discharge themselves by touching a safely grounded surface before accessing the equipment If the AC mains are used to provide power for I O these lines should be suppressed prior to distribution to the I O so that immunity levels for the I O are not exceeded Suppression for the AC I O power can be made using line rated MOVs...

Page 62: ...the PLC CPU automatically reads the configuration of the modules installed in the system and creates the overall system configuration Modules that have software configurable features can only use their default settings when autoconfigured 5 1 2 Software Configuration Most PLC systems use a customized configuration that is created using configuration software and stored to the CPU from a programmer...

Page 63: ... from its RAM memory at powerup 5 2 Configuring Racks and Slots Even though a VersaMax PLC does not have a module rack both autoconfiguration and software configuration use the traditional convention of racks and slots to identify module locations in the system Each logical rack consists of the CPU or an Expansion Receiver module plus up to 8 additional I O and option modules mounted on the same D...

Page 64: ...on 50 Figure 44 In a system with an Expansion Transmitter Module IC200BTM001 and up to seven expansion racks each with an Isolated Expansion Receiver Module IC200ERM001 or IC200ERM002 the additional racks are configured as rack 1 through rack 7 Figure 45 ...

Page 65: ...CPU serial ports as explained in this chapter For CPUE05 configure its Ethernet parameters as explained in chapter 6 Ethernet Configuration Configure the expansion modules if the system has expansion racks Add module carriers and define wiring assignments Place modules on carriers and select their parameters Configurable parameters of I O modules are described in the VersaMax Modules Power Supplie...

Page 66: ...uired for the modem to start data transmission after receiving the transmit request 0mS 0 255mS Default Idle Time Time in seconds the CPU waits to receive the next message from the programming device before it assumes that the programming device has failed and proceeds to its base state Communication with the programmer is terminated and will have to be reestablished 10 1 60 SFC Timer Faults Enabl...

Page 67: ...rs and analog memory Similarly there might be a small logic program but a larger amount of memory needed for registers and analog inputs and outputs 5 3 2 Configurable Memory for CPU Module IC200CPU001 CPU002 CPU005 Configurable memory CPU001 34K bytes maximum CPU002 42K bytes maximum CPU005 128K bytes maximum Application program size not configurable CPU001 for rel 1 50 compatibility CPU002 for r...

Page 68: ...n also be configured as a Local Station Manager Parity Determines whether parity is added to words Odd For CPUE05 when Port Mode is Local Station Manager default is None Odd Even None Data Rate bps Data transmission rate in bits per second Serial comms modes 19200 SNP 4800 9600 19200 38400 RTU 1200 2400 4800 9600 19200 38400 57600 Serial I O 4800 9600 19200 38400 57600 CPUE05 in Local Station Mana...

Page 69: ...s stored to the PLC For RTU an Unsupported Feature in Configuration fault is logged and the PLC transitions to Stop Faulted mode For Serial I O the same fault is logged when the transition to Run mode occurs The PLC will immediately transition to Stop Faulted mode 5 3 5 RTU and Serial IO Delays The receive to transmit turnaround and RTS drop delay parameters can be configured to customize communic...

Page 70: ... to change the configuration of the VersaMax CPU itself however 5 3 8 Storing a Configuration from a Programmer Ordinarily a VersaMax PLC system is configured by creating a configuration file on the programmer computer then transferring the file from the programmer to the PLC CPU via the CPU port The CPU stores the configuration file in its non volatile RAM memory The configuration is stored wheth...

Page 71: ...er there is a delay before the new protocol begins operating This delay is equal to the configured T3 time 5 4 Autoconfiguration When autoconfiguration is enabled and no previous autoconfiguration exists at powerup the CPU automatically reads the configuration of the modules installed in the system and creates an overall system configuration If a previous autoconfiguration is present at powerup th...

Page 72: ...ration during autoconfiguration unless no modules are present in the system For example if modules are configured in slots 1 2 and 3 then power is removed and the module in slot 1 is removed when power is reapplied the modules in slots 2 and 3 are autoconfigured normally The original module in slot 1 is not removed from the configuration The CPU generates a loss of module diagnostic for slot 1 Dif...

Page 73: ...peration communication is restored with a previously missing or failed Expansion Receiver Module The CPU starts scanning I O for the modules in that rack Addition of Module faults are not generated when scanning resumes However if communications cannot be restored with any modules in the rack Loss of Module faults are generated loss of rack 1 A previously configured Expansion Receiver Module is no...

Page 74: ...This is part of the basic CPU configuration as described in chapter 5 Note that Local Station Manager parameters are configured independently of the Port 1 parameters After the configuration is completed and stored to the PLC it is maintained in memory by the PLC CPU The configuration may be saved into and retrieved from Flash memory which provides nearly permanent backup of the configuration data...

Page 75: ...nique address of the Ethernet interface as a node on the network On a large network a subnet mask can be used to identify a section of the overall network A gateway address can be used to identify a gateway that joins one network with another These parameters must be correct or the Ethernet interface may be unable to communicate on the network and or network operation may be disrupted It is especi...

Page 76: ...gured for up to 32 Ethernet Global Data exchanges any combination of produced and consumed See Ethernet Global Data in chapter 13 for a discussion of this feature Configuration defines both the content of an exchange its data ranges and its operational characteristics Each Ethernet Global Data produced or consumed exchange must be configured individually for each PLC You can configure Up to 1200 d...

Page 77: ...ow The exchange must also be configured in each consumer as explained next Parameters Description Local Producer ID The address that uniquely identifies the CPUE05 as an Ethernet Global Data device across the network It is a dotted decimal number The default is the same as the IP address of the CPUE05 The default can be changed Exchange ID A number that identifies a specific data exchange Adapter ...

Page 78: ...ill be placed See Checking the Status of an Exchange in chapter 13 for details Note that the Status Word address must be unique it is not automatically assigned the next highest address Offset Reference Low Point High Point Description Status R 99 99 Status Where the PLC will place the status data Exchange Data Ranges example A list of 1 to100 data ranges that will be sent in the exchange Data is ...

Page 79: ... at least double the producer s producer period value The default is 0 which disables timeout detection The update timeout period should be greater than the exchange production period A value at least twice the production period is recommended Round this value to the nearest 10 milliseconds before you enter it The update timeout has a resolution of 10 milliseconds If you enter a value such as 22 m...

Page 80: ...olution of 1 millisecond and has 10 millisecond accuracy between PLCs on the same LAN NTP may be enabled in the configuration of the CPUE05 Once NTP time synchronization is configured the CPUE05 will synchronize itself to an external NTP time server if one exists This feature is supported IC200CPUE05 HK and previous versions only example Offset Reference Low Point High Point Description Time Stamp...

Page 81: ... no data being transferred for the exchange 6 6 Configuring Advanced User Parameters Advanced User Parameters are internal operating parameters used by the Ethernet interface For most applications the default Advanced User Parameters should not be changed If it is necessary to modify any of these parameters it must be done by creating an Advanced User Parameter file using any ASCII text editor Thi...

Page 82: ...ata exchanges to 4 6 6 2 Example Advanced User Parameter File AUP_0_0 stpasswd system set the password to system gucast_ttl 4 set the EGD unicast IP TTL to 4 6 6 3 Advanced User Parameter Definitions The following Advanced User Parameters can be configured for the CPUE05 Ethernet interface Name Description Default Range staudp Remote Station Manager UDP port 18245 4745H 0 65535 ffffH stpasswd Stat...

Page 83: ... 32767 7fffH wrcv_buf TCP receive buffer size in bytes 4096 1000H nmin_poll1 NTP min poll interval for host 1 The value specifies log 2 of the interval in seconds eg the value 3 means 8 secs 4 means 16 sec etc 6 0006H 64 seconds 4 14 000eH 16 16384 sec nmax_poll1 NTP maximum poll interval for host 1 in log 2 of seconds 10 000aH 1024 sec nmin_poll2 NTP min poll interval for host 2 in log 2 of secon...

Page 84: ...ices sends data to output devices performs internal housekeeping and performs communications tasks This sequence of operations is called the sweep The basic operating mode of the PLC is called Standard Sweep mode In this mode the CPU performs all parts of its sweep normally Each sweep executes as quickly as possible with a different amount of time consumed each sweep The PLC may instead operate in...

Page 85: ...User Manual Chapter 7 GFK 1503F Jan 2020 CPU Operation 71 7 1 Parts of the CPU Sweep Figure 47 ...

Page 86: ...hange has expired the CPU copies the data for that exchange from the Ethernet interface to the appropriate reference memory Application Program Logic Scan Next the CPU solves the application program logic It always starts with the first instruction in the program Itends when the END instruction is executed Solving the logic creates a new set of output data Output Scan Immediately after the logic s...

Page 87: ...n the PLC fault table and the PLC goes to Stop mode If the checksum calculation fails the programmer communications window is not affected Each sweep the CPU verifies the physical configuration of one module against its programmed configuration A missing additional or mismatched module causes a fault to be generated 7 2 Standard CPU Sweep Operation Standard Sweep operation is the normal operating ...

Page 88: ...ates a watchdog failure fault and goes to Stop mode Communications are temporarily interrupted 7 2 3 Constant Sweep Time Operation If the application requires that each CPU sweep take the same amount of time the CPU can be configured to operate in Constant Sweep Time mode This operating mode assures that the inputs and outputs in the system are updated at constant intervals This mode can also be u...

Page 89: ...in either of two Stop modes Stop with I O Disabled mode Stop with I O Enabled mode When the PLC is in Stop mode the CPU does not execute the application program logic You can configure whether or not the I O will scanned during Stop mode Communications with the programmer and intelligent option modules continue in Stop mode In addition faulted board polling and board reconfiguration execution cont...

Page 90: ...makes the END function useful for debugging a program The END function should not be placed in logic associated with or called by a Sequential Function Chart control structure If this occurs the PLC will be placed in STOP FAULT mode at the end of the current sweep and an SFC_END fault will be logged 7 5 3 Executing Rungs of Logic without Logical Power Flow The nested Master Control Relay can be us...

Page 91: ... has been in Run position for at least second move it to Stop position for at least second Then move it back to Run position The faults are cleared and the CPU goes to Run mode The LED stops blinking and stays on This can be repeated if necessary If the switch is not toggled as described after 5 seconds the Run LED goes off and the CPU remains in Stop Fault mode Faults stay in the fault table 7 6 ...

Page 92: ...sword allows access to the requested level and to all lower levels For example the password for level 3 allows access to levels 0 1 2 and 3 If PLC communications are suspended protection automatically returns to the highest unprotected level For example If a password is set at levels 2 3 but none at level 4 if the software disconnects and reconnects the access level is 4 Privilege level 1 is alway...

Page 93: ...ed and a fault is logged in the PLC fault table A request to change to a privilege level that is not password protected is made by supplying the new level and an empty password Notes on Using Passwords To re enable passwords after passwords have been disabled the PLC must be power cycled with the battery removed for long enough to completely discharge the super capacitor and erase the PLC s memory...

Page 94: ...e level even with the OEM key locked Operators can clear logic configuration and references and store a new application program to the CPU without knowing passwords If passwords and or the OEM key have been set and written to flash a read from flash updates the protection level In this case it is not necessary to reenter the password to gain access to a particular level A Clear All does not clear ...

Page 95: ...s in the system Application programs are created using the programming software and transferred to the PLC Programs are stored in the CPU s non volatile memory During the CPU Sweep described in the previous chapter the CPU reads input data from the modules in the system and stores the data in its configured input memory locations The CPU then executes the entire application program once utilizing ...

Page 96: ...ubroutines Subroutines can simplify programming and reduce the overall amount of logic Each subroutine can be called as needed The main program might serve primarily to sequence the subroutine blocks Figure 50 A subroutine block can be called many times as the program executes Logic that should be repeated can be placed in a subroutine block reducing total program size Figure 51 In addition to bei...

Page 97: ...ram can also be created in Sequential Function Chart format The PLC programming software can be used to create both types of logic 8 3 1 Sequential Function Chart Sequential Function Chart SFC is a graphic method of representing the functions of a sequential automated system as a sequence of steps and transitions Each step represents commands or actions that are either active or inactive The flow ...

Page 98: ...is controlled by a set of simple program functions that work like mechanical relays and output coils Whether or not a relay passes logical power flow along the rung depends on the content of a memory location with which the relay has been associated in the program For instance a relay might pass power flow if its associated memory location contained the value 1 The same relay would not pass power ...

Page 99: ...y Open Passes power if the associated reference is ON Normally Closed Passes power if the associated reference is OFF Continuation Passes power to the right if the preceding continuation coil is set ON 8 4 2 Coils Normally Open Sets the associated reference ON if the coil receives power Otherwise OFF Negated Sets the associated discrete reference ON if the coil does not receive power Otherwise OFF...

Page 100: ...et input receives power oftd Off Delay Timer Accumulates time while NOT receiving power tmr On Delay Timer Accumulates time while receiving power The current value is reset to zero when there is no power flow upctr Up Counter Increments by 1 each time the function receives transitional power dnctr Down Counter Countsdown froma presetvalue everytime thefunction receives transitional power 8 4 4 Mat...

Page 101: ...econd ge Greater Than or Equal To Tests whether one number is greater than or equal to another lt Less Than Tests whether one number is less than another le Less Than or Equal To Test whether one number is greater than or equal to another range Range Test the input value against a range of two numbers 8 4 6 Bit Operation Functions and Logical AND Performs Logical AND of two bit strings or Logical ...

Page 102: ...r values not equal to a specified value srh gt Search Greater Than Searches array for values greater than a specified value srh ge Search Greater Than or Equal Searches array for values greater than or equal to a specified value srh lt Search Less Than Searches array for values less than a specified value srh le Search Less Than or Equal Searches array for values less than or equal to a specified ...

Page 103: ...nd Temporary End of Logic The program executes from the first rung to the last rung or the END instruction whichever is encountered first This instruction is useful for debugging purposes commnt Comment A rung explanation svcreq Service Request A special PLC service function mcr Master Control Relay Starts a master control relay range An MCR causes all rungs between the MCR and its subsequentENDMC...

Page 104: ...n each type is normally used for a specific type of data as explained below However there is great flexibility in actual memory assignment Individual memory locations are indexed using alphanumeric identifiers called references The reference s letter prefix identifies the memory area The numerical value is the offset within that memory area 9 1 1 Word Memory References Each word memory address ref...

Page 105: ...elow The illustration shows 160 individually addressed bits with address 1 in the upper left and address 160 in the lower right addresses 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 1 0 0 0 0 0 0 1 0 1 0 0 0 1 1 1 1 0 0 0 1 1 0 0 1 0 0 0 0 1 1 0 0 0 0 0 1 1 1 0 0 1 0 1 0 0 1 0 1 0 0 0 1 0 1 0 1 0 0 0 0 1 1 0 0 0 0 0 1 1 1 0 0 1 0 1 0 1 1 0 1 0 0 0 1 1 1 0 1 0 0 0 0 1 1 0 0 0 0 0 1 1 0 1 1 1 0 1 1 1 0 0 ...

Page 106: ...ive coils S can be used as inputs to functions or function blocks SA SB and SC can be used as inputs or outputs of functions and function blocks G Used for Global Data Data in G referencesis retained through power loss G references can be used with contacts and retentive coils but not on non retentive coils 9 1 3 Transition Bits and Override Bits I Q M and G references have associated transition a...

Page 107: ...entive Q and M references that have not been declared to be retentive Q and M references that are used with non retentive coils coils negated coils S SET coils R RESET coils 9 3 System Status References The PLC stores system status data in predefined references in S SA SB and SC memory Each system status reference has a descriptive name For example time tick references are named T_10MS T_100MS T_S...

Page 108: ...red when an entry is removed from the I O fault table and when the I O fault table is cleared S0011 OVR_PRE Set when an override exists in I Q M or G memory S0012 reserved S0013 PRG_CHK Set when background program check is active S0014 PLC_BAT Set to indicate a bad battery in the CPU The contact reference is updated once per sweep S0015 16 reserved S0017 SNPXACT SNP X host is actively attached to ...

Page 109: ...C after correcting the condition SA0010 HRD_CPU Set when the diagnostics detects a problem with the CPU hardware Cleared by replacing the CPU module SA0011 LOW_BAT Set when a lowbattery fault occurs Cleared byreplacing thebattery then powering up the PLC SA0012 13 reserved SA0014 LOS_IOM Set when an I O module stops communicating with the CPU Cleared by replacing the module and cycling system powe...

Page 110: ... fault occurs that causes an entry to be placed in the I O fault table Cleared when the I O fault table has no entries SC0012 SY_PRES Set as long as there is at least one entry in the PLC fault table Cleared when the PLC fault table has no entries SC0013 IO_PRES Set as long as there is at least one entry in the I O fault table Cleared when the I O fault table has no entries SC0014 HRD_FLT Set when...

Page 111: ...BCD coding of the 16 bits has a value range of 0 to 9999 REAL Floating Point Real numbers use two consecutive 16 bit memory locations The range of numbers that can be stored in this format is 1 401298E 45 to 3 402823E 38 See the next page for more information INT Signed Integer Signed integer data uses 16 bit memory locations Signed integers are represented in 2 s complement notation Bit 16 is the...

Page 112: ... infinity for a number less than 3 402823E 38 You can determine where this occurs by testing the sense of the ok output POS_INF 7F800000h IEEE positive infinity representation in hex NEG_INF FF800000h IEEE negative infinity representation in hex If the infinities produced by overflow are used as operands to other REAL functions they may cause an undefined result This result is referred to as NaN N...

Page 113: ...nual Chapter 9 GFK 1503F Jan 2020 Program Data 99 The following timing diagram represents the on off time duration of these contacts Figure 58 These time tick contacts represent specific locations in S memory ...

Page 114: ...ians Degrees Control Functions Do I O Call End Comment Master Control Relay Drum Sequencer Service Request see chapter 11 PID see chapter 14 Relational Functions Equal Not Equal Greater Than Less Than Greater or Equal Less or Equal Range Data Move Functions Move Block Move Block Clear Shift Register Communication Request Relay Functions Contacts Coils Fault and No Fault Contacts Alarm Contacts Tab...

Page 115: ...ll Bit Operation functions require Word type data However they operate on data as a continuous string of bits with bit 1 of the first word being the Least Significant Bit LSB The last bit of the last word is the Most Significant Bit MSB For example if you specified three words of data beginning at reference R0100 it would be operated on as 48 contiguous bits Figure 59 Overlapping input and output ...

Page 116: ... be used to combine strings or to control many outputs with one simple logical structure The Logical OR function is the equivalent of two relay contacts in parallel multiplied by the number of bits in the string It can be used to drive indicator lamps directly from input states or to superimpose blinking conditions on status lights Figure 60 Parameters of the Logical AND and Logical OR Functions I...

Page 117: ...ding bit in string I2 to alternate between 0 and 1 changing state with each scan as long as power is received Longer cycles can be programmed by pulsing the power flow to the function at twice the desired rate of flashing the power flow pulse should be one scan long one shot type coil or self resetting timer The Exclusive OR function is useful for quickly comparing two bit strings or to blink a gr...

Page 118: ...gure 63 10 1 5 Bit Operation Functions Logical Invert NOT The Logical Invert NOT function sets the state of each bit in the output bit string Q to the opposite of the state of the corresponding bit in bit string I1 All bits are altered on each scan that power is received making output string Q the logical complement of I1 The function passes power flow to the right whenever power is received A len...

Page 119: ... Bit Operation Functions Shift Bits Right Shift Bits Left The Shift Left function shifts all the bits in a word or group of words to the left by a specified number of places When the shift occurs the specified number of bits is shifted out of the output string to the left As bits are shifted out of the high end of the string the same number of bits is shifted in at the low end Figure 66 The Shift ...

Page 120: ...ecial reference nickname ALW_OFF as a permissive to input B1 The function passes power flow to the right unless the number of bits specified to be shifted is zero Output Q is the shifted copy of the input string If you want the input string to be shifted the output parameter Q must use the same memory location as the input parameter IN The entire shifted string is written on each scan that power i...

Page 121: ...ength of the string or is less than zero The result is placed in output string Q If you want the input string to be rotated the output parameter Q must use the same memory location as the input parameter IN The entire rotated string is written on each scan that power is received Figure 69 Parameters of the Rotate Bits Right Left Functions Input Output Choices Description enable flow When the funct...

Page 122: ...f BIT is outside the range 1 BIT 16 length then Q is set OFF A string length of 1 to 256 words can be selected Figure 71 Parameters of the Bit Test Function Input Output Choices Description enable flow When the function is enabled the bit test is performed IN I Q M T S G R AI AQ IN contains the first word of the data to be operated on BIT I Q M T G R AI AQ constant BIT contains the bit number of I...

Page 123: ...he function passes power flow to the right unless the value for BIT is outside the range 1 BIT 16 length Then OK is set OFF Figure 73 Parameters of the Bit Set and Bit Clear Functions Input Output Choices Description enable flow When the function is enabled the bit operation is performed IN I Q M T SA SB SC G R AI AQ IN contains the first word of the data to be operated on BIT I Q M T G R AI AQ co...

Page 124: ...nues until a miscompare is found or until the end of the string is reached The BIT input stores the bit number where the next comparison should start a 0 indicates the first bit in the string The BN output stores the bit number where the last comparison occurred where a 1 indicates the first bit in the string Using the same reference for BIT and BN causes the compare to start at the next bit posit...

Page 125: ...length Constant The number of words in the bit string Max is 4095 for WORD and 2047 for DWORD Operation of the Masked Compare If all corresponding bits in strings I1 and I2 match the function sets the miscompare output MC to 0 and BN to the highest bit number in the input strings The comparison then stops On the next invocation of a Masked Compare Word it is reset to 0 When the two bits currently ...

Page 126: ...erences after the function block is executed are Figure 78 In this example contact T1 and coil M100 force one and only one execution otherwise the function would repeat with possibly unexpected results 10 1 11 Bit Operation Functions Bit Position The Bit Position function locates a bit set to 1 in a bit string Each sweep that power is received the function scans the bit string starting at IN When ...

Page 127: ... on ok flow none The OK output is energized whenever enable is energized POS I Q M T G R AI AQ The position of the first non zero bit found or zero if a non zero bit is not found Example In the example if I0001 is set the bit string starting at M0001 is searched until a bit equal to 1 is found Coil Q0001 is turned on If a bit equal to 1 is found its location within the bit string is written to AQ0...

Page 128: ...the bits in the sequencer are set to 0 except for the bit pointed to by the current step which is set to 1 When Enable is active and Reset is not active the bit pointed to by the current step number is cleared The current step numberis incrementedor decremented basedon the direction parameter Then the bit pointed to by the new step number is set to 1 The parameter ST is optional If it is not used ...

Page 129: ...t DIR flow When DIR is energized the bit sequencer s step number is incremented prior to the shift Otherwise it is decremented STEP I Q M T G R AI AQ constant none When R is energized the step number is set to this value ST I Q M T SA SB SC G R AI AQ none ST contains the first word of the bit sequencer Optional ok flow none The OK output is energized whenever the function is enabled Example In the...

Page 130: ...ace a text explanation in the program logic COMMENT Provide predefined On Off patterns to a set of 16 discrete outputs in the manner of a mechanical DRUM SEQUENCER The more complex Control Functions Service Request and the PID algorithms are described in other chapters of this manual 10 2 1 Control Functions Do I O The Do I O function updates inputs or outputs for one scan while the program is run...

Page 131: ...T G R AI AQ constant none For the input scan ALT specifies the address to store scanned input point word values For the output scan ALT specifies the address to get output point word values from to send to the I O modules ok flow none OK is energized when the scan completes normally Do I O for Inputs If input references are specified when the function receives power flow the PLC scans input points...

Page 132: ...rites values from references R0001 0004 to analog output channels AQ001 004 and Q0001 is turned on Because a reference is entered for ALT the values at AQ001 004 are not written to output modules Figure 86 If no reference were specified for ALT the PLC would write values at references AQ001 004 to analog output channels 10 2 2 Control Functions Call The Call function causes program execution to go...

Page 133: ...fter the end function in the rung No logic beyond the End of Logic function is executed and control is transferred to the beginning of the program for the next sweep The End of Logic function is useful for debugging purposes because it prevents any logic which follows from being executed The programming software provides an END OF PROGRAM LOGIC marker to indicate the end of program execution This ...

Page 134: ...l Relay function has an enable input and a name This name is used again with the ENDMCRN The Master Control Relay has no outputs there can be nothing after it in a rung Figure 91 With a Master Control Relay function blocks within the scope of the Master Control Relay are executed without power flow and coils are turned off The ENDMCRN function must be tied to power rail there can be no logic befor...

Page 135: ... Jump instructions corresponding to a single nested Label Nested Jumps can be either forward or backward Jumps There can be nothing after the Jump instruction in the rung Power flow jumps directly from the instruction to the rung with the named label CAUTION To avoid creating an endless loop with forward and backward Jump instructions a backward Jump must contain a way to make it conditional Label...

Page 136: ... The Comment function is used to enter a comment rung explanation in the program A comment can have up to 2048 characters of text Longer text can be included in printouts using an annotation text file It is represented in the ladder logic like this Figure 95 10 2 7 Control Functions Drum Sequencer The Drum Sequencer function is a program instruction that operates like a mechanical drum sequencer T...

Page 137: ... words each representing one step of the Drum Sequencer The value of each word represents the desired combination of outputs fora particular value of Active Step The number of elements in the array is equal to the length input Dwell Time R AI AQ none This optional input array of words has one element for each element in the Pattern array Each value in the array represents the dwell time for the co...

Page 138: ... Active Step address 1 Preset Step address 2 Step Control address 3 Timer Control Active Step The active step value specifies the element in the Pattern array to copy to the output memory location This is used as the array index into the Pattern Dwell Time Fault Timeout and First Follower arrays Preset Step A word input that is copied to the Active Step output when the Reset is On Step Control A w...

Page 139: ...f the COMMREQ function is shown in this chapter The detailed parameters needed to program specific communications tasks are provided in the documentation for each module 10 3 1 Data Move Functions Move Data The Move function copies data as individual bits from one location to another Because the data is copied in bit format the new location does not need to be the same data type as the original Wh...

Page 140: ...ces Description enable flow When the function is enabled the move is performed Length The number of bits words or double words of data to be copied This is the length of IN Length must be from 1 to 256 for all types except BIT If IN is a constant and Q is type BIT the length must be between 1 and 16 If IN is type Bit the length must be between 1 and 256 bits IN I Q M T G R AI AQ constant For bit o...

Page 141: ...om memory location M0001 to memory location M0033 M0001 and M0003 are defined as WORD types if length 3 Figure 99 Even though the destination overlaps the source for 16 bits the move is done correctly Before using the Move function INPUT M0001 through M0048 Figure 100 After using the Move function INPUT M0033 through M0080 Figure 101 ...

Page 142: ...eived Figure 102 Parameters of the Block Move Function Input Output Choices Description enable flow When the function is enabled the block move is performed I1 to I7 constant I1 through I7 contain seven constant values ok flow none The OK output is energized whenever the function is enabled Q I Q M T G R AI AQ For Word data SA SB SC For Real data R AI AQ Output Q contains the first element of the ...

Page 143: ...The function passes power to the right whenever power is received Figure 104 Parameters of the Block Clear Function Input Output Choices Description enable flow When the function is enabled the array is cleared IN I Q M T SA SB SC G R AI AQ IN contains the first word of the array to be cleared The length of IN must be between 1 and 256 words Length The number of words that will be cleared This is ...

Page 144: ...ccessible throughout the program because they are overlaid on absolute locations in logic addressable memory Figure 106 For VersaMax CPUs when this function is used to rotate a bit sequence around a range of discrete references separate references must be used for ST and Q and additional logic must be provided to copy the output word from the Q reference back to the ST reference This function may ...

Page 145: ...mple the shift register operates on register memory locations R0001 through R0100 R0001 is defined as type Word of length 100 When the reset reference CLEAR is active the Shift Register words are set to zero When the NXT_CYC reference is active and CLEAR is not active the word from output status table location Q0033 is shifted into the Shift Register at R0001 The word shifted out of the Shift Regi...

Page 146: ...ule After sending the COMMREQ the program can either suspend execution and wait for a reply for a maximum waiting period specified in the command or resume immediately Figure 109 Parameters of the COMMREQ Function Input Output Choices Description enable flow When the function is energized the communications request is performed IN R AI AQ IN contains the first word of the command block SYSID I Q M...

Page 147: ...gth of the Command Block depends on the amount of data sent to the device The Command Block contains the data to be communicated to the other device plus information related to the execution of the COMM REQ The Command Block has the following structure address Length in words address 1 Wait No Wait Flag address 2 Status Pointer Memory address 3 Status Pointer Offset address 4 Idle Timeout Value ad...

Page 148: ...al data is not changed by this function Data can be converted to BCD format to drive BCD encoded LED displays or presets to external devices such as high speed counters When the function receives power flow it performs the conversion making the result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is outside...

Page 149: ...changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function always passes power flow when power is received unless the data is out of range Figure 113 Parameters of the Convert to Signed Integer Function Input Output Choices Description enable flow When the function is enabled the conversion is performed IN For BCD...

Page 150: ...f real data The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function always passes power flow when power is received unless the real value is out of range Figure 115 Note that loss of precision can occur when converting from Real type data to Double Precision Integer because Real data ha...

Page 151: ...ts the real value equivalent of the input data The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function passes power flow when power is received unless the specified conversion would result in a value that is out of range Note that loss of precision can occur when converting from Double ...

Page 152: ...ult value placed in T0016 is 678 000 Figure 118 10 4 5 Data Type Conversion Functions Convert Real Data to Word Data The Convert to Word function outputs the Word equivalent of Real data The original data is not changed by this function When the function receives power flow it performs the conversion making the result available via output Q The function passes power flow when power is received unl...

Page 153: ... T G R AI AQ Contains the word form of the original value in IN Example Figure 120 10 4 6 Data Type Conversion Functions Truncate Real Number The Truncate function copies a Real number and rounds the copied number down to an integer or double precision integer The original data is not changed by this function When the function receives power flow it performs the conversion making the result availa...

Page 154: ...the value is out of range or IN is NaN Q R AI AQ For integer only I Q M T G Q contains the truncated INT or DINT value of the original value in IN Example In the example the displayed constant is truncated and the integer result 562 is placed in T0001 Figure 122 10 5 Math and Numerical Functions This section describes the Math and Numerical functions of the Instruction Set Standard Math Functions ...

Page 155: ...is no math overflow If an overflow occurs the result is the largest value with the proper sign and no power flow Parameters of the Standard Math Functions Input Output Choices Description enable flow When the function is enabled the operation is performed I1 All data types R AI AQ constant INT data type only I Q M T G I1 contains a constant or reference for the first value used in the operation I1...

Page 156: ...6 bit word is 1 negative move a 1 or hex 0FFFFh to the second word Converting from Double Precision Integer to Integer data is easier because the low 16 bit word first register is the integer portion of a Double Precision Integer 32 bit word The upper 16 bits or second word should be either a 0 positive or 1 negative value or the Double Precision Integer number will be too big to convert to 16 bit...

Page 157: ...rameter I1 The Modulo function operates on these types of data INT Signed integer DINT Double precision signed integer When the function receives power flow it divides input I1 by input I2 These parameters must be the same data type Output Q is calculated using the formula Q I1 I1 DIV I2 I2 The division produces an integer Q is the same data type as inputs I1 and I2 OK is always ON when the functi...

Page 158: ...rations is minimum maximum DINT I2 All data types R AI AQ constant INT data type only I Q M T G I2 contains a constant or reference for the value to be divided into I1 Range for constants in double precision signed integer operations is minimum maximum DINT ok flow none The OK output is energized when the function is performed without overflow Q All data types R AI AQ INT data type only I Q M T G ...

Page 159: ... unscaled data These limits together with the values for OHI and OLO are used to calculate the scaling factor that will be applied to the input value IN OHI OLO R AI AQ constant OHI and OLO contain a constant or reference for the upper and lower limits of the scaled data IN R AI AQ constant IN contains a constant or reference for the actual value to be scaled ok flow none The OK output is energize...

Page 160: ...input IN The output Q must be the same data type as IN The Square Root function operates on these types of data INT Signed integer DINT Double precision signed integer REAL Floating Point OK is set ON if the function is performed without overflow unless one of these invalid REAL operations occurs IN 0 IN is NaN Not a Number Otherwise OK is set OFF Figure 129 Parameters of the Square Root Function ...

Page 161: ...ll data types R AI AQ INT data type only I Q M T G Output Q contains the square root of IN Example In the example the square root of the integer number located at AI001 is placed into the result located at R0003 whenever I0001 is ON Figure 130 10 5 5 Math and Numerical Functions Trigonometric Functions There are six Trigonometric functions Sine Cosine Tangent Inverse Sine Inverse Cosine and Invers...

Page 162: ...a result Q such that ACOS IN 0 Q π The Inverse Tangent function accepts the broadest range of input values where IN Given a valid value for the IN parameter the Inverse Tangent Real function produces a result Q such that ATAN IN π 2 Q π 2 Parameters of the Trigonometric Functions Input Output Choices Description enable flow When the function is enabled the operation is performed IN R AI AQ constan...

Page 163: ...value I2 and the result is placed in output Q The EXPT function has three input parameters and two output parameters The OK output receives power flow unless the input is NaN Not a Number or is negative Figure 133 Parameters of the Logarithmic Exponential Functions Input Output Choices Description enable flow When the function is enabled the operation is performed IN or I1 I2 R AI AQ constant For ...

Page 164: ... in output Q The OK output will receive power flow unless IN is NaN Not a Number Figure 135 Parameters of the Radian Conversion Function Input Output Choices Description enable flow When the function is enabled the operation is performed IN R AI AQ constant IN contains the real value to be operated on ok flow none The OK output is energized when the function is performed without overflow unless IN...

Page 165: ...ess Than or Equal Test whether one number is less than or equal to another Range Tests whether one number lies between two other numbers When the function receives power flow it compares input IN1 to input IN2 These parameters must be the same data type Figure 137 If inputs IN1 and IN2 match the specified relational condition output Q receives power flow and is set ON 1 otherwise it is set OFF 0 D...

Page 166: ...mpared IN2 must be a valid number Constants must be integers for double precision signed integer operations IN2 is on the right side of the relational equation as in IN1 IN2 Q flow none Output Q is energized when IN1 and IN2 match the specified relation Example In the example two double precision signed integers are tested for equality When the relay I0001 passes power flow to the LE Less or Equal...

Page 167: ...e Constants must be integer values for double precision signed integer operations L2 R AI AQ constant INT and WORD only I Q M T G L2 contains the end point of the range Constants must be integer values for double precision signed integer operations IN R AI AQ INT and WORD only I Q M T G IN contains the value to be compared against the range specified by L1 and L2 Q flow none Output Q is energized ...

Page 168: ...ion Contact Each relay contact and coil has one input and one output Together they provide logic flow through the contact or coil Input Output 10 7 1 Relay Functions Normally open Normally closed Continuation Contacts A contact is used to monitor the state of a reference Whether the contact passes power flow depends on the state or status of the reference being monitored and on the contact type A ...

Page 169: ...the last executed continuation coil is the flow state used on the next executed continuation contact If the flow of logic does not execute a continuation coil before it executes a continuation contact the state of the contact is no flow There can be only one continuation coil and contact per rung the continuation contact must be in column 1 and the continuation coil must be in the last column 10 7...

Page 170: ...Sets reference OFF non retentive Negated ON OFF Sets reference OFF non retentive Sets reference ON non retentive Retentive M ON OFF Sets reference ON retentive Sets reference OFF retentive Negated Retentive M ON OFF Sets reference OFF retentive Sets reference ON retentive Positive Transition P OFF ON If power flow into the coil was OFF the previous sweep and is ON this sweep sets the coil ON Negat...

Page 171: ...tentive memory T Negated Retentive Coil The negated retentive coil sets a discrete reference ON when it does not receive power flow The state of the negated retentive coil is retained across power failure Therefore it cannot be used with references from strictly non retentive memory T Positive Transition Coil If the reference associated with a positive transition coil was OFF when the coil receive...

Page 172: ...E2 ON for one logic sweep When E2 goes from ON to OFF power flow is removed from E2 and E3 turning coil E3 ON for one sweep Figure 145 SET Coil SET and RESET are non retentive coils that can be used to keep latch the state of a reference either ON or OFF When a SET coil receives power flow its reference stays ON whether or not the coil itself receives power flow until the reference is reset by ano...

Page 173: ... operate on these types of data INT Signed integer DINT Double precision signed integer BOOL Bit data type BYTE Byte data type WORD Word data type Applies to Array Move only 10 8 1 Table Functions Array Move The Array Move function copies a specified number of elements from a source array to a destination array When the function receives power flow it copies the number of elements specified from t...

Page 174: ...ndex of the source array DNX I Q M T G R AI AQ constant DNX contains the index of the destination array N I Q M T G R AI AQ constant N provides a count indicator ok flow none OK is energized whenever enable is energized DS For all SA SB SC R AI AQ For INT BIT BYTE WORD I Q M T G The starting address of the destination array For ARRAY_MOVE_ BOOL any reference may be used it does not need to be byte...

Page 175: ...ngth 16 Figure 149 Example 3 Using word memory for SR and DS the third least significant bit of R0001 through the second least significant bit of R0002 of the array containing all 16 bits of R0001 and four bits of R0002 is read and then written into the fifth least significant bit of R0100 through the fourth least significant bit of R0101 of the array containing all 16 bits of R0100 and four bits ...

Page 176: ...d Indication FD is set ON and the Output Index output NX is set to the relative position of this element within the array If no array element is found before the end of the array is reached the Found Indication FD is set OFF and the Output Index output NX is set to zero Valid values for input NX are 0 to length 1 NX should be set to zero to begin searching at the first element This value increment...

Page 177: ...6 R0004 7 R0005 7 and R0100 7 then the search will begin at R0004 and conclude at R0004 when FD is set ON and a 4 is written to R0101 Figure 152 Example 2 Array AR is defined as memory addresses AI001 AI016 The values of the array elements are 100 20 0 5 90 200 0 79 102 80 24 34 987 8 0 and 500 Initially AQ001 is 5 When EN is ON each sweep will search the array looking for a match to the IN value ...

Page 178: ... not change during the execution of the sweep These contacts provide a pulse having an equal on and off time duration The contacts are referenced as T_10MS 0 01 second T_100MS 0 1 second T_SEC 1 0 second and T_MIN 1 minute The following timing diagram represents the on off time duration of these contacts Figure 154 These time tick contacts represent specific locations in S memory Function Block Da...

Page 179: ...nge the Preset Value while the timer or counter is running The first CV and third Control words can be read but should not be written or the function will not work 10 9 1 Timer and Counter Functions on Delay Stopwatch Timer A retentive On Delay Stopwatch Timer ONDTR increments while it receives power flow and holds its value when power flow stops Time may be counted in tenths 0 1 hundredths 0 01 o...

Page 180: ...r Function Input Output Choices Description address R The function uses three consecutive words registers of R memory to store the following Current value CV word 1 Preset value PV word 2 Control word word 3 Do not use this address with other instructions Careful Overlapping references cause erratic timer operation enable flow When enable receives power flow the timer s Current Value increments R ...

Page 181: ...goes high Timer continues to accumulate time until ENABLE goes low RESET goes high or current value becomes equal to the maximum time H ENABLE goes low timer stops accumulating time When power flow to the timer stops the current value stops incrementing and is retained Output Q if energized will remain energized When the function receives power flow again the current value again increments beginni...

Page 182: ...Values of the timers will be the same This update occurs as long as the enabling logic remains ON When the current value equals or exceeds the Preset Value PV the function begins passing power flow to the right The timer continues accumulating time until the maximum value is reached When the enabling parameter transitions from ON to OFF the timer stops accumulating time and the Current Value is re...

Page 183: ...es high timer starts accumulating time E ENABLE goes low before current value reaches preset value PV Q remains low timer stops accumulating time and is cleared to zero CV 0 Example In the example a delay timer with address TMRID is used to control the length of time that coil is on This coil has been assigned the Nickname DWELL When the normally open momentary contact with the Nickname DO_DWL is ...

Page 184: ...ple occurrences of the same timer with the same reference address are enabled during a CPU sweep the Current Values of the timers will be the same Each time the function is invoked with the enabling logic set to OFF the Current Value is updated to reflect the elapsed time since the timer was turned off When the Current Value CV is equal to the Preset Value PV the function stops passing power flow ...

Page 185: ...gure 164 Operation of the Off Delay Timer Function Figure 165 A ENABLE and Q both go high timer is reset CV 0 B ENABLE goes low timer starts accumulating time C CV reaches PV Q goes low and timer stops accumulating time D ENABLE goes high timer is reset CV 0 E ENABLE goes low timer starts accumulating time F ENABLE goes high timer is reset CV 0 G ENABLE goes low timer begins accumulating time H V ...

Page 186: ...meter For example an address parameter of R0001 would use R0002 as the PV parameter Q flow none Output Q is energized when the current value is less than the preset value The Q state is retentive on power failure no automatic initialization occurs at power up time tenths hundredths or thousandths of seconds Time increment for the low bit of the PV preset and CV current value 10 9 4 Timer and Count...

Page 187: ...value to copy into the counter s preset value when the counter is enabled or reset Q flow none Output Q is energized when the Current Value is greater than or equal to the Preset Value Example of the Up Counter Function In the example every time input I0012 transitions from OFF to ON up counter PRT_CNT counts up by 1 internal coil M0001 is energized when 100 parts have been counted When M0001 is O...

Page 188: ...ther down counter up counter or any other instruction or improper operation will result Careful Overlapping references will result in erratic counter operation enable flow On a positive transition of enable the Current Value is decremented by one R flow When R receives power flow it resets the Current Value to the Preset Value PV I Q M T G R AI AQ constant none PV is the value to copy into the cou...

Page 189: ...t value When parts enter the storage area the up counter increases the current value of the parts in storage by 1 When a part leaves the storage area the down counter decrements by 1 decreasing the inventory storage value by 1 The two counters use different register addresses When a register counts its current value must be moved to the current value register of the other counter Figure 170 Refer ...

Page 190: ...EQ 8 Reset Watchdog Timer SVCREQ 9 Read Sweep Time from Beginning of Sweep SVCREQ 10 Read Folder Name SVCREQ 11 Read PLC ID SVCREQ 13 Shut Down Stop PLC SVCREQ 14 Clear Fault SVCREQ 15 Read Last Logged Fault Table Entry SVCREQ 16 Read Elapsed Time Clock SVCREQ 18 Read I O Override Status SVCREQ 23 Read Master Checksum SVCREQ 24 Reset Ethernet Daughter Board SVCREQ 26 30 Interrogate I O 11 1 SVCREQ...

Page 191: ...171 When the SVCREQ receives power flow the PLC is requested to perform the function number FNC indicated Parameters for the function are located beginning at the reference given for PARM This is the beginning of the parameter block for the function The number of 16 bit references required depends on the SVCREQ function being used Parameter blocks may be used as both inputs for the function and th...

Page 192: ...xample of the SVCREQ Function In the example when the enabling input I0001 is ON SVCREQ function number 7 is called with the parameter block located starting at R0001 Output coil Q0001 is set ON if the operation succeeds Figure 172 11 3 SVCREQ 1 Change Read Constant Sweep Timer Use SVCREQ 1 to enable or disable Constant Sweep Time mode change the length of the Constant Sweep Time read whether Cons...

Page 193: ... timer value without changing the selection for sweep mode state enter SVCREQ function 1 with this parameter block Figure 175 Read the Constant Sweep State and Time To read the current timer state and value without changing either enter SVCREQ function 1 with this parameter block Figure 176 Successful execution will occur unless 1 A number other than 0 1 2 or 3 is entered as the requested operatio...

Page 194: ... the successful result of the first rung line On any sweep in which OV_SWP is not set M00001 is turned off Figure 178 11 4 SVCREQ 2 Read Window Times SVCREQ 2 can be used to read the times of the programmer communications window and the system communications window These windows can operate in Limited or Run to Completion Mode Mode Name Value Description Limited Mode 0 The execution time of the wi...

Page 195: ...ng output Q00102 is set the CPU places the current time values of the windows in the parameter block starting at location R0010 Figure 179 11 5 SVCREQ 3 Change Programmer Communications Window Mode Use SVCREQ 3 to change the programmer communications window mode Limited or Run to Completion The change occurs during the next CPU sweep after the function is called The time of the window cannot be ch...

Page 196: ...The change occurs during the next CPU sweep after the function is called The time of the window cannot be changed it is always 6ms SVCREQ 4 passes power flow to the right unless a mode other than 0 Limited or 2 Run to Completion is selected The parameter block has a length of one word 11 6 1 Changing the System Communications Window Mode To change the programmer window enter SVCREQ 4 with this par...

Page 197: ...econd word of the parameter block Figure 183 To change the word count the first word of the parameter block must contain a one Figure 184 The PLC will change the number of words to be checksummed to the new value Example of SVCREQ 6 In the example when enabling contact FST_SCN is set the parameter blocks for the checksum function are built Later in the program if input I0137 turns on the SVCREQ re...

Page 198: ...ata is provided in an unexpected format 11 8 1 Parameter Block Format for SVCREQ 7 For the date time functions the length of the parameter block depends on the data format The data block is either BCD or ASCII BCD format requires 6 words packed ASCII requires 12 words 13 words for 4 digit year For both data types Hours are stored in 24 hour format Day of the week is a numeric value from 1 Sunday t...

Page 199: ... date and time the function returns 00 Parameter Block Format Example High Byte Low Byte Read Date and Time in BCD format Sun July 3 1998 at 2 45 30 p m 1 change or 0 read address 0 read 1 BCD format address 1 1 BCD format month year address 2 07 July 98 year hours day of month address 3 14 hours 03 day seconds minutes address 4 30 seconds 45 minutes null day of week address 5 0 06 Friday 4 Digit ...

Page 200: ... 31 1 20 space space month address 4 20 space 30 0 day of month day of month address 5 35 5 30 leading 0 hours space address 6 31 1 20 space hours address 7 3A 31 1 minutes minutes address 8 33 3 31 1 seconds address 9 30 0 3A space seconds address 10 20 space 30 0 day of week day of week address 11 32 2 Mon 30 leading 0 4 Digit Year Parameter Block Format Example High Byte Low Byte Read Date and ...

Page 201: ...ones day of week tens address 12 32 2 Mon 30 leading 0 Example of SVCREQ 7 In the example when called for by previous logic a parameter block for the time of day clock is built It requests the current date and time then sets the clock to 12 noon using BCD format The parameter block is located at location R0300 Array NOON has been set up elsewhere in the program to contain the values 12 0 and 0 Arr...

Page 202: ...tion has no associated parameter block 11 9 2 Example of SVCREQ 8 In this example power flow through enabling output Q0027 or input I1476 or internal coil M00010 causes the watchdog timer to be reset Figure 187 11 10 SVCREQ 9 Read Sweep Time from Beginning of Sweep Use SVCREQ 9 to read the time in milliseconds since the start of the sweep The data format is unsigned 16 bit integer 11 10 1 Output P...

Page 203: ...cter 00h If the program name has fewer than seven characters null characters are added to the end Low Byte High Byte address character 1 character 2 address 1 character 3 character 4 address 2 character 5 character 6 address 3 character 7 0 11 11 2 Example of SVCREQ 10 In this example when enabling input I0301 goes OFF register location R0099 is loaded with the value 10 which is the function code ...

Page 204: ...l character 00h If the PLC ID has fewer than seven characters null characters are added to the end Low Byte High Byte address character 1 character 2 address 1 character 3 character 4 address 2 character 5 character 6 address 3 character 7 0 11 12 2 Example of SVCREQ 11 In this example when enabling input I0302 goes OFF register location R0099 is loaded with the value 11 which is the function code...

Page 205: ... PLC Fault Table The I O scan continues as configured 11 13 1 Parameter Block for SVCREQ 13 This function has no parameter block 11 13 2 Example of SVCREQ 13 In the example when a Loss of I O Module fault occurs SVCREQ 13 executes The PARM input is not used This example uses a JUMP to the end of the program to force a shutdown if the Shutdown PLC function executes successfully This JUMP and LABEL ...

Page 206: ...length of 1 word It is an input parameter block only There is no output parameter block 0 clear PLC fault table 1 clear I O fault table 11 14 2 Example of SVCREQ 14 In the example when input I0346 is on and input I0349 is on the PLC fault table is cleared When input I0347 is on and input I0349 is on the I O fault table is cleared When input I0348 is on and input I0349 is on both are cleared The pa...

Page 207: ...0 or 1 is entered as the requested operation or the fault table is empty 11 15 1 Input Parameter Block for SVCREQ 15 For this function the parameter block has a length of 22 words The input parameter block has this format 2 Digit Year Format 4 Digit Year Format address 0 Read PLC fault table 8 Read PLC fault table 1 Read I O fault table 9 Read I O fault table The format of the output parameter blo...

Page 208: ... 20 day of month hour 2 Digit Year Format year month address 21 year month 4 Digit Year Format spare month address 21 spare month year address 22 year 11 15 2 Long Short Value The first byte of word address 1 contains a number that indicates the length of the fault specific data in the fault entry These possible values are PLC fault table 00 8 bytes short 01 24 bytes long I O fault table 02 5 byte...

Page 209: ...Its length is 3 words address seconds from power on low order address 1 seconds from power on high order address 2 100 microsecond ticks The first two words are the elapsed time in seconds The last word is the number of 100 microsecond ticks in the current second 11 16 2 Example of SVCREQ 16 In the example when internal coil M0233 is on the SVCREQ with a parameter block located at R0127 reads the ...

Page 210: ...50 Figure 194 11 17 SVCREQ 18 Read I O Override Status Use SVCREQ 18 to check for any overrides in the CPU s I and Q memories 11 17 1 Output Parameter Block for SVCREQ 18 This function has an output parameter block only Its length is 1 word address 0 No overrides are set 1 Overrides are set 11 17 2 Example of SVCREQ 18 The following SVCREQ reads the status of I O overrides memory into location R10...

Page 211: ... Program checksums may not be valid during a Run Mode Store address Master Program Checksum Valid 0 not valid 1 valid address 1 Master Configuration Checksum Valid 0 not valid 1 valid address 2 Number of Program Blocks including _MAIN address 3 Size of User Program in Bytes DWORD data type address 5 Program Additive Checksum address 6 Program CRC Checksum DWORD data type address 8 Size of Configur...

Page 212: ... to reset Ethernet occur simultaneously Ethernet daughterboard will be reset only once rather than multiple times SVC_REQ 24 is useful to recover Ethernet interface from failures caused by heavy traffic or high bit error rate PLC fault table and LAN status bits below can be used to determine whether the Ethernet interface on IC200CPUE05 is healthy or faulted The meaning of each individual status b...

Page 213: ...CREQ checks the installed modules and compares them to the software configuration Output Q0001 is turned on after the SVCREQ is complete Figure 198 11 21 SVCREQ 29 Read Elapsed Power Down Time Use SVCREQ 29 to read the amount of time elapsed between the last power down and the most recent powerup If the watchdog timer expired before power down the PLC is not able to calculate the power down elapse...

Page 214: ...n 2020 The Service Request Function 200 11 21 2 Example of SVCREQ 29 In the example when input I0251 is ON the Elapsed Power Down Time is placed into the parameter block that starts at R0050 The output coil Q0001 is turned on Figure 199 ...

Page 215: ...iguring SNP Protocol COMMREQ Data Block for Configuring RTU Protocol COMMREQ Data Block for Configuring Serial I O Serial I O COMMREQ Commands Initialize Port Set Up Input Buffer Flush Input Buffer Read Port Status Write Port Control Cancel Operation Autodial Write Bytes Read Bytes Read String Details of RTU and SNP protocol are described in the Serial Communications User Manual GFK 0582 12 1 Form...

Page 216: ...00 12 1 1 Parameters of the COMMREQ Function Input Output Choices Description enable flow When the function is energized the communications request is performed IN R AI AQ IN contains the first word of the command block SYSID I Q M T G R AI AQ constant SYSID contains the rack number most significant byte and slot number least significant byte of the target device For the CPU SYSID must specify rac...

Page 217: ...information related to the execution of the COMMREQ The Command Block has the following structure address Length in words address 1 Wait No Wait Flag address 2 Status Pointer Memory address 3 Status Pointer Offset address 4 Idle Timeout Value address 5 Maximum Communication Time address 6 to address 133 Data Block 12 1 3 Example of the COMMREQ Function In the example when M0021 is ON a Command Blo...

Page 218: ...r the old form length 10H or the new form length 12H of the COMMREQ can be used Only the new form supports the new parameters Note Either the old form length 10H or the new form length 12H of the COMMREQ can be used Only the new form supports the new parameters 12 2 1 Timing If a port configuration COMMREQ is sent to a serial port that currently has an SNP SNPX master for example the programmer co...

Page 219: ... currently configured for RTU the SNP ID associated with the CPU settings must match the multi drop ID The programmer must use the same serial communications parameters baud rate parity stop bits etc as the currently active RTU Slave protocol for it to be recognized When the CPU recognizes the programmer the CPU removes the RTU Slave protocol from the port and installs SNP Slave as the currently a...

Page 220: ... port 1 and the programmer communicates normally 4 The programmer stores a new configuration to port 1 The new configuration sets the port for SNP Slave at 4800 baud it will not take effect until the port loses communications with the programmer 5 When the CPU loses communications with the programmer the new configuration takes effect 12 2 5 Example COMMREQ Command Block for Configuring SNP Protoc...

Page 221: ...ress 19 user provided Device identifier bytes 3 and 4 Address 20 user provided Device identifier bytes 5 and 6 Address 21 user provided Device identifier bytes 7 and 8 The device identifier for SNP Slave ports is packed into words with the least significant character in the least significant byte of the word For example if the first two characters are A and B the Address 18 will contain the hex va...

Page 222: ...lex Mode Address 18 Station Address 1 247 Device Identifier Address 19 21 not used Device Identifier Address 22 0 255 units of 10ms e g 10 100ms Receive to transmit delay Address 22 0 255 units of 10ms e g 10 100ms RTS drop delay Note The data block length Address 0 for a COMMREQ that includes the Receive to transmit delay and RTS drop delay should be 12H not 10H Both forms Length 10H and 12H are ...

Page 223: ...ddress 13 0 Long Timeout Address 14 0 7 bits 1 8 bits Bits per Character Address 15 0 1 stop bit 1 2 stop bits Stop Bits Address 16 not used Interface Address 17 0 2 wire 1 4 wire Duplex Mode Address 18 21 not used Device Identifier Address 22 0 255 units of 10ms e g 10 100ms Receive to transmit delay Address 22 0 255 units of 10ms e g 10 100ms RTS drop delay Note The data block length Address 0 f...

Page 224: ...s in Run mode When the port reverts back to SNP Slave the same serial communications parameters baud rate parity stop bits as the currently active Serial I O protocol are used Therefore the programmer must use the same parameters for it to be recognized If any of the parameter values associated with the Serial I O protocol are not supported by the SNP Slave protocol the programmer will not be able...

Page 225: ...reater than input buffer size OR number bytes requested to write is zero or greater than 250 bytes 3 03h COMMREQ data block length is too small String data is missing or incomplete 4 04h Receive timeout awaiting serial reception of data 8 08h Unable to access PLC memory 12 0Ch COMMREQ data block length too small 48 30h Serial output timeout The serial port was unable to transmit the string Could b...

Page 226: ...tring and modem 10 0Ah Modem responded with RING indicating that the modem is being called by another modem Modem is unable to complete the requested command Retry the modem command later 11 0Bh Unknown response received from the modem Modem unable to complete the request Check the modem command string and modem Response should be CONNECT or OK 50 32h COMMREQ timeout The COMMREQ did not complete w...

Page 227: ...whether Write Bytes Read Bytes and Read String COMMREQs can be pending when other COMMREQs are executed Currently pending COMMRE Qs NEW COMMREQ Autodial 4400 Write Bytes 4401 Initialize Port 4300 Set Up Input Buffer 4301 Flush Input Buffer 4302 Read Port Status 4303 Write Port Control 4304 Read Bytes 4402 Read String 4403 Cancel Operation 4399 Serial Port Setup FFF0 Write Bytes 4401 No No Yes Yes ...

Page 228: ...e position within the string where the transmission is halted is indeterminate In addition the final character received by the device the CPU is sending to is also indeterminate 12 4 5 Set Up Input Buffer Function 4301 This function can be used to change the size of the internal memory buffer where input data will be placed as it is received By default the buffer is set to a maximum of 2K bytes As...

Page 229: ...ngth to zero If zero is entered as the buffer length the buffer size will be set to the 2K bytes default If a length greater than 2K bytes is specified an error is generated 12 4 6 Flush Input Buffer Function 4302 This operation empties the input buffer of any characters received through the serial port but not yet retrieved using a read command All such characters are lost Example Command Block f...

Page 230: ...adecimal MEANING address 0003 0003 Data block length address 1 0000 0000 NOWAIT mode address 2 0008 0008 Status word memory type R address 3 0000 0000 Status word address minus 1 R0001 address 4 0000 0000 Not used address 5 0000 0000 Not used address 6 4303 10CF Setup input buffer command address 7 0076 004C Port status memory type M address 8 0101 065 Port status memory offset M101 Port Status Th...

Page 231: ...ad characters in the buffer 8 OF OverFlow error Set Overflow error occurred on the serial port or internal buffer Cleared Read Port Status invoked 7 FE Framing Error Set Framing error occurred on the serial port Cleared Read Port Status invoked 6 PE Parity Error Set Parity error occurred on the serial port Cleared Read Port Status invoked 5 CT CTS is active Set CTS line on the serial port is activ...

Page 232: ...protocol and is dependent on the current Duplex Mode of the port For 2 wire and 4 wire Duplex Mode the transmit driver is only enabled during transmitting Therefore RTS on the serial line will only be seen active on port 2 configured for 2 wire or 4 wire Duplex Mode when data is being transmitted For point to point Duplex Mode the transmit driver is always enabled Therefore in point to point Duple...

Page 233: ... is transmitting a string from a serial port transmission is halted The position within the string where the transmission is halted is indeterminate In addition the final character received by the device the CPU is sending to is also indeterminate 12 4 10 Autodial Function 4400 This feature allows the VersaMax CPU to automatically dial a modem and send a specified byte string To implement this fea...

Page 234: ...o internally saved values Example Autodial Command Block This example COMMREQ command block dials the number 234 5678 using a Hayes compatible modem Word Definition Values 1 0009h CUSTOM data block length includes command string 2 0000h NOWAIT mode 3 0008h Status word memory type R 4 0000h Status word address minus 1 Register 1 5 0000h not used 6 0000h not used 7 04400 1130h Autodial command numbe...

Page 235: ... o 6Fh Although printable ASCII characters are used in this example there is no restriction on the values of the characters which can be transmitted Operating Notes Note Specifying zero as the Transmit time out sets the time out value to the amount of time actually needed to transmit the data plus 4 seconds CAUTION If an Initialize Port 4300 COMMEQ is sent or a Cancel Operation 4399 COMMREQ is sen...

Page 236: ...5 Data block length address 1 0000 0000 NOWAIT mode address 2 0008 0008 Status word memory type R address 3 0000 0000 Status word address minus 1 R0001 address 4 0000 0000 Not used address 5 0000 0000 Not used address 6 4402 1132 Read bytes command address 7 0030 001E Read time out 30 seconds address 8 0005 0005 Number of bytes to read address 9 0008 0008 Input data memory type R address 10 0100 0...

Page 237: ...t complete until either the terminating character has been received or the time out interval expires In either of those conditions the port status indicates the reason for completion of the read operation If the time out interval is set to zero the COMMREQ remains pending until it has received the requested string terminated by the specified end character If this COMMREQ fails for any reason no da...

Page 238: ...wo characters first character is in the low byte address 3 third and fourth characters third character is in the low byte address n subsequent characters Operating Note If the input data memory type parameter is specified to be a word memory type and if an odd number of bytes are actually received then the high byte of the last word to be written with the received data is set to zero As data is re...

Page 239: ...e that makes it possible to communicate on a 10BaseT network in either halfduplex or full duplex mode Using 10 100 hubs allows CPUE05 to communicate on a network containing 100Mb devices Figure 202 Use the Ethernet interface to Send and receive Ethernet Global Data Ethernet Global Data can be used for highly efficient periodic data transfer on the LAN Access data from CPUE05 using a Host computer ...

Page 240: ...orts up to 32 simultaneous Ethernet Global Data exchanges Ethernet Global Data exchanges are configured using the PLC programming software then stored to the PLC Both Produced and Consumed exchanges may be configured CPUE05 supports up to 1200 data ranges across all Ethernet Global Data exchanges and can be configured for selective consumption of Ethernet Global Data exchanges 13 1 2 SRTP Server C...

Page 241: ...hernet network The IP Address is assigned using the configuration software as described in chapter 6 The IP address is 32 bits long and has a netid part and a hostid part The format of the IP address depends on the network class Figure 203 Each IP address on a network has The same class Each network is a Class A Class B or Class C network A Class A network can support 16 777 214 hosts Class B 65 5...

Page 242: ...e network needs to communicate with a node on another network a Router transfers the data between the two networks Example Networks Connected by a Router The following figure shows Network 1 and Network 2 connected by Router R Figure 204 Host B can communicate with host C directly because they are on the same network Their IP addresses have the same netid However to send data to host A which is on...

Page 243: ...h Ethernet Global Data exchange must be configured individually for each PLC and consists of one or more data ranges See chapter 6 for configuration information 13 4 1 The Frequency of Sending Receiving an Exchange During configuration the repetition period of each Ethernet Global Data exchange is set up for the producer The range is 10 milliseconds to 1 hour which is selectable in increments of 1...

Page 244: ...n Figure 206 Each device in a group responds to the group s assigned ID number For CPUE05 the Group IDs are 1 to 32 Each Group ID corresponds to a Multicast Class D IP address reserved by the Internet authorities The default Multicast IP addresses used by Ethernet Global Data are Group ID IP Address 1 2 32 224 0 7 1 224 0 7 2 224 0 7 32 Group Multicast IP Addresses used by Ethernet Global Data sho...

Page 245: ...l Data exchanges The timestamp from the Ethernet interface does not affect the time of the CPU s internal time clock Figure 207 Synchronizing the Timestamp The timestamp clock in the Ethernet interface is synchronized to either the clock in the CPU or an external Network Time Protocol NTP server NTP is supported in IC200CPUE05 HK and previous versions only The CPU Time Clock If no NTP servers are ...

Page 246: ... NTP servers can be used to improve the availability of time servers When the time is obtained from an NTP server dates from January 1 1970 are supported by the Ethernet Interface 13 4 5 Configuring NTP for the CPUE05 Ethernet Interface This feature is supported in IC200CPUE05 HK and previous versions only To implement Network Time Protocol in the Ethernet interface in CPUE05 the IP address of one...

Page 247: ...r produced and or consumed Ethernet Global Data Type Description Producer or Consumer R Register memory in word mode P C AI Analog input memory in word mode P C AQ Analog output memory in word mode P C I Discrete input memory in byte mode P C Q Discrete output memory in byte mode P C T Discrete temporary memory in byte mode P C M Discrete momentary memory in byte mode P C SA Discrete system memory...

Page 248: ...ernet Global Data in different PLC modes PLC Mode or Action Exchanges continue to be Produced Consumed RUN Outputs Enabled yes yes STOP I O Enabled yes yes STOP I O Disabled no no The latest data from the network is available to the application when the PLC transitions from Stop to Run mode 13 4 9 EGD Synchronization Ethernet Global Data attempts to provide the most up to date process data consist...

Page 249: ... the fresh data The timer of the produced exchange is not reset when this sample is sent This can result in more samples in the network than would be expected from the configured period Timing Examples The following illustrations show the relationship between the PLC output scan time the produced exchange timer and data samples on the network Example 1 Only one sample is produced on the network pe...

Page 250: ... problem with the Ethernet Interface with the network with PLC backplane communication or with your application The LOG TALLY and STAT Station Manager commands are especially useful Refer to the VersaMax PLC Ethernet Station Manager Manual GFK 1876 for information on how to access and use the Station Manager 13 5 1 What to do if you Cannot Solve the Problem If you still cannot solve your problem c...

Page 251: ...t is connected to network and blinks when there is traffic LAN LED remains OFF if module is not connected to the network 3 If the STAT LED is amber check the PLC Fault Table With the Station Manager feature you can also use the LOG command as explained in GFK 1876 The VersaMax PLC Ethernet Station Manager Manual If a problem occurs during power up the Ethernet interface may not begin operating Che...

Page 252: ...e configuration to the PLC Power cycle the PLC Clear faults and press the Restart pushbutton for less than 5 seconds to restart the Ethernet interface LAN Green flickering STAT Slow blink green PORT 1 Off Waiting for IP Address LAN Ethernet interface is online Flickers during activity STAT IP Address has not been configured PORT 1 PLC CPU is controlling Port 1 IP address has not been configured or...

Page 253: ... Green flickering STAT Green PORT 1 Off Operational LAN Ethernet interface is online Flickers during activity STAT No exception detected PORT 1 PLC CPU is controlling Port 1 If LAN is off the problem may be Network cable not connected either at the PLC or at the hub Hub disconnected failed Network cable not properly terminated If STAT is amber an exception condition has occurred LAN Green flickeri...

Page 254: ...ving the Ethernet interface generate faults in the PLC Fault table The table on the next page lists Ethernet interface faults and corrective actions To display fault text for the Ethernet interface access the PLC Fault Table from the programmer For the Ethernet interface the leftmost 14 digits of extra fault data show the corresponding log Events 2 digits and Entries 2 3 4 5 and 6 in that order 4 ...

Page 255: ...e correct Comm_req Bad task ID programmed Message from PLC for unknown Ethernet interface task Check COMMREQ function block Comm_req Wait mode not allowed Check COMMREQ to make sure sent in no wait mode LAN data memory exhausted check parms resuming The Ethernet interface does not have free memory to process communications LAN I F capacity exceeded discarded request Verify that connection limits a...

Page 256: ...rnet interface Status Bits Brief Description 1 2 Reserved always 0 3 Full duplex 4 12 Reserved always 0 13 LAN OK 14 Resource problem 15 Reserved always 0 16 LAN Interface OK 17 80 Reserved Bit 3 Full Duplex If this bit 3 is 1 CPUE05 is operating in full duplex Ethernet mode Full duplex or half duplex operation is automatically negotiated between the CPUE05 and its immediately connected network de...

Page 257: ...t sweeps The Exchange Status word uses the error codes below to report exchange status Refer to the section Troubleshooting Common Ethernet Difficulties later in this chapter Value Decimal Error Description 0 Exchange status has not been updated Produced Initial value until the first producer period refresh occurs Consumed The data has not been refreshed and timeout has not expired 1 No error Prod...

Page 258: ...ia Port 1 This port can be configured for either CPU serial communications SNP RTU Serial I O or local Station Manager use While Port 1 is configured as a local Station Manager it cannot be used for CPU serial communications or firmware loading However if the port is configured as a CPU port instead the default setting it can temporarily be forced to local Station Manager operation using the Resta...

Page 259: ...The remedy is to reduce the requests or increase the processing capacity in the PLC Cause Corrective Action Heavy SRTP traffic Reduce the size number or frequency of SRTP requests at the remote SRTP client Long PLC sweep time Modify the PLC application to reduce the PLC sweep time PLC Communication Window set to LIMITED mode Change to RUN TO COMPLETION mode If none of the above corrective actions ...

Page 260: ...al error codes All Ethernet Global Data EGD exchanges default to status code 18 0012H during a loss or reset of the Ethernet interface EGD operation will resume after the restart is complete These restart and runtime errors occur when the CPUE05 cannot process the attempted volume of EGD and or SRTP requests As these errors have been observed only when the CPUE05 is connected to a repeater type ne...

Page 261: ...eceived at the CPUE05 Analyze the broadcast and multicast network traffic received at the CPUE05 Reduce such traffic if possible 13 6 5 Station Manager Lockout under Heavy Load Sustained heavy EGD and or SRTP Server load can utilize all processing resources within the Ethernet interface effectively locking out the Station Manager function The Station Manager appears inoperative under either local ...

Page 262: ...lish communication The SRTP connection in the CPUE05 remains open for approximately 5 minutes while TCP attempt to reconnect during this interval the SRTP connection is unavailable If all the SRTP connections in the CPUE05 are in use or otherwise unavailable a new SRTP client connection must wait until the TCP reconnect time expires on an existing connection The SRTP connection timeout is normal e...

Page 263: ...he PID Function PID Algorithm Selection and Gain Calculations Determining the Process Characteristics Setting and Tuning Loop Gains Example 14 1 Operands of the PID Function Figure 213 The PID function compares feedback from a process variable PV with a desired process set point SP and updates a control variable CV based on the error The PID function uses PID loop gains and other parameters stored...

Page 264: ...t S SA SB and SC and constant No MAN When energized to 1 through a contact the PID function block is in manual mode If this input is 0 the PID function block is in automatic mode NA Flow No UP If energized along with MAN increases the Control Variable by 1 CV count per solution of the PID function NA Flow No DN If energized along with MAN decreases the Control Variable by 1 CV count per solution o...

Page 265: ...6 bit analog process variables Some parameters must be defined in either PV counts or units or in CV counts or units The SP input must be scaled over the same range as the PV because the PID function calculates error by subtracting these two inputs The process PV and control CV counts do not have to use the same scaling Either may be 32000 or 0 to 32000 to match analog scaling or from 0 to 10000 t...

Page 266: ...d the value less than 0 or the PID block will not function Leave these at 0 until the PID loop gains are set up or tuned A Dead Band might be added to avoid small CV output changes due to variations in error PV Counts Dead Band 0 to 32767 never negative Dead Band 32768 to 0 never positive 6 Address 5 PID_IND Proportional Gain Kp PID_ISA Controller gain Kc Kp PID_IND Change in the Control Variable ...

Page 267: ...ms units Displayed as seconds with two decimal places For example Kd entered as 120 is displayed as 1 20 Sec and results in a Kd Error delta time or 120 4 3 contribution to the PID Output if Error changing by 4 PV Counts every 30ms Kd can be used to speed up a slow loop response but is very sensitive to PV input noise This noise sensitivity can be reduced by using the derivative filter which is en...

Page 268: ...D Total integral contribution to PID Output is Kc Ki Error dt Ki is usually the second gain set after Kp Repeats 0 001 Sec 0 to 32 767 repeats sec 9 Address 8 CV Bias Output Offset Number of CV Counts added to the PID Output before the rate and amplitude clamps It can be used to set non zero CV values when only Kp Proportional gains are used or for feed forward control of this PID loop output from...

Page 269: ... CV cannot change more than 32000 CV Counts times the solution time interval seconds divided by Minimum Slew Time For example if the Sample Period is 2 5 seconds and the Minimum Slew Time is 500 seconds CV cannot change more than 32000 2 5 500 or 160 CV Counts per PID solution The integral term value is adjusted if the CV rate limit is exceeded When Minimum Slew Time is 0 there is no CV rate limit...

Page 270: ...sed for the PID calculation is forced to be zero If however theerror value is outsidethe deadband limits the magnitude of the error used for the PID calculation is reduced by the deadband limit error error deadband limit Bit 4 Anti resetwindup action When this bit is 0 the anti reset windup action uses a reset integral term back calculation When the output is clamped the accumulated integral term ...

Page 271: ...peration of the PID block see below This allows a remote operator interface device such as a computer to take control away from the PLC program Caution If you do not want to allow remote operation of the PID block make sure the Control Word is set to 0 If the low bit is 0 the next 4 bits can be read to track the status of the PID input contacts as long as the PID Enable contact has power Control W...

Page 272: ...t externally to solve the PID algorithm using an alternate SP value The original SP value is maintained until overwritten Set and maintained by the CPU unless bit 1 0 Override of Control Word is set to 1 Non configurable unless bit 1 0 Override of Control Word is set to 1 17 Address 16 Internal CV Tracks CV output Set and maintained by the CPU Non configurable 18 Address 17 Internal PV Tracks PV i...

Page 273: ...ate values Do not write to this location 24 26 Address 23 Address 25 Previous Solution Time Internal storage of time of last PID solution Normally do not write to these locations Some special circumstances may justify writing to these locations Note If you call the PID block in Automatic mode after a long delay you might want to use SVC_REQ 16 or SVC_REQ 51 to load the current CPU elapsed time clo...

Page 274: ...g delay you may want to use SVC_REQ 16 or SVC_REQ 51 to load the current CPU time into the stored previous solution time word 24 of the reference array described on page 14 9 This will update the last PID solution time and avoid a large step change of the integral term 14 3 2 Manual Operation The PID function block is placed in Manual mode by providing power flow to both the Enable and Manual inpu...

Page 275: ...solutions If the sweep time is less than 10 milliseconds the PID function waits until enough sweeps have occurred to accumulate an elapsed time of 10 milliseconds For example if the sweep time is 9 milliseconds the PID function executes every other sweep and the time interval between solutions is 18 milliseconds If a specific PID function is executed more than once per sweep by referencing the sam...

Page 276: ...shows how the PID_IND algorithm works Figure 214 The ISA Algorithm PID_ISA is similar except that its Kc gain coefficient is applied after the three terms are summed so that the integral gain is Kc Ti and the derivative gain is Kc Td Bits 0 1 and 2 in the Config Word set the Error sign Output Polarity and Derivative Action respectively 14 4 1 Error Term Both PID algorithms calculate the Error term...

Page 277: ... SP PV SP The change in the error term depends on changes in both SP and PV If SP is constant SP 0 and SP has no effect on the derivative term When SP changes however it can cause large transient swings in the derivative term and hence the output Loop stability may be improved by eliminating the effect of SP changes on the derivative term To calculate the Derivative based only on the change in PV ...

Page 278: ...troduces errors in CV after the PID output no longer needs to be limited For example windup would prevent the CV output from moving off a clamp value immediately There are two optional methods for preventing reset windup If the Anti resetwindup Action bit bit 4 of Config Word word 13 of the reference array is zero the default the integral term is adjusted at each PID solution to match the error in...

Page 279: ...other hand the Sample Period should not be too small such as less than the total time constant divided by 1000 or the Ki Error dt term for the PID integral term will round down to 0 For example a very slow process that takes 10 hours or 36 000 seconds to reach the 63 level should have a Sample Period of 40 seconds or longer Variations of the time interval between PID function solutions can have sh...

Page 280: ...urve Figure 215 The following process model parameters can be determined from the PV unit reaction curve K Process open loop gain final change in PV change in CV at time t0 Tp Process or pipeline time delay or dead time after t0 before the process output PV starts moving Tc First order Process time constant time required after Tp for PV to reach 63 2 of the final PV One way to measure these parame...

Page 281: ...esponse Increase Kp if PV step response is too slow or reduce Kp if PV overshoots and oscillates without reaching a steady value 4 Once a Kp is found start increasing Ki to get overshooting that dampens out to a steady value in two to three cycles This may require reducing Kp Also try different SP step sizes and CV operating points 5 After suitable Kp and Ki gains are found try adding Kd to get qu...

Page 282: ...i and Kd are determined Kp and Kd are multiplied by 100 while Ki is multiplied by 1000 The resulting values are entered into the corresponding reference array word locations 14 6 4 Example The following PID example has a sample period of 100 ms a Kp gain of 4 00 and a Ki gain of 1 500 The set point is stored in R0001 the control variable is output in AQ0002 and the process variable is returned in ...

Page 283: ... Array Initialization using M00006 Reference Array Initialization using M00006 Reference Array Initialization using M00006 Reference Array Initialization using M00006 3 Sample Period R102 10 4 Dead Band R103 5 5 Dead Band R104 5 6 Kp R105 400 7 Kd R106 0 8 Ki R107 1500 9 CV Bias R108 0 10 CV Upper Clamp R109 2000 11 CV Lower Clamp R110 400 12 Minimum Slew Time R111 0 13 Config Word R112 0 14 Manua...

Page 284: ...User Manual Chapter 14 GFK 1503F Jan 2020 PID Built in Function Block 270 Figure 216 ...

Page 285: ...a to a PLC CPU without a Programmer Present The EZ Program Store device IC200ACC003 can be used to store and update the configuration application program and reference tables data of a VersaMax PLC The update can include Ethernet Global Data and Advanced User Parameters for Ethernet A programmer and PLC CPU are used to initially write data to the device In addition to writing data to the device th...

Page 286: ...abit Serial Data Flash for non volatile storage Pushbutton initiates update from the device to a PLC Dual color status LED Configurable OEM key password protection Compatible with all VersaMax CPU models release 2 10 and later 15 1 Read Write Verify Data with a Programmer Present With a programmer present the PLC CPU can read write or verify a program configuration and tables in the EZ Program Sto...

Page 287: ...ay cause unexpected operation 15 1 2 Matching OEM Protection If the PLC s that will be updated by the EZ Program Store device are protected by an OEM key password be sure the same OEM key password is present in the configuration stored to the EZ Program Store device otherwise no update will be possible If the PLC s being updated had no OEM key password assigned the EZ Program Store device must als...

Page 288: ...ly to update only RAM memory in the target PLC Select RAM FLASH to update both 15 1 5 Using the EZ Program Store Device with the Programmer Figure 219 To read write or verify some or all of the data follow these steps 1 Plug the EZ Program Store device into port 2 of the VersaMax PLC CPU The device s LED turns green after about 2 seconds The delay allows time for proper seating of the device 2 If ...

Page 289: ...a programmer computer is also connected to the PLC at the same time the programmer cannot be used to change the PLC mode 4 Start the programming software and change the request timeout values as needed 5 Connect the programmer to the PLC CPU 6 Use the programming software to read write or verify the data When performing an update with the programmer present the pushbutton on the EZ Program Store d...

Page 290: ...es that the Run Stop switch is enabled regardless of the configuration of the switch Figure 223 2 If the PLC s Run LED is blinking and the LED on the device is green stop the PLC by moving the Run Stop switch from Run On to Stop Off position Figure 224 If the switch is already on the Stop Off position move it from Run then back to Stop to affirm the change After the mode is changed to Stop No I O ...

Page 291: ...am Store device turns amber and the Port 2 LED on the PLC blinks Figure 226 4 Wait for the update to complete Reading and writing large programs hardware configurations and reference tables to or from the EZ Program Store device may take 30 seconds or more to complete When the device s LED turns solid green and the CPU s Run LED starts blinking the update has completed successfully ...

Page 292: ...s detected before the old data was erased When the PLC is placed into Run mode it continues using the old data If the device s LED is blinking green amber and the CPU s Run LED is off an error occurred during the transfer after the data in the PLC was erased Try the update again by disconnecting and reconnecting the device and pressing the pushbutton If the second update fails contact the update p...

Page 293: ...ions Model Typical Time in microseconds CPU001 002 1 7 CPU005 E05 0 8 A 3 Function Block Timing The following tables show the sweep impact times and size information for all supported function blocks of the CPU A 3 1 Sweep Impact Times The tables show two sweep impact times are shown for each function An Increment time is shown for functions that can have variable length inputs table functions Ena...

Page 294: ...uction time A 3 2 Sizes of Timers Counters Math Functions Trig Functions Log Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Timers On Delay Timer 119 90 90 69 15 Timer 110 80 81 60 15 Off Delay Timer 11...

Page 295: ...00 10 11 ATAN REAL 820 12 542 10 11 Logarithmi c LOG REAL 878 12 577 10 11 LN REAL 821 12 542 10 11 A 3 3 Sizes of Exponential Functions Radian Conversion Relational Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increme nt Size Enable d Disable d Ena...

Page 296: ... 14 Less Than Equal INT 40 12 30 10 10 Less Than Equal DINT 46 12 30 10 16 Less Than Equal REAL 60 12 40 10 14 Range INT 50 12 33 10 13 Range DINT 55 12 40 10 22 Range WORD 50 12 33 10 13 A 3 4 Sizes of Bit Operations Data Move Functions The size of a function is the number of bytes consumed in user logic space for each instance of the function in a ladder diagram application program Group Functio...

Page 297: ...70 12 56 10 13 Mask Compare WORD 158 12 110 10 25 Mask Compare DWORD 150 12 100 10 25 Bit Sequencer 150 109 101 77 0 24 16 Data Move Move INT 45 12 32 10 2 83 10 Move BIT 80 12 60 10 10 76 13 Move WORD 46 12 32 10 2 82 10 Move REAL 60 12 47 10 2 75 13 Block Move INT 60 12 50 10 28 Block Move WORD 60 12 50 10 28 Block Move REAL 113 12 94 10 13 Block Clear 100 12 83 10 4 63 11 Shift Register BIT 130...

Page 298: ...22 BIT 129 12 92 10 1 08 22 BYTE 109 12 80 10 4 75 22 WORD 110 12 90 10 5 50 22 Search Equal INT 90 12 70 10 6 59 19 DINT 90 12 60 10 7 14 22 BYTE 81 12 60 10 2 58 19 WORD 90 12 70 10 6 59 19 Search Not Equal INT 100 12 78 10 6 66 19 DINT 110 12 81 10 7 14 22 BYTE 74 12 57 10 2 56 19 WORD 100 12 78 10 6 66 19 Search Greater Than INT 100 12 80 10 6 69 19 DINT 94 12 70 10 7 12 22 BYTE 90 12 69 10 2 ...

Page 299: ...ed in user logic space for each instance of the function in a ladder diagram application program Group Function CPU001 002 CPU005 E05 Increment Size Enabled Disabled Enabled Disabled Conversion Convert INT to REAL 60 12 40 10 10 Convert REAL to INT 683 12 455 10 13 Convert DINT to REAL 60 12 40 10 13 Convert REAL to DINT 673 12 451 10 13 Convert WORD to REAL 60 12 40 10 10 Convert REAL to WORD 642...

Page 300: ...10 10 15 100 12 72 10 10 16 110 12 80 10 10 18 346 12 251 10 10 23 377 12 361 10 10 26 30 912 12 912 10 10 29 72 12 60 10 10 Nested MCR ENDMCR Combined 31 33 31 33 4 Drum Sequencer 267 222 184 152 34 DO I O timing is the time to output values to discrete output module Service Request 14 Clear Fault Table timing was done when fault table contained no faults Service Request 26 30 Interrogate I O tim...

Page 301: ...can time tables discrete modules are grouped by type Module Type Module Catalog Number IC200 Discrete Input Type 1 MDL140 MDL640 MDD846 MDL141 MDL643 MDD847 MDL143 MDD842 MDD848 MDL144 MDD843 MDD849 MDL631 MDD844 MDD850 MDL635 MDD845 MDL930 Discrete Input Type 2 MDL240 MDL644 MDL241 MDL650 MDL243 MDD840 MDL244 MDL632 MDL636 Discrete Output Type 1 MDL329 MDD843 MDD849 MDL331 MDD844 MDD850 MDL740 MD...

Page 302: ...nts 294 369 Analog Input 4 Channels 160 190 Analog Input 8 Channels 239 312 Analog Input 15 Channels 377 526 Analog Output 2 Channels 109 161 Analog Output 4 Channels 145 202 Analog Output 8 Channels 217 285 Analog Output 12 Channels 289 367 Intelligent Analog Input 4 Channels 237 281 Intelligent Analog Input 7 Channels 261 305 Intelligent Analog Input 8 Channels 272 313 Intelligent Analog Output ...

Page 303: ...crete Output w ESCP Per Point Fault Reporting 176 260 Intelligent Discrete Input 20 Points 643 763 Intelligent Discrete Output 12 Points 714 756 Analog Input 4 Channels 317 389 Analog Input 8 Channels 527 631 Analog Input 15 Channels 896 1054 Analog Output 2 Channels 204 266 Analog Output 4 Channels 296 374 Analog Output 8 Channels 480 592 Analog Output 12 Channels 664 809 Intelligent Analog Input...

Page 304: ... Type 2 165 223 Discrete Output w ESCP Per Point Fault Reporting 177 261 Intelligent Discrete Input 20 Points 651 766 Intelligent Discrete Output 12 Points 728 757 Analog Input 4 Channels 324 393 Analog Input 8 Channels 541 646 Analog Input 15 Channels 920 1087 Analog Output 2 Channels 206 267 Analog Output 4 Channels 300 377 Analog Output 8 Channels 489 596 Analog Output 12 Channels 678 815 Intel...

Page 305: ...e Output w ESCP Per Point Fault Reporting 850 914 Intelligent Discrete Input 20 Points 4050 4086 Intelligent Discrete Output 12 Points 5135 5135 Analog Input 4 Channels 2054 2093 Analog Input 8 Channels 3660 3660 Analog Input 15 Channels 6471 6471 Analog Output 2 Channels 1221 1251 Analog Output 4 Channels 1991 2021 Analog Output 8 Channels 3531 3560 Analog Output 12 Channels 5071 5099 Intelligent...

Page 306: ... Exchange Overhead Exchange overhead includes the setup time for each exchange that will be transferred during the sweep This overhead varies depending on whether the exchange is consumed or produced and if the time stamp for the exchange originates from the PLC itself or from a remote Network Time Protocol NTP server When computing the sweep impact include overhead time for each exchange NTP time...

Page 307: ...ized The chart below indicates the maximum number of EGD exchanges that the CPUE05 can realistically support of a certain size and data refresh period under Best Case conditions These numbers will scale downwards based on the size of the user program the presence of other Ethernet traffic etc The term Best Case indicates the following setup parameters apply No user logic is present so the logic sw...

Page 308: ...ht to modify or improve the designs or specifications of the products mentioned in this manual at any time without notice Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson product remains solely with the purchaser 2019 Emerson All rights reserved Emerson Terms and Conditions of Sale are ...

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