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1. 21 OONN NODOOATAAIHAHAAHAAHAHAAA AWW WANN N Table of Contents Connections to Computer or 21 Serial Connection to OP 9001 Communications Master 21 fermination nunana he 21 Power 21 enr P n 22 Configuration Selections 22 Single Module PLC Based Systems 22 Multi Module PLC Applications Uses Communications Master 22 CGredurig MOSSaOUDS ad DE de 23 Label and Message Definition Templates 24 lere 25 PUY SICA 25 EICCING veas cus eens RU TUI SEN BE GS ss 29 Communication 4 25 Communication Failure Operation 25 Panel Mounting Dimensions modu niega
2. l MOV MOVE 12 Source N7 0 MOV MOVE Source N7 1 MOV Sour N7 54 N7 2 OP 620 select message 4 fo top line select Good Parts 235 message 8 Process Step 1 to bottom 2 LIT z from N7 54 into top line Eu data field Do Register MSB LSB N7 0 Top Line Message Selection N71 Bottom Line Message Selection N7 2 N7 3 N74 7 5 7 6 7 7 7 8 Top Line Data Top Line Data High Bottom Line Data Bottom Line Data High Function Selection page 21 home page optimate com Intelligent Peripherals for Control Displaying long BCD Numbers Long up to 8 digit BCD numbers can be displayed by the OP 620 This number format is a standard capability for PLC Direct PLCs However the A B SLC PLCs do not have an easy means of handling long BCD numbers Due to the limitations of the SLC this capability will not be commonly implemented The example in the next column illustrates the method for displaying large numbers Registers N7 54 and N7 55 contain an 8 digit BCD number with the most significant 4 digits in N7 55 Count Val 75490213 Process Step 1 Arrow Adjustment of Setpoint Data The figure to the right illustrates arrow adjustment of setpoint data and a whole lot more The process is enabled when B3 0 is energized The first program
3. Menu Level Function No 02 Menu Level Function No Level 1 Function No No4 Menu Level Function No Nes Level 1 Function No pes peperere Tope sd Menu Level Function No sie r P o rjo T 2 rjEjM ej Menu Level Function No w 1 11111 1 1 Menu Level 12 304 Function No eee T 7 3 Function Nol Menu Level 111213 Function No no 11111 Menu Level Function No no 1 11111 Menu Level 1121 3 4 Function No n Menu Level Function w 1 11111 Veru Levall 3 7 9 3 Facer No n 1 11111 Menu Level HERE Function No Page A 18 Installing and Using the Example Programs OP 620 APPLICATION WORKSHEET pAGE PUSHBUTTONS LAMPS DESCRIPTION A M Alternate Momentary System Type Fi UL Panel F2 PLC Base Register Addr gt GC PLC CONFIGURATION F4 PLC Family Eg qo CPU Model Protocol PLC Addres
4. Function 2 MOV 4 Source 4 i Dest N7 O MOV MOVE Source 7 21 Dest N7 2 MOV MOVE Source 6 Dest 7 1 BA 4 5 U 1 MOV ili MOVE Source N7 2 Dest N7 2 BA N77 pos MOVE Source 5 0 Dest N7 O MOV MOVE Source 7 Dest N7 l B3 E B4 4 U 5 page 30 by Koyo home page optimate com Intelligent Peripherals for Control OptilMate Series Example Program Continued from previous page Rung 12 77 I de O0 E menu or in the middle of a function and they realize that they BA need to exit without making any changes then they can use the CLEAR ABORT button for that purpose If the panel is in the menu tree when the CLEAR ABORT button is pressed the panel will exit the menu and default back to the messages that are in the top and bottom line message registers If the user is in afunction this rung can be used to unlatch different bits within the program that pertain to any given function which could be B4 cC 7 Ow AN B4 active at the time B4 0 B4 1 B4 3 etc U This rung can also with other conditions such as 3 machine jams emergency conditions etc that might warrant B4 exiting the menu by clearing the menu enable bit or disabling U a function Messages can also be loaded to the display to 4 des
5. Displaying Long BCD Numbers ha dante adt BERE Ua Displaying Floating Point Numbers erint emt and x Arrow Adjustment of Setpoint Data 10 Usmga M n CG 11 Menu Tree Example eara doer ce drea oa i d aant gard bees ee bane 12 Examples of Use with an Allen Bradley 14 Interfacing to A B Memory tected ek ete e bie e hea bera dee ote show bodie ad 14 USING e UNCON BURON css saires ae vene dee eee ed 14 Displaying Floating Point Numbers 14 Displaying Messages on the LCD Display 15 Displaying Long BCD Numbers 5 45 EXER eee e 16 Arrow Adjustment of Setpoint Data 16 Using a Menu 17 A Menu Tree Example 18 Setup Interconnect ie rs ec arra rra Rer D RR RR prn x 20 Legending the Function Keys 20 Connection to the System
6. Decision oelection Single Multi Chose Multi module Module PLC Type This applies to the Communications master Choose appropriate type Protocol This applies to the OP 9001 Communications master Choose appropriate baud rate bits stop bits amp parity Note that if 8 data bits and even or odd parity are selected only 1 stop bit is available Address Each panel must have a unique address Panel The OP WINEDIT software will Protocol automatically select the OptiMate Hex protocol for communications between the OP 9001 and the panel This is all transparent to the user Buttons select momentary or alternate action as required for your application Messages Define messages as required for your application Configuration must be downloaded from the IBM PC compatible to each panel This is done over the serial link Panel must be selected for DIP switch in back of the module for module to accept configuration data After the download to the panel is complete wait a few seconds before switching the DIP switch from to Run The DIP switch must be in the position for the module to operate with the selected host The Term switch must in the OFF position unless the panel is at the end of a cable in an RS422 system Run page 34 Intelligent Peripherals for Control OptilMate Series Creating Messages Text ZOCharacters Max Message f
7. rect OP 620 by Koyo home page optimate com END page 19 Intelligent Peripherals for Control OptilMate Series Examples of Use with Interfacing to A B Memory OptiMate panels interface to Allen Bradley SLC 5 03 SLC 5 04 and Micrologix PLCs via integer file type N The 5 03 and 5 04 have file type N7 as standard Other N type files can be created The Micrologix has a fixed file type N7 Please refer to Allen Bradley documentation for information on setting up and using N type files Note When using an OP 620 with an A B PLC always ensure that at least 9 words of memory are allocated to ensure proper communications All of the examples that follow assume that the OP 620 module has been configured through the OP WINEDIT Editor for a file type 7 and base register address 0 With this configuration the status and control registers will be at N7 7 and N7 8 respectively The following is a table relating status and an Allen Bradley PLC Using a Function Button The five function buttons below the LCD display will appear as control relay coils in vour program The following example turns on output O 0 5 when button F2 is active button F2 7 1 control register bits to their 7 locations Register MSB Lx 7 0 Top Line Message Selection N7 1 Bottom
8. with bottom line of isplay PLC Register e Register M 5 For long BCD The OP 620 Operator Panel uses a bank of 9 or floating point data only contiguous PLC registers The register set Value is the four most signifi definition 15 shown in the table below cant BCD digits of data for Direct oy Koyo gt ENT ENTER button is active Not necessarily Data Entry see DA bit gt AB Abort key active gt MA Menu operation is currently active gt Up Arrow Up arrow key is active gt Down Arrow Down ar row key is active e Register X 8 Control bits B v LLL LL 1 1 the bottom line OP 620 Panel PLC Register e Register M 6 The function M ap number selected through the menu ree e Register 7 Status register PLC Register Function MSB gt 15 Register ENTIMA FS DA F5 F4 F3 F2 F1 M 0 first Top line message selection Status Register m of gt 5 are status of the five function keys Set to 1 Bottom Line message selection 1 when the button is ac M 2 Top line data tive M 3 Top line data 2 for long BCD gt DA Data available As 4 Bottom line data sociated with data entry M 5 Bottom line data 2 for lon BCD g has been entered L gt FS Function Selected M 6 Function selection Indicates that a function M 7 Status register has been sel
9. All Models Series 90 Micro MODICON ModBus RJ45 port OP MCBL 1 TI305 7 325 07 325 07 Requires DCU OP ACBL 2 SIMATIC TI305 2 2 4 2 OP 3CBL 2 330 37 PPX 330 37 1 Requires DCU 3255 07 or 325 w Stage Kt Requires DCU 3305 37 PPX 330S 37 2 Requires DCU 335 37 PPX 335 37 Phone Jacks If DCU is used 1405 7 425 CPU PPX425 CPU Only port OP 4CBL 1 000202204 Top port 15 pin OP 4CBL 1 435 CPU PPX 435 CPU Bottom port 25 pin OP ACBL 2 OP 4CBL 1 Bottom port OP ACBL 1 Only port OP ACBL 2 Smart Slice I O panels 5 03 5 04 Only port A B SLC 500 Page A 6 Installing and Using the Example Programs Connecting Cable Details Connecting Cable The 620 connecting cable may vary depending on which CPU you use Refer to the previous page to select the proper cable for connecting to your PLC RJ12 PLC DB15 PLC 12 22 72 2 not used 3 Din 4 Dout 5 not used 6 not used RJ11 PLC DB15 1 Din RJ11 1 2 Dout 4 5 3 not used 0 2 YOM A 5 not used 13 5 not used 14 4 On line 13 2 Bout Dou 1 132 not used 12 2 not used 112 not used DB25 PLC 5 10 2 used 2 3 9 not used 3 2 8 not used 7 5 7 0 47 6 not used
10. 620 O perator P anel Manual Number OP 620 M WARNING Thank you for purchasing automation equipment from PLC Direct We want your new DirectLOGIC automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your product design installation or operation If you have any questio
11. Depending on which PLC you are using you may require as many as three cables to use the example programs e An OP ACBL 1 configuration cable to connect your personal computer to the OP panel to load the configuration program into the panel A panels use the OP ACBL 1 for the configuration cable This cable is also used to connect an OP panel to an Allen Bradley SLC 500 CPU e Acable to connect your personal computer to the PLC to load the DirectSOFT example ladder programs into your PLC See the DirectSOFT user manual for help in selecting the proper cable to use with your PLC e Acable to connect the OP panel to the PLC Use the information on the next two pages to select the proper cable to use with your PLC Page A 5 Choosing Your Connecting Cables Depending on which PLC you are using you may require as many as two cables Here are the requirements e OP ACBL 1 all units require this cable for configuration This is a 9 pin female to 15 pin male cable that connects your personal computer to the OP panel This cable is also used to connect an OP panel to the Allen Bradley SLC 500 CPUs listed e CPU Cables You will also need the appropriate cable to connect your CPU to the OP panel Use the chart shown to the right to choose the correct communications cable OP 9001 Cable Connectors If youre planning to use multiple panels and an OP 9001 then you will need to build your own custom cables Since the prop
12. Function keys can be custom labeled by the user with plastic inserts The inserts can be custom legended with text and or graphics and slipped into a protective pocket behind the faceplate The OP 620 Operator Panel is part of Optimation s Opti ate series Each OptiMate panel is designed to connect to most PLCs with a single cable connection OptiMate panels can be used individually or together with any combination of other OptiMate panels When used with a PLC operation is transparent to the user Terminal functions tie directly into your PLC ladder logic program The OP 620 takes care of the rest OptiMate Series Applications Machine control Process control Security systems HVAC Plant monitoring control PLC applications Features 2 line x 20 character LCD Numeric arrow adjustment 5 User defined function keys Menu tree capability PLC compatible RS232 RS422 communica tions Stand alone operation capable Multipanel operation capable Direct oy Koyo OP 620 home page optimate com page 1 Intelligent Peripherals for Control OptilMate Series Configuration Options PLC Stand Alone OptiMate panels plug directly into most PLCs A simple cable connection allows you to interface and control the OptiMate panel via PLC data registers and ladder logic The OP 620 operator terminal uses a bank of PLC registers Complete Operator interface is performed with 9 PLC registers for
13. To install the example programs if using WIN 95 follow these steps 1 2 Select the Explorer icon and open If the hard drive is drive C select the C icon Make a new directory in the hard drive of your computer For example if you are using an OP 620 panel Select the File menu then select New and then Folder Notice the New Folder icon that appears Select the folder and name it OP 620 by selecting the File menu and selecting Rename Type in the new name Copy all the contents of the example program disk Insert the diskette in drive A and select and open the 3 1 2 Floppy A icon Notice the disk has numerous files of example programs Select all the programs by opening the Edit menu and selecting Select All Open the Edit menu again and select Copy Paste the program disk contents into the new C drive 620 directory Open the OP 620 directory open the Edit menu and select Paste The example programs are now loaded onto the hard drive of your computer Remove the diskette from drive A Step 6 Loading the The next step is to load the configuration program into the OP panel as follows OP WINEDIT Example Program 1 into the OP Panel 6 7 Open the OP WINEDIT also called OPEditor software When the initial screen appears select Existing System A File Open window appears Open the example program file that you just loaded on your hard drive OP 620 A list of files appears all havin
14. adii o adr idend o 25 Appendix A Example Programs A 1 Understanding the Example Programs A 2 Software Requirements A 2 9 Steps to Using the Example Programs A 3 Step 1 Power Supply Connections A 3 Step 1A Multi Panel Power Supply Connections Optional A 4 Step 2 Selecting Configuration Mode Setting the OP Panel DIP Switches A 5 Step 3 Selecting Cables e deeds Rr RR m d E e sae A 5 Choosing Your Connecting Cables PE RUE ERE A 6 Connecting Gable Details 7 Step 4 Connecting Configuration Cable 1 A 8 Step 5 Installing Example Programs on Your Personal Computer Hard Drive A 8 Step 6 Loading OP WINEDIT Example Program into the OP Panel A 9 Step 7 Setting the OP Panel DIP Switch Positions for Program Run Mode A 10 Step 8 Loading DirectSOFT Example Program into the PLC 10 Step 9 Connecting the OP Panel to the PLC and Running the Program A 10 Running the OP 620 Example
15. C20 op K enel enable Fill Tank 1 SET function C C20 C72 X3 C6 V200 K2 8 C72 enable Drain lank 1 C6 Energies SET function RESET C20 5005 C2 Sets Menu Return C73 enable Tank 2 Maximum SET MR bit SET Level function Oince the process is C72 RESET complete reset the e function enable bit FS C disable menu by clearing SET the ME m cDIrect oy Koyo home page optimate com OptilMate Series page 13 Intelligent Peripherals for Control Implementing Data Entry using a Menu Function The logic shown below 15 another typical example of how a setpoint function might be implemented Suppose the selection for Tank 2 Maximum Level was made from the menu tree From the logic on the previous page this will result in C73 being set Accordingly the first rung shown below selects the appropriate setpoint message for the top line and a prompt message for the bottom line It also initializes the setpoint value for arrow adjustment The first rung disables itself and enables the second rung When the setpoint data is entered afterthe FS flag 15 cleared the DA bit will be set Then the second rung will copy the setpoint value back to its working location set the DAK bit and pass control to the third rung The third rung waits until DA bit has been cleared by the OP 620 then clears the DAK and re enable the menu If the menu retur
16. Pressing the arrow keys would adjust the value up or down while continuously writing the value to data register 2 or M 4 When the adjustment is complete the operator would press ENTER The OP 620 will then set DA DA will remain set until a new message is selected via M or M 1 or the DAK bit is set page 5 Function Buttons The OP 620 contains five user definable pushbuttons These pushbuttons can be custom labeled and used for any purpose The pushbuttons can be individually configured as either alternate action or momentary pushbuttons Alternate action buttons alternate state each time they are pressed Momentary buttons are active only while they are being pressed The status register holds the current state of each of the five pushbuttons typical PLC application these pushbuttons would be mapped to control contacts for easy ladder logic interface Menu Tree Operation The OP 620 terminal is designed to allow you to create a menu tree for function selection The menu tree allows for interactive selection of a required function operation from a menu or list of options The OP 620 allows up to four levels of menu Each menu selection can be either a function or the next lower menu level With this type of tree arrangement you can construct an application menu that goes from general to specific You can also place frequently used menu selections on the top layer and infrequent selections on low
17. Next we need to set the three Temperature Control parameters 5 Press Menu and use the AW pushbuttons to select the following Temperature Control screen Temperature Control Enter Arrow Clear Press Enter to get the following screen Setpoint Zonel Temp Enter Arrow Clear First we will set the Zone 1 temperature Press Enter to get the following screen Zonel Temp SP 100 Enter New Temp 200 Select Zone1 temperature by using the AW pushbuttons and pressing Enter For example the 100 on the top line indicates the current Zone1 temperature setting If we wish to change our selection to 200 press the pushbutton until 7200 is displayed on the bottom line and press Enter 200 replaces the 100 on the top line The Zone1 temperature is now set and the display returns to the following screen Setpoint Zonel Temp Enter Arrow Clear Page A 14 Installing and Using the Example Programs 6 We now need to set the Zone 2 and Zone 3 temperatures in the same manner To set the Zone 2 temperature press the AW pushbuttons until the Zone1 portion of the display changes to Zone2 as follows Setpoint Zone2 Temp Enter Arrow Clear Press Enter and set the Zone 2 temperature the same way that you set the Zone 1 temperature Repeat the same procedure for the Zone 3 temperature All setup parameters are now set and you are ready to run the program 7 Afterthe last setup par
18. The figure on right the illustrates the actor ALA process of creating messages for your d program to use The first step involves ES simply using a message template to 46 t 5 define on paper each of the messages We suggest copying the template page and using it to define all of your messages The next step is to use the OP WINEDIT editor to enter the messages as defined Remember to use carets wherever variable data is to be used Exam ple Message Definitions The OP WINEDIT editor will guide you through other definable parameters including data type message type etcetera as shown below J rec t OP 620 page 35 Koyo home page optimate com Intelligent Peripherals for Control OptilMate Series Label and Message Definition Templates Message Text 20Characters Max Message Definition Template 4 08 A Ww Pushbutton Label Strip Pattern rec t OP 620 page 36 Koyo home page optimate com Intelligent Peripherals for Control OptiMate Series Specifications Physical Recessed Mount Housing 6 6 Lx4 0 H x 1 25 D Cutout
19. which has been configured as a floating point display message Since the data is a floating point number it uses two 16 bit registers The two registers have to be looked at together not individually for you to be able to make any sense of the data In this example the data is loaded from V3010 and V3011 using the LDR load real number instruction to the bottom line display registers V2004 and V2005 The top line is text message 8 Process Step 1 AvgPart Hr 8 79E 02 Direct oy Koyo OptilMate Series d 1 1 Select OUT V2000 message for top line K8 Select message 8 V2001 for bottom line DD V3002 Put BCD double from V3002 OUTD V2002 OP 620 home page optimate com OUTD V2004 into line data field Select message 8 for top line Select message 7 for bottom line Put floating point value from V3010 into bottom line data field page 9 Intelligent Peripherals for Control Arrow Adjustment of Setpoint Data The figure to the right illustrates arrow adjustment of setpoint data and a whole lot more The process is enabled when C74 is energized The first program rung places the Enter Setpoint and Display Setpt messages in the top and bottom lines initializes the setpoint value
20. 5 5 CTS 4 RTS 3 Din 2 Dout 1 not used 8 Pin Mini DIN DB15 NE 4 2 e 5 12 RS 422 Pinout PLC Panel Din 112 Dout Din 12 Dout Dout 4 9 Din Dout 10 Din 0V 5 0V RTS CTS RTS CTS __ 2 RJ12 6P6C 123456 OP 2CBL HJ1 DB15 1234 1515 tied 14 tied 13 tied OV 12 not used OP 4CBL 1 1 not used Oz not used 9 not used 4 1 25 not used 24 not used 23 not used 22 not used 21 not used 20 not used 19 not used 18 not used 17 not used 16 not used 15 not used 14 not used OP ACBL 2 Mini DIN 3 Din 2 Dout 5 0V 9 not used 2 1 not used 102 not used aoe 11 not used s nin 12 notused 4 AS used 132 not used J 14 used 6 not used 15 not used 7 not used 8 not used Page A 7 Installing and Using the Example Programs Step 4 Connecting Once the example programs are loaded in your personal computer the first step will be to load the configuration program from the computer into the OP panel so make Cable OP ACBL 1 this cable connection first Connect the configuration cable between the serial port of the OP panel and the serial port of the personal computer when configuring panels using the OP WINEDIT software The OP WINEDIT software requires you to select the serial port number com1 com2 being used for configuration
21. C20 V2006 K2 C7 5 SET C C6 6 SET Rung 6 This rung disables the menu enable ME bit via C61 It checks for the function select FS bit When the FS bit is set the program knows that a function has been selected If the function number has been decoded correctly as shown in the previous two rungs then the panel needs to exit the menu so the program can implement the function The only way to leave the menu is to disable the ME bit If the ME bit is not disabled after a function is selected the OP 620 s display will lock When the ME bit is reset the panel will leave the menu mode and the display will return to PLC program control The program is continued on the next page page 16 Intelligent Peripherals for Control Example Program Continued from previous page Rung 7 This rung is the first rung in the logic for function 1 defined in the menu tree as Set Fluid Level When C70 is enabled and C100 is not the function begins The second predefined message Desired Level is loaded into the top line V2000 of the display Since message 2 is an arrow adjust message the initial starting point for the adjustment has to be loaded into the top line data register V2002 In this case the data which is stored in V2210 is copied from V2210 to V2002 Next message 3 Adjust then ENTER is loaded into the bottom line V2001 of the display Then C100 is set w
22. arrow C43 DL250 V40600 V40617 DL330 R016 R037 Using a Function Button DL330P R016 R017 and R020 R027 The five function buttons below the LCD display will appear DL340 R016 R037 and R100 as control relay coils in your program assuming the memory R106 mapping rung described previously is in your program The DL350 V40600 V40617 following example turns on output Y 1 when button F1 is active DL430 V40600 V40635 CO DL440 V40600 V40677 1 gt DL450 40600 40777 F1 button Memory Mapping The examples on the following pages use an OP 620 SP1 connected to PLC Direct DLI0S DL205 DL350 DLAOSseries T ELE PLC The OP 620 is configured for a base address of V2000 The program rung onthe right should be placed in the program to copy the status register to V40600 VCO copy from OUT V40601 VC20 to the control register This is necessary V40600 because the OP 620 writes to the status register and reads from the control register LD V4060 1 Control Register V2010 rec t OP 620 page 7 Koyo home page optimate com Intelligent Peripherals for Control OD Process H Fill Drain Displaying Messages on the LCD Display AT Messages of various types can be configured via OP WINEDIT and downloaded to the OP 620 The message definitions shown in the figure above will be used inall
23. communications port to your PLC s programming port on the CPU Start DirectSOFT on your personal computer Select Open Document A dialog box appears Open the example program file that you just loaded on your hard drive 620 A list of files appears all having prj after the file name These are the example program files Notice that the program files are named for the OP panel and PLC being used and end with prj Select the example program for the OP panel and PLC you are using For example if you are using an OP 620 panel with a DL205 PLC select and open the file titled 620 205 pr When the program opens its ladder rungs will appear on the monitor screen Select the PLC menu then Connect then select the link to use All the program examples are saved without PLC link information so you have to re connect to your particular CPU If a message appears which asks you to select the source of program to view select Disk Make sure the CPU is in Program mode Then download the program to the CPU One method is to select the File menu Write Program then select To PLC When the program download is complete putthe CPU in Run Mode Select the PLC menu PLC Modes then select Run The program is now running Step 9 Connecting The next step is to connect the OP panel to the PLC using the cable you selected the OP Panel to the earlier Once the OP panel is connected to the PLC you can run the program Read PLC a
24. flag is also set the OP 620 will return to the same point in the menu C73 C120 C121 Max Level Load message 17 to the top line message register Initial value for arrow adjust message Copied from T2 Max Level holding register to top line data register Adjust then ENTER Load message 19 to the bottom line message register Disable current rung and enable next rung When data entry complete DA bit set copy new value from top line data register to holding register for T2 Max Level Set DAK Data Acknowledge bit so panel will clear DA bit Enable next rung which will wait for the panel to clear the DA bit Disable current rung disable current rung Energizes the ME bit to Re Enable the Menu Since the function is complete clear the bit that enabled the function E Clear the DAK bit RESET PLCS rect OP 620 by Koyo home page optimate com C121 C5 Since the DA bit has been cleared OptiMate Series page 14 Intelligent Peripherals for Control Example Program using an OP 620 The example program shown in the following 4 pages describes how to implement a program using an OP 620 The program uses the menu tree an arrow adjust message a data display message and text messages Itisacomplete program which will run on a DL105 DL205 DL350 or DL405 PLC The program uses a two level deep menu tree with two menu functions The first menu level contain
25. from the value in V3001 and enables the second rung The second rung continually copies the setpoint value to the display value so long as it is enabled It latches itself until unlatched by the next rung while disabling the first rung The third rung waits until the data available flag is set C5 then copies the setpoint back to V3001 It also unlatches the second rung and by activating C77 enables the next block of logic whatever that might be in the program Enter Setpt 1 234 Display Setpt 1 234 T ET eDirect C75 V2002 C76 C77 OUT F v2004 C76 OUT LD OP 620 V2002 OUT V3001 C77 OUT by Koyo home page optimate com OptiMate Series select message 1 for top line initialize setpoint from value held in V3001 select message 3 for bottom line enable second rung copy sefpoint value into display value enable 3rd rung disable 1sf rung copy new setpoint back to V3001 enable next block of logic page 10 Intelligent Peripherals for Control OptilMate Series Using a Menu Tree The OP 620 allows you to predefine and use a layered menu tree for function selection The operation of this menu tree is taken care of entirely by the OP 620 panel The only requirement that the user has is to enable or disable the menu operation and branch to the appropri
26. in dicating the PC and OP panel are connected If only the TX transmitter LED is flashing or if the TX RX LEDs are not alternating between flashes check that the OP panel is set to the configuration mode by setting the RUN PGM DIP switch to the PGM position 2 Check to make sure the configuration cable OP ACBL 1 is properly con nected For cable details refer to the Appendix A Connecting the Configura tion Cable OP ACBL 1 section 3 Make sure the correct communications port is selected with the software such as COM1 COM2 COMS COMA 4 Check the 24VDC power source and connections 5 After checking the above items repeat the online panel Download or Upload procedure Hear Panel View 2224 OP ACBL 1 Opti Mate C2 Check cable connections RUN 1 mm Place the iind switch n the TERM position when contiguring the panel TERM switch stays in the off position RUN PGM DIP Switch Page B 2 Maintenance and Troubleshooting Panel to PLC If you experience communications difficulties between the OP panel and PLC for a Communications period of twelve seconds the LEDs in the corners of the five pushbuttons will flash Problems rapidly In this case you should check the following items 1 Observe the TX and RX LEDs on the rear of the panel Both LEDs should be a steady flash or glow depending on baud rate If not check and make sure you are using the proper communications
27. interlocks the function selects setting B4 0 4 1 etc with the function select and menu enable flags to ensure that only one function is enabled each time a function is selected OptilMate Series Implementing a Menu Function The program logic shown below illustrates how a typical function might be implemented Suppose the selection was made by the operator to Drain Tank 1 According to the logic just shown this would result in control relay B4 2 being latched The first rung of the Drain Tank 1 function shown below will put messages into the top and bottom lines of the display The second rung energizes output O 0 4 to open the drain until level sensor input 1 2 5 senses that itis empty The third rung re enables the menu and sets it to return back to the Drain Tank 1 selection when the tank is empty The third rung also disables the function By putting the function select relay N7 7 6 in series we force the program to wait until the function select has been cleared before re enabling the menu MOV MOVE Source Tank Draining Load message 15 to the top line message register Dest MOV ME Please Wait B3 B3 N7 8 MOVE Load message 16 enable menu by Source setting the ME bit ius to the bottom line message register FS ME EQU NA NZS EQUAL gt L enable Process 1 Drain until 2 5 sensed SoUceA N
28. loaded into the bottom line V2001 of the display Then C102 is set to enable the next rung Last C71 is reset to disable the current rung Rung 11 Rung 11 updates the data field of the display message on the top line The OP 620 s user can view the data as it changes within V2211 Aslong as this rung is active the top line data register V2002 will be updated with the current data stored in V2211 Rung 12 Message 6 on the bottom line prompts the user to Push F1 when Done When the 620 s user wishes to stop viewing 4 the data they should press the first pushbutton F1 This will complete function 2 When a momentary action button is pressed a new set of messages are loaded into the display registers Message Press Menu is loaded into the top line and message 7 a blank message is loaded into the bottom line of the display Next C61 15 reset to re enable the menu enable ME bit via rung 3 Finally C102 is reset to disable the current and 12 previous rungs After this rung is completed the OP 620 will display the Press Menu message until the menu button is pressed The program is continued on the next page rec t OP 620 page 18 Koyo home page optimate com Intelligent Peripherals for Control Example Program Continued from previous page Rung 13 This rung is an abort rung If the OP 620 s user 15 in the menu or in t
29. message integer or fixed point Numeric Types amp Values e nteger e Fixed Point BCD Values between 0 amp 9999 with appropriate decimal placement BCD Double values between 0 amp 99999999 with appropriate decimal placement Binary Values between 0 amp 65535 with appropri ate decimal placement Floating Point Values between 3 402823E 38 to 3 402823 38 in the format of X X XE XX page 37 Appendix Example Programs In This Chapter installing Example Programs Selecting and Connecting Cables Running Example Programs Program Worksheets Installing and Using the Example Programs Understanding the One of the best ways to learn how to use the OP panel is to load the example Example Programs programs which are on the supplied diskette and run the program for your PLC A Cement Kiln System is used to demonstrate the ladder logic required to support the various OP panel features The program provides ladder logic which demonstrates controlling pushbuttons lamps messages and menu operations Use an understanding of this example program to help develop programs for your own applications Follow the instructions in this chapter for installing and running the example programs Hopper Selected 1 3 Kiln Speed 0 1 0090 Software Requirements Conveyor Flow Q Th
30. rung places the Enter Setpoint and Display Setpt messages in the top and bottom lines initializes the setpoint value from the value in N7 37 and enables the second rung The second rung continually copies the setpoint value to the display value so long as it is enabled It latches itself until unlatched by the next rung while disabling the first rung The third rung waits until the data available flag is set N7 7 5 then copies the setpoint back to N7 37 It also unlatches the second rung and by activating B3 3 enables the next block of logic whatever that might be in the program Enter Setpt 1 234 Display Setpt 1 234 rect OP 620 by Koyo home page optimate com OptiMate Series select message 6 for fap line select message 8 for bottom line Put BCD double from N7 54 amp N7 55 into data field select message 1 for line inifialize sefpoint from value held in N7 37 select message 3 for bottom line enable second rung copy setpoint value to disolay value enable 3rd rung disable 2nd rung copy new setpoint back fo N7 37 enable next block of logic page 22 Intelligent Peripherals for Control Using a Menu Tree The OP 620 allows you to predefine and use a layered menu tree for function selection The operation of this menu tree is taken care of entirely by the OP 620 terminal The only requirement that th
31. size for above 3 55 Hx5 807L e Panel Fasteners Four 6x32 threaded studs shown above on ends symmetrical about center line Weight 10 ounces 4 00 Fanel Cutout Housing Outline Colors Dark gray housing with dark gray panel Keypad keys white with dark gray letters White with user supplied label LCD Display 2 line x 20 character STN with LED backlight character size 6 20 5 5mm high x 3 2mm wide cH Electrical e Power 8 30VDC 1 8Watts Panel Mounting Dimensions 150mA 12VDC 75 24VDC Environmental e Power on surge see figure below e Enclosure NEMA 4 1 5A for 2 milliseconds maximum when properly installed e Temperature 01050 Amps 0 005 Seconds Power on Surge e Power connector Pluggable terminal block 2 position Communications RS232 and RS422 4800 to 19200 baud Compatible with major PLC protocols 15 pin female D shell connector Communications Failure Operation Should the module when not selected for configuration ever fail to communicate successfully for a period of 12 seconds the LEDs inset in the corner of the 5 buttons will all simultaneously flash at a rapid rate Direct oy Koyo OP 620 home page optimate com e Humidity 95 non condensing Message Types 160 user defined messages available e General Text message e Data display message one data value per line e Arrow adjustment data
32. the input power and carefully wipe the panel with a cloth moistened with plain water There are no internal fuses for the input power circuits so external circuit protection is needed to ensure the safety of service personnel and the safe operation of the equipment itself To comply with EU specifications the input power must be fused Use a fuse rated at twice the input current rating of the panel For example if the panel has an input current rating of 0 5 amperes use a fuse rated for 1 ampere Introduction The Purpose of this Manual Contents of the Manual Supplemental Manuals Technical Assistance Installing and Using the Example Programs This User Manual provides user information on panel installation panel configuration and programming the OP 620 The purpose of this manual is to teach programming techniques which may be applied while implementing the panels After reading the manual completely load and run the example programs which are on the supplied diskette using the directions in Appendix A Inside this manual you will learn about planning implementing and utilizing the OptiMate OP 620 panel Also included are application examples to improve the learning process and working knowledge of the OptiMate units Reference the appropriate PLC CPU User Manuals for the commands and address references required for your system If you are using a DirectLOGIC PLC product you will want to keep the
33. 1 through 160 display a particular predefined message on the display simply place that message s number in the message selection register For example lets assume that we have defined message 16 as Mary had a little and message 22 as white fleeced lamb If we wanted to put these two lines on the top and bottom lines of the display respectively we would simply need to put the number 16 in register M and 22 in register 1 If any number other than to 160 is placed in a message selection register the associated line will not change Placing Numeric Data in the Display Certain predefined messages may incorporate a numeric data field One numeric field per line is allowed This field may be either a display data field ora data entry field Messages that contain data are entered through the configuration editor with a caret symbol as a place holder for each numeric digit An example of the use of numeric data is the message widgets sold Assume that this is message 36 entered through the configuration editor Also assume that a total of 465 widgets have been sold today To display the current number of widgets sold on the bottom line of the display you would place 36 in register M 1 and 465 in register M 4 The bottom line of the display would then read widgets sold 465 Displaying Data with a Decimal Point The OP 620 panel allows you to display fixed point numbers Fixed p
34. 110 9 8 7 6 5 4 3 9 1 0 bit that you define Fora PLCDAIFE CTDL105 DL205 DL350 or MSR Mende etat A VOO 5 2 1 om negiser family the recommended memory is the registers beginning at v40601 16 15 14 13 12 11 10 9 8 7 6 5 4 3 9 1 Control Register R400 Any block of registers within the data word range can be used This will result in the following control relay association for The first seven PLC registers in the block used by the 620 the status and control registers panel are used for numeric information As such they ideally 30000 suited for general purpose data registers V2000 and V4000 area for the DL105 DL205 DL350 DL405 and R400 range for the 305 The last two registers use individual bits for control and status These registers are better suited for the control relay register range of memory The solution to this minor conflict is to define the base register address in general purpose data register memory and place a rung in your PLC program to copy the last two registers to from control relay registers The following table lists the control relay register addresses for the various PLC Direct PLCs DL130 V40600 V40617 ENTER DL230 V40600 V40617 Up arrow C42 DL240 V40600 V40617 Down
35. 1111 Menu Level Function Menu Level 2 3 Function No 1111 11111 Menu Level Function No no 1111 11111 e e Menu Level 2 3 Function No MT TTT TTT 111 1111111 Menu Level Function No no 1111 11111 no 1111 11111 Menu Level Function No B Page 21 Installing and Using the Example Programs OP 9001 Multi Panel Configurations The Termination Resistor If you are connecting more than one OptiMate panel to a single CPU this is referred to as multi panel configuration Multi panel configurations require the OP 9001 Communications Master which the CPU communicates to for obtaining data from the connected OP panels The OP 9001 Communications Master looks for an address within the range of 0 to 30 for each panel connected Each panel connected in a RS 422 link must have a unique address A more detailed description of multiple panel configuration and installation is given in the 9001 User Manual The last panel must be terminated when using a RS 422 communications link by setting DIP switch 2 to the TERM ON position Operator panels communicatiing more than 50 feet distance must use RS 422 and also be properly terminated NOTE Only the ast panel of each RS 422 link should have the termination DIP switch 2 set to the TERM position All other panels should have the DIP switch set to th
36. 620 s user Notice that both the function select FS and the menu enable ME bits are placed in the rung to ensure that a function has been selected before it determines which function the user selected After it determines that the FS and ME bits are set the function number is decoded to determine which function the user seleted To decode the function number selection register V2006 is compared with a constant number The constant number K2 etc represents the desired function Once the function number has been determined a coil is set This coil 15 used only for this particular function Rung 4 represents function 1 and rung 5 represents function 2 These rungs can be duplicated for all the function numbers within the program Later in the program a rung needs to be added for each bit that starts a function process C70 C71 etc When that particular bit has been set the program knows which function was entered and then the program can implement that function using whatever logic is necessary Two examples are described within this program Direct oy Koyo OP 620 home page optimate com OptilMate Series First Scan SPO LD OUT m V2000 LD 7 OUT V2001 C60 SET Always On SP LD 2 V2007 OUT VCO LD VC20 OUT V2010 C60 C6 a st jf FS ME C C20 V2006 KI C70 4 SET C
37. 7 6 4 Automatic function Sense Source B 5 POUR enable Fill Tank 1 SouceA L function Sdn 1 enu Enable MEG Latches the EQU B4 EQUAL 1 enable Drain Tank 1 L Menu Return bit SourceA 76 2 function BA 1 Since the process is Source B 2 complete unlatch the 2 i STR BA enable One function enable bit SouceA 175 Level function Source B 10 e e Y B3 L disasble menu by clearing the ME bit Direct oy Koyo OP 620 home page optimate com page 25 Intelligent Peripherals for Control Implementng Data Entry using a Menu Function The logic shown below is another typical example of how a setpoint function might be implemented Suppose the selection for Tank 2 Maximum Level was made From the logic on the previous page this will result in B4 3 being latched Accordingly the first rung shown below selects the appropriate setpoint message for the top line and a prompt message for the bottom line It also initializes the setpoint value for arrow adjustment The first rung disables itself and enables the second rung When the setpoint data 1s entered after the FS flag is cleared the second rung will copy the setpoint value back unlatch B3 1 to disable the function and unlatch B3 4 to re enable the menu If the menu return flag is also latched the OP 620 will return to the same point in the menu Level Load me
38. 9 2k Odd None RJ12 9600 19 2k Odd None For Allen Bradley you may connect to Channel 0 bottom serial port using DF1 in full duplex mode Additionally the Allen Bradley software allows the bottom port to a unique PLC address The Allen Bradley software default is PLC address one You must ensure the OP panel configuration address matches the PLC address you have assigned The Allen Bradley port only communicates using either 4800 or 9600 baud No other baud rates are supported between the OP panel and Allen Bradley PLC For example on Allen Bradley PLC s the serial port baud rate defaults to 1200 baud and must be changed The baud rate for channel 0 must be set to 4800 or 9600 baud to match the OP WINEDIT configuration Also the base memory area must be expanded to include the full range of registers such as N7 0 through N7 7 OTHER PLCs Regardless of which PLC brand you are implementing the communications parameters should be reviewed and properly configured Please check the appropriate manual for your PLC product to ensure proper communications port and panel type settings Page B 4
39. DirectSOFT User Manual handy while programming your system For other PLC brands you must reference their User manuals to properly program the ladder logic required to operate the OP panels For Multi Panel applications utilizing the 9001 Communications Master please refer to the OP 9001 User Manual Part Number 9001 After completely reading this manual including Appendix B Troubleshooting the OP 620 if you are not successful with implementing the OP 620 you may call PLCDirect at 800 633 0405 Monday through Friday from 9 00 A M to 6 00 P M Eastern Standard Time Our technical support group will work with you in answering your application questions If you have a comment or question about our products services or manuals which we provide please fill out and return the suggestions card included with this manual OP 620 Operator Panel The OP 620 Operator Panel is a low cost high performance man machine interface with a broad range of operator input and display capabilities The panel includes a 2 line by 20 character LCD display arrow adjustment data entry five function keys and menu tree capability OP WINEDIT configuration software allows you to predefine up to 160 messages These messages can be later selected for Intelligent Peripherals for Control OPTIMATE SERIES MODEL 620 TERMINAL CLEAR a display by your PLC program to display status variable data and allow numeric data input
40. Line Message Selection N7 2 Top Line Data NE N7 3 Top Line Data High bit location bit location 1 2 Bottom line Data High N7 6 Function Selection N7 7 Fs DAT FS F3 F1 N7 7 0 ME N7 8 0 N7 8 BD DAKMR ME F2 7 7 1 N7 8 1 F3 7 7 2 N7 8 2 F4 7 7 3 BD N7 8 3 F5 N7 7 4 DA N7 7 5 FS N7 7 6 AB 7 7 7 7 7 8 Displaying Floating Point Numbers ENTER 7 7 9 Floating point numbers can be displayed by the OP 620 This Up arrow N7 7 10 number format is a standard capability for PLC Direct DL250 Down 7 7 11 DL350 DL450 PLCs However SLC PLCs do arrow have a means of handling floating point numbers Due to the limitations of the SLC this capability will not be commonly implemented with A B PLCs 620 20 home page optimate com Intelligent Peripherals for Control Displaying Messages on the LCD Display Messages of various types can be configured via OP WINEDIT and downloaded to the OP 620 The message definitions shown in the figure above will be used in all of the examples that follow The example on the right shows a couple of messages being displayed to the LCD display The top line uses data display message 4 The data for the data field is coming from N7 54 Thebottom line is text message 8 Direct oy Koyo OptilMate Series
41. Program A 11 Demo Example Worksheet 3 49 29 0 doc deoa od oat add ro e c Gode Roa odo A 16 Example Message Worksheet A 17 Example Menu Worksheet scars quiam eee REPE dub Rey ek dus ay eee uet A 18 OP 620 Application 19 OP 620 Message Worksheet A 20 OP 620 Menu Worksheet 2 udis A 21 OP 9001 Multi Panel Configurations A 22 Appendix B Troubleshooting the OP 620 B 1 Troubleshooting the OP 620 Panel B 2 Troubleshooting 2 Panel Configuration Problems B 2 Panel to PLC Communications B 3 Allen Bradley Panel to PLC Communications Problems B 4 EU Information This product is manufactured in compliance with European Union EU Directives and carries the CE mark The following information is provided to comply with EU documentation requirement
42. Temperature Zone 3 and can be set from 1 to 2 000 Once all five parameters are setup we are ready to run the program This is done by pressing the F1 pushbutton To stop the program press F2 This is a simple program but it shows how a program can be developed for a practical application for the OP panel Follow these step by step directions to setup the parameters and run the example program 1 After starting the DirectSoft example program the initial OP panel display IS OP 620 KILN DEMO MENU Setup Start The first thing we want to do is setup the parameters so press the Menu pushbutton to get the following screen Raw Meal Control Enter Arrow Clear Page A 12 Installing and Using the Example Programs Press either of the up down arrow pushbuttons AorW to get the following Screen Temperature Control Enter Arrow Clear Notice that pressing either AW pushbutton toggles the display between these two screens These are the two main categories of setup parameters In the second line of each screen are three choices of pushbutton selections we can make at this point e Enter Press this to setup the parameter currently shown Arrow Press either AW pushbutton to toggle between the two screens Press this pushbutton to return to the initial screen Let s setup the Raw Meal Control first so press either AW pushbutton to get to that screen and press Enter The follow
43. The figure below shows programming cable connectors and wiring specifications Wiring diagrams Configuration refer to the cable connectors not the communication ports OP ACBL 1 OP 1500 shown but con nections are the same for Computer 9 Female DB9 4 not used O 9 not used 3 3 Dout 8 CTS 2 2 Din e 72 RTS 5 8 Cable Connector Step 5 Installing the Example Programs on Your Personal Computer Hard Drive safe place aMilename prj Male DB15 other OP panels 9 not used 102 not used 112 not used 12 2 not used 13 not used 14 2 not used 15 2 not used Cable Connector 1 not used 2 Dout 3 Din 4 not used 5 OV 6 not used 7 not used 8 not used It is possible to load the examples from the diskette however we recommend copying them to the hard drive in your computer and keeping the original diskette ina To install the example programs if using Windows 3 1 follow these steps 1 Call up the DOS Prompt Make a new directory on the hard drive in your computer For example if the hard drive is drive C and you are using an OP 620 panel type MD C OP 620 2 Copy all the files from the example program disk to the new directory For example if the diskette is in drive A and the hard drive is drive C type COPY A C OP 620 Page A 8 Installing and Using the Example Programs
44. age 1 Press Menu to the top line of the display Message 7 which is blank is loaded to blank the bottom line of the display The control relay C60 is set to energize the menu enable ME bit via rung 3 Rung 2 This rung is the Memory Mapping rung It should be active every scan Since it is easier to treat individual bits pushbuttons DA ME DAK etc as coils and contacts within the program a memory mapping scheme is needed to mimic the status and control registers This allows the individual bits of the status and control registers to be treated as coils and contacts The OP 620 writes data to the status register V2007 so it s data can be copied to a control relay register such as VCO V40600 Therefore the program can look at the corresponding bits within register VCO to determine if a button has been pressed DA is set etc The OP 620 reads from the control register V2010 Therefore a control relay register such as VC20 V40601 can be designated to mimic the panel s control register The corresponding bits in VC20 are updated in the PLC program then that register is mapped copied to the panel s control register The panel will read the updated control register and act accordingly Rung 3 This rung sets the menu enable ME bit This bit allows the user to enter the menu tree when the MENU button is pressed Rungs 4 and 5 Rungs 4 and 5 are used to determine which function was selected by the OP
45. age 2 Intelligent Peripherals for Control OptilMate Series dse with PLC RI Register Definition The following describes the function ofthe registers shown in the table DPTIMATE SERIES MDDEL 620 TERMINAL MENU ABORT ENTER Memory mapping is a technique that maps the memory of an OptiMate panel into the registers of the programmable controller By knowing where the data of a specific OptiMate panel is mapped this data can be moved changed or monitored using ladder logic The term PLC register is used for describing the area of memory within the programmable controller that can be used for data storage PLC registers are sometimes known as data registers or internal registers Register M When a number from 1 160 is placed in this register the predefined mes sage associated with that number will be displayed on the top line of the LCD dis play Register 1 When a number from 1 160 is placed in this register the predefined message associated with that number will be displayed on the bottom line of the LCD display Register M42 Numeric data associated with top line dis play described in more detail in following paragraphs Register M3 For long BCD or floating point data only Numeric value is the four most significant BCD digits of data for the top line MSB LSB e Register M 4 Numeric data 16 15 14 13 12 11 10 9 8 716 5 4 3 2 1
46. ameter is entered press Clear Abort to return to the following initial screen OP 620 KILN DEMO MENU Setup F1 Start To start the program press the F1 pushbutton Notice that the F1 indicator light momentarily lights and the screen quickly changes to the following KILN STARTING Press F2 to Stop The above screen only appears momentarily before changing to the following SYSTEM RUNNING Press F2 to Stop The program is now running using the parameters we preset If you wish to stop the program press F2 The program stops the F2 indicator light goes on and following screen appears KILN SYSTEM STOPPED Press F2 to Continue Press F2 to resume running the program You have now run through the entire example program Print a hardcopy of the example program and study the ladder logic to see how the program operates Hopefully this example will help you utilize the OP panel for your own applications Page A 15 Installing and Using the Example Programs KILN DEMO EXAMPLE WORKSHEET PUSHBUTTONS LAMPS DESCRIPTION OP 620Kiln Demo A M V Alternate Momentary System Fi j Start Panel OP 620 F2 Xi Sto PLC Base Register Addr OO PLC CONFIGURATION F4 go PLC Family F5 CPU Model HE Protocol PLC Address 73S RCT Lamp1 system Running PLC Timout Lamp2 System Startin Pari
47. ate function logic when a function selection is made We will use the menu tree definition shown below for our example The OP WINEDIT Editor screen shown below displays the menu structure including function associations on the lower section of the display For example if the operator selects Process 1 Automatic from the menu tree function number 5 would be placed in the function select register If Process No 2 is selected no function number is selected the terminal display will go to the next lower layer of the menu Process 2 Automatic Any menu item that has lower level menu items below it will when selected branch to the next level If the MENU button is pressed the terminal will back the menu tree up to the next higher level towards the trunk Arrow keys will step the panel through selection items on the same level of the same branch The lowest level items on any branch will be function selections NANSEN SASAS rec t OP 620 page 11 Koyo home page optimate com Intelligent Peripherals for Control A Menu Tree Example The following pages show examples using a Menu Tree They show how to determine when a function has been selected and how to decode a function number The examples also show how to implement a function with text display messages and how to implement a function containin
48. cable and that it is securely connected 2 Examine the PGM RUN DIP switch to make sure it is placed in the RUN position to load and run the ladder program You must cycle OP panel power for address switch changes to take effect Hear Panel View Opti RUN 1 ON 2 RX TX LEDs 42 PGM RUN DIP Switch Place the PGM RUN switch in the RUN position when running the program 3 Examine the communications information for the proper PLC type protocol type baud rate parity stop bit address number Use the user manual for the PLC product you are using to determine the proper settings 4 If you are using an OP cable verify cable pinout For RS422 connections use a Belden 9729 or equivalent cable 5 Check 24VDC power source and connections Direct LOGIC DirectLOGIC PLCs you are using the secondary communications port such as PLC DirectLOGIC PLC port 2 ensure the communications port address and protocol setting match Page B 3 Allen Bradley Panel to PLC Communications Problems OTHEH PLC Maintenance and Troubleshooting PLC Model Port Baud Rates Bit DL105 230 240 Top 9600 Odd 9600 19 2k Odd None 9600 Odd None Bottom 9600 19 2 DL330 DCU only 4800 9600 19 2k Odd None DL340 Bottom 4800 9600 19 2k Odd None 1 Bottom 4800 9600 19 2K DL430 440 Top Top 9600 Bottom 9600 19 2k Odd None DB25 9600 1
49. cribe the problem to the user if so desired BA Rung 13 U This rung energizes the data acknowledge bit DA DAK whenever the data available DA bit is latched by the OP 620 7 7 7 8 It will stay active until the panel sees that hasbeenset 13 At that time the panel will unlatch the DA bit which will deactivate the rung If you choose to unlatch the DA bit in this 5 manner this rung should be placed at the end of the program 14 END where it can be checked every scan Rung 14 This rung marks the end of the program rec t OP 620 page 31 Koyo home page optimate com Intelligent Peripherals for Control OptiMate Series Legending the OP 620 panel is a relatively simple process in the panel overlay Use the following along the top and bottom edges a a Pull the bezel out and over the available options for doing so Patterns are provided on the next to last sheet of this document Function Key Legend tranparency the transparency directly or print on paper and pho tocopy onto the transparency The figure below is a Legending the Function Keys that basically involves sliding a label transparency into a pocket e Remove the bezel from the panel The bezel snaps to the panel box snaps to remove Opti iMate e Create legend transparencies There are a number of gt Use the built in label making capability of the OP WINEDIT software to create labels Eit
50. ct the option BCD double when the display message is being defined your display will handle numbers between 0 and 99 999 999 The OP 620 will use data in the register pair 2 and 3 for the top line Likewise 4 and 5 are used for the bottom line The data must be in BCD format When placing a BCD double number in the display registers the first register numerically in the sequence of two registers 2 or M 4 will contain the 4 least significant digits of the number The second register in the sequence M 3 or 5 contains the data for the 4 most significant digits of the BCD double number If the data displayed on the top line of the panel is 92345678 the top line data registers will contain the following shown in BCD Hex format BCD Double Data Register 2 5678 M 3 9234 OP 620 home page optimate com OptiMate Series Displaying Floating Point Numbers The OP 620 has the capability to display Floating Point or Real numbers if you select the option Floating Point when the display message is being defined in the OP WINEDIT software Floating point numbers cag only be used with the PLC DIIeCI DL250 DL350 and the DL450 CPUs since they are only compatible CPUs that support the IEEE 32 bit floating point number format The floating point numbers are stored in the IEEE 32 bit floating point format within the PLC They always occupy 2 l6 bit r
51. d the rest for alternate The first pushbutton is the only one used for this example Press Menu Desired Level Adjust then ENTER Actual Level Entry Dane Push Menu Arrow Fixed Display Fixed Push Fl when Done Tank 1 Set Fluid Level Display Fluid Lewel Direct oy Koyo OptilMate Series The program implements the following tasks Initializing the display e Mapping the status and control registers to from con trol relay registers setting and Resetting the Menu Enable bit ME e Decoding a function number Implementing a function containing an arrow adjust message Implementing a function containing a data display mes sage e Displaying text messages e Using a function key pushbutton e Using the CLEAR ABORT button to escape from a OP 620 home page optimate com menu or function Resetting the Data Available DA bit using the Data Acknowledge DAK bit BCD ECD Intelligent Peripherals for Control Example Program Rung 1 This rung only happens on the first program scan It places the initial messages onto OP 620 s LCD display It loads message 1 Press Menu to the top line of the display Message 7 which 15 blank is loaded to blank the bottom line of the display The bit B3 3 is latched to disable the current rung and to energize the menu enable ME bit via rung 3 Rung 2 This rung sets the menu enable ME bit as l
52. display message selection data entry and function key interface The OP 620 continuously accesses these PLC registers and performs operations under ladder logic control on a real time basis PLCS are slave devices on their standard communications ports This means that a panel attached to the standard port must control the transfer of information by reading and writing the PLC registers OptiMate panels will perform this communications for most major PLC protocols Configuration for particular PLC protocols and interconnect cabling is covered in the following pages Direct oy Koyo OP 620 home page optimate com CAES i P P Sams Vu gt gt PLC Multi Panels Larger systems involving operator panels and I O can be successfully addressed using OptiMate panels These applications utilize the OP 9001 Communications Master to transfer data between the PLC and the individual OptiMate modules OptiMate panels can be located together to form custom panels or they can be distributed anywhere within 4000 feet The OP 9001 Communications Master provides a transparent interface between the PLC and a group of OptiMate panels The communication interface between modules requires only four wires System configuration is simple using OP WINEDIT software that runs on any IBM PC compatible computer This modular approach to custom applications provides a nearly limitless number of possibilities p
53. e and type in a message in the following manner Float Pt Also select floating point as the message format To display a number simply move it into either the top or bottom line data registers and load the page 4 Intelligent Peripherals for Control OptiMate Series Temperature 73 5 Float 6 32E 02 ss appropriate message number into the corresponding top orbottom line message selection register If the number 632 15 is to be displayed in message 58 it will be displayed as the following Float 6 32E 02 Numeric Data Entry Numeric data can be entered through the adjustment arrow keys To do so the message must be marked for data entry via the configuration editor Note Only one data entry message may be active at a time If data entry 15 selected simultaneously for both lines unexpected operation may Occur With the exception of floating point all of the numeric features described for data display apply to numeric data entry This includes the definition of the caret symbol place holder within the message as well as double number types Direct oy Koyo Data Entry Adjustment with the Arrow Keys A message can be set up for arrow adjustment through the OP WINEDIT software To do so define the message with a numeric field Select arrow adjustment If there are limits select and enter minimum and maximum values When the data screen is required i
54. e example programs require that you have two software packages loaded on your personal computer DirectSOFT programming software and e OP WINEDIT OptiMate Editor configuration software If you do not have these software packages obtain and install them on your personal computer using the instructions in their user manuals Once you have both programs installed on your personal computer you are ready to use the following step by step instructions for installing and using the example programs Page 2 Installing and Using the Example Programs 9 Steps to Using the Example Programs SOFT OP WINEDIT lt Pushbuttons Memory Requirements 2 Process Data Fault messages 2 Line x 20 character ENTER An external power supply should be used to power the Optimation unit The power supply must supply a voltage of 8 to 30 VDC Connect the power supply using the supplied terminal block connector The connector is keyed to prevent reversing the polarity Pin 1 is the positive connection 8 to 30VDC while pin 2 is the common OVDC or ground connection Step 1 Power Supply Connections Use 18 24 AWG conductor wire and connect the power supply to the supplied connector block as follows Connect the positive 8 to 30 VDC lead to terminal 1 and connect the common ground lead to terminal 2 Receptacle Terminal 2 1 2 Opti Mate Power Gro
55. e next step BA When the panel clears the DA bit two new messages MOVE loaded to the display Message 5 Entry Done Push Menu is source loaded to the top line of the display Message 7 a blank Dest 70 message is loaded to the bottom line of the display Next B3 4 is unlatched to re enable the menu enable ME bit via rung 2 MOV Finally B4 4 is unlatched to disable the current rung MOVE After this rung is completed the OP 620 will display the Souce 7 Entry Done Push Menu message until the menu button is pressed Des N7 l The DA bit can be cleared two different ways One is to replace the data entry message with another message the other B3 is to energize the data acknowledge DAK bit N7 8 2 In this U example the latter was chosen Rung 13 explains that process 4 in more detail U 4 The program is continued on the next page 620 29 home page optimate com Intelligent Peripherals for Control Example Program Continued from previous page Rung 9 This rung is the first rung in the logic for function 2 defined in the menu tree as Display Fluid Level When 4 1 15 enabled and B4 5 is not the function begins The fourth predefined message Actual Level is loaded into the top line N7 0 of the display since message 2 15 a data display message the initial display value has to be
56. e off left position After changing the DIP switch settings remember to cycle power on panel to activate the new switch settings Page 22 Appendix B Troubleshooting the OP 620 In This Chapter Troubleshooting Panel Configuration Problems Panel to PLC Communications A B Panel to PLC Communications Maintenance and Troubleshooting Troubleshooting the OP 620 Panel Troubleshooting In this section we explain how to isolate potential problems which may occur while using the OP 620 If you are unable to troubleshoot and correct your problem using these procedures please contact our technical product support team between the hours of 9 00 AM and 6 00 PM EST Monday through Friday Call 1 800 633 0405 or fax 770 889 7876 We have organized the troubleshooting section into two categories e Panel configuration problems e Panel and PLC communications failures Panel Configuration We explained in previous sections that the OP WINEDIT configuration software is Problems used to create OP panel applications and to download and upload your OP panel programs If you are online with the panel and communications fails the following error message is displayed Could not communicate with panel OP WINEDIT If this occurs check the following in the order given 1 Check the rear panel RX TX LEDs while attempting the Upload or Down load operation Both LEDs should be giving slow alternating flash signals
57. e user has is to enable or disable the menu operation and branch to the appropriate function logic when a function selection is made We will use the menu tree definition shown below for our example The OP WINEDIT Configuration Editor screen shown below displays the menu structure including function associations in the lower section of the display For example if Direct oy Koyo OP 620 home page optimate com OptilMate Series the operator selects Process 1 Automatic from the menu tree function number 5 would be placed in the function select register If Manual is selected no function number is selected the terminal display will go to the next lower layer of the menu Tank 1 Any menu item that has lower level menu items below it will when selected branch to the next level Ifthe MENU button 15 pressed the terminal will back the menu tree up to the next higher level towards the trunk Arrow keys will step the panel through selection items on the same level of the same branch The lowest level items on any branch will be function selections 23 Intelligent Peripherals for Control A Menu Tree Example The following pages show examples using a Menu Tree They show how to determine when a function has been selected and how to decode a function number The examples also show how to implem
58. eared two different ways One is to replace the data entry message with another message the other is to set the data acknowledge DAK bit C22 In this example the latter was chosen Rung 14 explains that process in more detail The program is continued on the next page Direct Function 1 fg OptilMate Series LD FS 2 OUT mE V2000 V2210 OUT 2002 OUT P V2001 C70 rst LD V2002 OUT nul V2210 C101 C100 RST LD OP 620 by Koyo home page optimate com K5 OUT Ban V2000 OUT 2001 C61 RST RST 17 Intelligent Peripherals for Control OptilMate Series Example Program Function 2 Continued from previous page C71 C102 10 Rung 10 This rung is the first rung in the logic for function 2 defined in the menu tree as Display Fluid Level When C71 is enabled and C102 is not the function begins The fourth predefined message Actual Level is loaded into the top line V2000 of the display Since message 2 is a data display message the initial display value has to be loaded into the top line data register V2002 In this case the initial value which is stored in V2211 is copied from V2211 to V2002 Next message 6 Push when is
59. ected through M 8 Control register use of the menu tree OP 620 home page optimate com Control Register gt ME Menu Enable Must be set for menu op eration to be enabled Normally your control program would clear this bit when a function is in process gt MR Menu Return Used at the end of a func tion If set will cause the menu to return to the same point in the menu tree as when the function started If not set func tion complete will not re turn directly into menu gt DAK Data acknowl edge This bit is used for repeat data entry into the same message Setting to 1 acknowledges data en tered from the keyboard as accepted by the PLC program The 620 Termi nal will unlock the data on the screen message clear the DA bit and al low new data entry This bit must be cleared after DA status register is cleared gt BD Buzzer disable When this bit is set to 1 the buzzer that beeps every time a button is pressed will be disabled i e not beep page 3 Operational Overview Displaying Messages on the LCD Display Through the OP WINEDIT configuration software up to 160 predefined messages can be entered and stored in the OP 620 These messages are 20 characters long and can include a field for the display and or entry of numeric data Any predefined message can be displayed on either the top or bottom line The messages entered via the configuration editor are numbered
60. egister locations regardless of the size of the number Refer to the PLC manufacturer s programming documentation for more information on the IEEE 32 bit floating point number format An IEEE 32 bit floating point number has a range of 3 402823E 38 to 3 402823E 38 The OP 620 will be able to display any number within that range The panel always uses the format TX XXE XX to display the numbers The panel does not have the ability to display all the significant digits of a floating point number it only displays the first 3 significant digits The OP 620 does not round the numbers up or down instead it truncates the remaining digits The two examples in the table below show the data contained in the PLC registers and the value displayed on the panel in its format Notice how the data 15 truncated not rounded Registers 12301 789 123 96783 OP 620 Display 1 23 04 1 23 02 The configuration of a floating point number message is similar to any other message First you select the message number then you type in the text using 9 caret symbols as a place holder for each of the 9 floating point number symbols Next select the Floating Point option for the data format Suppose you wanted to configure message 58 to display a floating point number In the OP WINEDIT software vou would select OP 620 as module type Then to configure message 58 simply select it with the mous
61. ent PLCs as well as to IBM PCAT compatible ports are available Serial Connection to OP 9001 Communications Master Connection to an OP 9001 Communications Master over a serial link is via RS422 The Communication Master port connections are reversed from the panel ports to enable direct pin to pin connection For distances under 50 feet in a low electrical noise environment a ribbon cable connection works quite well Forlonger distances or in noisy environments a two pair shielded RS422 cable is recommended We recommend Belden 9729 or equivalent cable Termination The termination DIP switch on the back ofthe panel switches in a terminating resistor This terminating resistor does not apply to an RS232 connection and should be in the OFF position for RS232 In an RS422 connected system such as with the OP 9001 Communication Master the termination switch should be on in the last and only the last panel on the cable Run Direct oy Koyo OP 620 home page optimate com Power OptiMate modules can operate on any voltage between 8 and 30 VDC Power must be connected to the terminal plug located on the back of the module There is a brief 0 5 to 2 millisecond power on surge to 1 5 amps This is typical of nearly any type of electronic equipment and is due to the initial charging of power capacitors This surge is not normally a problem for a commercial power supply For multi panel systems using multiple
62. ent a function with text display messages and how to implement a function containing arrow adjustment of a setpoint The base register address forthe following examples is N7 0 The examples use the messages and the menu tree shown in the figure below 15 Tank Draining Please Wait T2 Max Level Arrow Fixed Adjust then ENTER Direct oy Koyo Process 1 Manual Tank 1 Drain Tank 1 Process 2 E Process 2 Automatic Process 2 Manual Tank 2 Maximum Level OP 620 home page optimate com OptiMate Series page 24 Intelligent Peripherals for Control Decoding a Function Number The program below illustrates menu tree function selection using the menu tree shown on the previous page The first rung enables the menu tree when B3 3 is active Note Enabling the menu tree does not automatically put the terminal into the menu Once enabled the terminal will bring up the menu tree when the operator presses MENU Until then the display is under PLC program control The second rung sets the appropriate function enable bit when a selection is selected from the OP 620 Function selection will activate the FS flag N7 7 6 The value comparison to the value held in the function register will latch the appropriate enable relay B4 0 B4 1 etc The last rung shown will also disable the Menu Enable ME bit by latching B3 4 Note that the logic shown
63. er cable choice really depends on your application we offer the following connectors OP CMCON 1 pack of 4 ribbon cable connectors 2 pack of 4 solder type connectors OP CMCON 3 pack of 2 D shell connectors with screw terminals for use with OP 9001 amp multiple OP panels e OP PSCON pack of 4 power supply block connectors For electrically noisy environments we recommend an individually paired and shielded cable such as Belden 9729 or equivalent This type of cable requires the solder type or D shell with screw terminal connectors For distance of 30 feet or less you can use ribbon cable For ribbon cable we recommend Belden 9L28015 or 3M 3365 15 7 requires RS232 Data Communications Unit D3 232 DCU MicroLogix also DC versions Installing and Using the Example Programs DirectLOGIC DL105 DirectLOGIC DL205 Only port OP 2CBL Only port OP 2CBL DL240 Top port OP 2CBL Bottom port OP 2CBL DL230 02 module Only port OP 4CBL 2 DL330P Requires Dcu 2 DL340 oes Bottom port OP ACBL 2 Requires DCU OP ACBL 2 RS232 RS422 OP GCBL 1 Serial Port RS232 5422 OP GCBL 1 Serial Port DL350 DirectLOGIC DL405 DL430 DL440 D4 DCM module Slice I O panels GE Series 1 IC610CPU105 106 GE Series 90 30 All Models 311 351 GE
64. er layers The graphic below is an example of a typical menu tree Process Part type 1 Process Part type 2 Manual Control Tum Pump On Tum Pump Off Tum Heater On Tum Heater Off Tum Mixer On Tum Mixer Off Setpoint Entry Tank Level Setooints set Minimum Level set Maximum Level set Low Alarm Level set High Alarm Level Temperature Settings Temperature Setpoint set Low Alarm Temp set High Alarm Temp Sample Menu Tree Direct oy Koyo Intelligent Peripherals for Control The example shown has three menu layers The top level has four selections If the ENTER key is pressed while a function Process Part Type 1 is displayed the associated function number will be writento X 6 and the FS flag will be set within the PLC The top level menu selection Manual Control is a sub menu If it is selected via the ENTER key the second menu level will appear In this case each item on the second level is a function If selected each will place it s function number in X 6 and also set the FS flag The Setpoint Entry selection from the top level menu will bring up a second level menu of two items Each second level item will in turn bring up another level The items at the bottom level will perform actual function selections In this branch the items on the first and second levels are sub menu items the items on the third level are functions When a function is selected through the menu tree the PLC program sh
65. g after the file name These are all configuration programs Select the configuration program for the OP panel and PLC you are using For example if you are using an OP 620 panel with a DL205 PLC select and open the file titled 620 205 ocf A screen appears having all the configuration parameters for running the example program using an OP 620 with a DL205 PLC Make sure your OP ACBL 1 cable is connected between your personal computer and the OP panel that the DIP switch slides are set to ON and that the OP panel power supply is on Select Configure Panel When the next window appears select Write to Panel This loads the program into the OP panel After the program is loaded close the open windows and select Exit Software This closes out the OP WINEDIT software The OP panel is now configured and the OP ACBL 1 cable can be disconnected Page A 9 Installing and Using the Example Programs Step 7 Setting the To run the example programs set the RUN PRG DIP switch to RUN OP Panel PRG RUN DIP Switch to RUN NOTE You must cycle power to the panel turn power off set DIP switch and turn power back on to activate new switch settings Set to RUN RUN 1 m En PGM Step 8 Loading the The next step is to load the DirectSOFT example program into the PLC as follows DirectSOFT Example Program 1 into the PLC Connect the communications cable from your personal computer
66. g arrow adjustment of a setpoint The base register address for the following examples is V2000 The examples use the messages and the menu tree shown in the figure below Tank Draining Please Wait e I2 Max Level Arrow Fixed Adjust then ENTER Process 1 Manual Fill Tank 1 E Drain Tank 1 Process 2 3 Process 2 Automatic Process 2 Manual Tank 2 Maximum Level rect OP 620 by Koyo home page optimate com OptiMate Series page 12 Intelligent Peripherals for Control Decoding a Function Number The program shown below illustrates menu tree function selection using the menu tree shown on the previous page The first rung enables the menu tree when C60 is active Note Enabling the menu tree does not automatically put the terminalinto the menu Once enabled the terminal will bring up the menu tree when the operator presses MENU Until then the display is under PLC program control The second rung sets the appropriate function enable bit when a selection is selected from the OP 620 Function selection will activate the FS flag which based on our register copy shownearlier will be C6 The value held inthe function register V2006 M 6 is compared to a constant value When one of the comparisons becomes true that rung will set the appropriate enable relay C70 C71 etc The last rung shown will disable the Menu Enable ME bit by setting C61 U
67. he middle of a function and they realize that they need to exit without making any changes then they can use the CLEAR ABORT button for that purpose If the panel is in the menu tree when the CLEAR ABORT button is pressed the panel will exit the menu and default back to the messages that are in the top and bottom line message registers If the user is in a function this rung can be used to reset different bits within the program that pertain to any given function which could be active at the time C70 C71 C100 etc This rung can also be OR d with other conditions such as machine jams emergency conditions etc that might warrant exiting the menu by clearing the menu enable bit or disabling a function Messages can also be loaded to the display to describe the problem to the user if so desired Rung 14 This rung sets the data acknowledge DAK bit whenever the data available DA bit is set by the OP 620 It will stay active until the panel sees that the DAK has been set At that time the panel will reset the DA bit which will deactivate the rung If you choose to reset the DA bit inthis manner this rung should be placed at the end of the program where it can be checked every scan Rung 15 This rung marks the end of the program 13 14 15 OptilMate Series C61 9 RST C70 RST C71 RST C100 RST C101 RST C102 RST NET ON NN DAK C22
68. her print on screen from OP WINEDIT which illustrates the process 4 Previous Loop Other options include the following gt Uses a computer graphics program and a laser printer to create the transparency directly Alter nately print on paper and photocopy to a transpar ency gt Use press on letters onto a transparency sheet gt Usea typewriter lettering machine or press on let ters to letter onto paper then photocopy e Cutalong outline Slide into overlay pocket Pushbut ton legends slide in from the bottom e Re attach bezel Push bezel onto box until it snaps to gether rec t OP 620 page 32 by Koyo home page optimate com Intelligent Peripherals for Control Connection to the System OptiMate panels are designed for communication connection to system devices The panel can be connected to a computer PLC or communication master over the serial port RS232 or RS422 Connection to a Computer or PLC Connection of an OptiMate panel to a computer or PLC can be accomplished over either an RS 232 or RS422 link RS232 is limited to one OptiMate module to one computer serial port RS422 allows up to 31 modules to be connected to one computer port Since PLCs are slave devices RS422 link for a PLC is limited to one OptiMate module Refer to manufacturer s documentation for PLC or computer serial link connector pinouts Interface cables for connection to several differ
69. hich enables the next rung A rung of this type which loads arrow adjustment messages should only execute one time within the function therefore C70 is reset to disable the current rung Rung 8 When the user is finished entering the data the user will press the ENTER key as prompted by the bottom line message The OP 620 will set the data available DA bit C5 When the DA bit is set rung 8 will copy the newly entered data from the top line data register V2002 to the data s storage register 22 10 Next the program sets C101 to enable the next rung and resets C100 to disable the current rung Notice that the function select FS bit C6 is in series with C100 and the DA bit This ensures that the panel has cleared the function select flag before allowing the program to accept the new data Rung 9 Rung 9 completes function 1 It waits until the OP 620 clears the data available DA bit C5 before prompting the user for the next step When the panel clears the DA bit two new messages are loaded to the display Message 5 Entry Done Push Menu is loaded to the top line of the display Message 7 a blank message is loaded to the bottom line of the display Next C61 is reset to re enable the menu enable ME bit via rung 3 Finally C101 is reset to disable the current rung After this rung is completed the OP 620 will display the Entry Done Push Menu message until the menu button is pressed The DA bit can be cl
70. icrosoft Corporation OPTOMUX and PAMUX are trademarks of OPTO 22 Copyright 1998 PLC Direct Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of PLC Direct Incorporated PLC Direct retains the exclusive rights to all information included in this document Manual Revisions If you contact us in reference to this manual be sure and include the revision number Title 620 Operator Panel User Manual Manual Number 620 Original 8 97 Cover Copyright Original Issue Contents Rev 6 98 Made minor revisions before reprinting Table of Contents OP 620 Operator Fane Introduction 22 0 a gg PeP m Configuration RE E PLC Stand Alone oc iu eua mater dut 04 e wk PLC RUPEE Use With A PLC Memory Mappi
71. ing screen appears Hopper Selection Enter Arrow Clear Press Enter The following screen appears Meal Hopper 1 3 2 Arrow UP DOWN 1 Select Hopper 1 2 or 3 by using the AW pushbuttons and pressing Enter For example the 2 on the top line indicates that Hopper 2 is currently selected If we wish to change our selection to Hopper 1 press AW pushbuttons until a 1 is displayed on the bottom line and press Enter A 1 replaces the 2 on the top line and the display returns to the previous Hopper Selection screen Pressing Clear Abort cancels any changes made and returns the display to the initial screen Next we need to set the kiln speed With the Hopper Selection screen displayed press AW pushbuttons to get the following screen Kiln Speed Control Enter Arrow Clear Page A 13 Installing and Using the Example Programs 4 Press Enter The following screen appears Kiln Speed 25 New Kiln Speed 50 Select kiln speed by using the AW pushbuttons and pressing Enter For example the 25 onthe top line indicates that a speed of 2596 of maximum speed is currently selected If we wish to change our selection to 50 of maximum speed press the pushbutton until a 50 is displayed on the bottom line and press Enter A 50 replaces the 25 onthe top line and the display returns to the previous Kiln Speed Control screen Both Raw Meal Control parameters are now set
72. loaded into the top line data register N7 2 In this case the initial value which is stored in N7 21 is copied from N7 21 to N7 2 Next message 6 Push when is loaded into the bottom line N7 1 of the display Then B4 5 is latched to enable the next rung Last B4 1 is unlatched to disable the current rung Rung 10 Rung 10 updates the data field of the display message on the top line The OP 620 s user can view the data as it changes within N7 21 As long as this rung is active the top line data register N7 2 will be updated with the current data stored in 7 21 Rung 11 Message 6 on the bottom line prompts the user to Push F1 when Done When the OP 620 s user wishes to stop viewing the data they should press the first pushbutton F1 This will complete function 2 When F1 a momentary action button is pressed a new set of messages are loaded into the display registers Message Press Menu is loaded into the top line and message 7 a blank message is loaded into the bottom line of the display Next B3 4 is unlatched to re enable the menu enable ME bit via rung 2 Finally B4 5 is unlatched to disable the current and previous rungs After this rung is completed the OP 620 will display the Press Menu message until the menu button is pressed The program is continued on the next page Direct OP 620 OptilMate Series
73. n the program place the number of the preconfigured message in the selection register and its current value in the associated data register The digits marked by carets will initially display the current value As the operator presses the up or down arrow key the numeric value will increment or decrement respectively As it 1s adjusted the value will be continuously updated in the PLC data register When adjustment is complete the operator will press the ENTER button When this happens the data available DA status bit will be set The DA bit will remain set until a new message number is placed in the message selection register M or 1 or the DAK bit is set Adjustment of data will be limited to within the limits defined through the configuration editor Data also will be limited to the number of digits defined by carets in the message OP 620 home page optimate com Example of Arrow Adjustment of Numeric Data Suppose that your automatic banana peeler has a peel rate that can be adjusted between 1 and 50 bananas per second With the configuration editor you define message 15 as Set Peel Rate You would also select arrow adjustment and range limits of 10 to 500 in tenths When this message is used vour PLC program would put 15 in register M or M 1 and the current peel rate value in 2 M 4 If the current peel rate was 5 7 bananas per second the display would read Set Peel Rate 5 7
74. nd Running through the following section Running The OP 620 Example Program while at the the Program same time doing the setup and actually running the program on your OP panel It would be helpful to print a hardcopy of the example program and study the ladder logic to see how the program operates In addition see the Kiln Demo Worksheets at the end of this chapter to help understand the program There are also blank worksheets to use for your own applications Page A 10 Running the OP 620 Example Program Installing and Using the Example Programs In this example program a Cement Kiln System is used to demonstrate the ladder logic required to support the various OP panel features The program provides ladder logic which demonstrates controlling pushbuttons lamps messages and menu operations Items listed in the figure below such as Hopper Selection Kiln Speed Start Stop Run controls and Kiln Zone Temperatures are monitored and controlled by the OP panel example program a HopperSelected 1 3 H Speed 0 10096 opper opper opper lt Conveyor Flow There are two parts to the program 1 Using the MENU function to enter the setup parameters and 2 Starting and stopping the program We will discuss setup first Use your imagination to picture the operation of the kiln system shown The first thing we must do is the program setu
75. ng arr rcr Register Definition CNET TIT Operational Overview ee eee ees Displaying Messages on the LCD Display Placing Numeric Data In the 2 ike mita rm Rn Eo nao Rm Displaying Data with a Decimal Point ence un ae Displaying Fixed Point Numbers uae iode ar eor ed ects ede ku EH met Pre dd os Displaying BCD and Binary Numbers Displaying Double Numbers vuoto choles shew diuo sd ru e Iq SIRE RE Displaying Floating Point Numbers Numeric Data Entry uus sae dace dk es dc d do ao xc CO SEED A jn RC e Data Entry Adjustment with the Arrow Example of Arrow Adjustment of Numeric Data Function Buttons A RMPTL rc n Menu Tree Operation se uuu wane ware CONTOU ON AS e Examples of Use with Register Usage Using F ncton BUON ER IRE we Displaying Messages on the LCD Display
76. ns concerning the installation or operation of this equipment or if you need additional information please call us at 1 800 633 0405 This publication is based on information that was available at the time it was printed At PLC Direct we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product Trademarks This publication may contain references to products produced and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners PLC Direct disclaims any proprietary interest in the marks and names of others Stage is a trademark of Koyo Electronics Industries Co LTD Texas Instruments is a registered trademark of Texas Instruments Inc TIWAY Series 305 Series 405 TI305 and T1405 are trademarks of Texas Instruments Inc Siemens and SIMATIC are registered trademarks of Siemens AG GE is a registered trademark of General Electric Corporation Series One is a registered trademark of GE Fanuc Automation North America Inc MODBUS is a registered trademark of Gould Inc IBM is a registered trademark of International Business Machines MS DOS and Microsoft are registered trademarks of Microsoft Corporation Windows is a trademark of M
77. ntil the ME bit is reset the Menu may appear to lock up when a function is selected Note that the logic shown interlocks the function number comparison setting C70 C71 etc with the function select and menu enable flags to ensure that only one function is enabled each time a function is selected Implementing a Menu Function The program logic shown below illustrates how a typical function might be implemented Suppose the selection was made by the operator to Drain Tank 1 According to the logic just shown this would result in control relay C72 being set The first rung of the Drain Tank 1 function shown below will put messages into the top and bottom lines of the display The second rung energizes output Y 4 to open the drain until level sensor input X3 senses that it is empty The third rung re enables the menu and sets it to return back to the Drain Tank 1 selection via the MR menu return bit when the tank is empty The third rung also disables the function By putting the function select relay C6 in series we force the program to wait until the function select has been cleared before re enabling the menu C72 Tank Draining Load message 15 to the top line message register Please Wait C60 ME C20 enable menu by Load message 16 1 OUT setting ME bif to the bottom line message register 59 055 enable Process 1 C72 X3 H SET Automatic function t 4 YA C
78. of the examples that follow The following example shows a couple of messages being displayed to the LCD display The top line uses data display message 4 The data for the data field 15 coming from V3000 The bottom line is text message 8 Select mossage 4 to top line Select message 8 to bottom line Put data bees from V3000 into line data fleid rect OP 620 by Koyo home page optimate com OptiMate Series Process Step TIT V2000 V2001 V2002 V2003 V2004 V2005 V2006 V2007 V2010 Top line message selection Bottom line message selection Top line data Top line data 2 for long BCD Bottom line data Bottom line data 2 for long BCD Function Selection Status register Control register page 8 Intelligent Peripherals for Control Displaying long BCD Numbers The example shown on the right is similar to the last example The primary difference is that it uses a BCD double number in the top line display The top line uses data display message 6 which has been configured as a BCD double display The data for the data field is coming from V3002 amp V3003 The bottom line is text message 8 Count Val 75490213 Process Step 1 Displaying Floating Point Numbers The example shown on the right is similar to the previous example The primary difference is that it displays a floating point number The bottom line uses data display message 7
79. oint numbers are numeric values that have a known decimal point placement and are Direct oy Koyo Intelligent Peripherals for Control simply handled as integer values within the PLC program The only time you use an actual decimal point is for display to the operator An example of a fixed point number is a program that uses temperature as a control variable Within the program all temperatures are scaled in tenths of a degree The values are integer temperature of 73 5 degrees would be 735 in a data register For the convenience of the operator you would want the display to include the decimal Displaying Fixed Point Numbers Fixed point numbers are handled by simply placing a decimal point or period in the message field during configuration In other words the message Temperature would be entered during configuration say message 47 If 47 were placed in register M and the value 735 in register M42 the display would read Temperature 73 5 onthe top line Displaying BCD and Binary Numbers Normally numeric values to be displayed are values contained in one 16 bit register One 16 bit register will handle values between 0 and 65535 in binary format or 0 to 9999 Gn BCD format For these type numbers register M 2 is used for numeric value for the top line and register M 4 is used for the bottom line Displaying Double Numbers The OP 620 will handle larger numeric numbers If you sele
80. ong as B3 3 15 latched and B3 4 is not The ME bit allows the user to enter the menu tree when the MENU button is pressed Rungs 3 and 4 Rungs 3 and 4 are used to determine which function was selected by the OP 620 s user Notice that both the function select FS and the menu enable ME bits are placed in the rung to ensure that a function has been selected before it determines which function the user selected After it determines that the FS and ME bits are set the function number is decoded to determine which function the user selected To decode the function number selection register N7 6 is compared with a constant number The constant number 1 2 etc represents the desired function Once the function number has been determined a coil is latched This coil is used only for this particular function Rung 3 represents function and rung 4 represents function 2 These rungs should be duplicated for all the function numbers within the program Later in the program a rung needs to be added for each bit that starts a function process B4 0 4 1 etc When that particular bit has been latched the program knows which function was entered and then the program can implement that function using whatever logic is necessary Two examples are described within this program Rung 5 This rung disables the menu enable ME bit via B3 4 It checks for the function select FS bit When the FS bit is set the program knows
81. ould start the function process Once a function is selected the menu selection is locked The OP 620 will be locked up until the PLC program decodes the function number and clears the ME flag Once the ME flag is cleared the panel will return the LCD display to the control of your program Once you have completed vour function you may return to the same point in the menu by setting ME and MR To require the user to start the menu selection process from the beginning don t set MR only set ME The menu enable is totally under PLC program control If ME is set the menu operationis enabled Iffor any reason you need to take control of the display back from the menu just clear the ME bit The panel will leave the menu tree and display the message numbers in X and 1 Each menu tree message takes up one of the 160 available total messages OP 620 home page optimate com OptilMate Series Configuration Configuration of the OP 620 Terminal or system of OptiMate modules is performed via an IBM PC compatible computer with the Windows operating system Optimation supplies OP WINEDIT software that will allow you to select module configuration system configuration and PLC protocol definition If the OP 620 15 to be operated stand alone with a PLC the configuration selection must be made to select the proper PLC protocol information If it is part of a multi panel system each panel must be configured under the m
82. p There are two main categories of setup parameters Raw Meal Control and Temperature Control We will discuss Raw Meal Control first There are two parameters which must be setup for Raw Meal Control e Hopper Selection This parameter selects which hopper is going to provide the material for the kiln system The choices are Hopper 1 Hopper 2 or Hopper 3 e Speed This parameter selects the speed that the material will travel through the kiln system The speed is specified as a percentage of the maximum possible speed and can be set for any speed between 1 lowest speed and 100 highest speed Page A 11 Installing and Using the Example Programs 2 Line x 20 character CLEAR Opti Mare Indicator Light F1 F2 F4 F5 There are three parameters which must be setup for Temperature Control e Setpoint Zone1 Temp This parameter selects the temperature that the material will be exposed to while traveling through Temperature Zone 1 The temperature can be set to any setting from 1 to 2 000 with 1 being the lowest temperature setting and 2 000 being the highest e Setpoint Zone2 Temp This parameter selects the temperature that the material will be exposed to while traveling through Temperature Zone 2 and can be set from 1 to 2 000 e Setpoint Zone3 Temp This parameter selects the temperature that the material will be exposed to while traveling through
83. play Since message 2 is an arrow adjust message the initial starting point for the adjustment has to be MOV loaded into the top line data register N7 2 In this case the data MOVE which is stored in N7 20 is copied from N7 20 to N7 2 Source 3 Next message 3 Adjust then ENTER is loaded into the bottom line N7 1 of the display Then B4 3 is latched which Des N7Z l enables the next rung A rung of this type which loads arrow adjustment messages should only execute one time within the B4 function therefore B4 0 is unlatched to disable the current L rung TE Rung 7 U When the user is finished entering the data the user will DA FS press the ENTER key as prompted by the bottom line message 84 N77 N77 The OP 620 will set the data available DA bit N7 7 5 When the DA bit is set rung 7 will copy the newly entered data from the top line data register N7 2 to data s storage register Dest 7 20 N7 20 Next the program latches B4 4 to enable the next rung and unlatches B4 3 to disable the current rung BA Notice that the function select FS bit N7 7 6 is in series L with B4 3 and DA bit This ensures that the panel has 4 cleared the function select flag before allowing the program to Ee accept the new data U Rung 8 Rung 8 completes function 1 It waits until the OP 620 clears the data available DA bit N7 7 5 before prompting the user for th
84. power supplies we recommend tying the DC commons grounds together for each separate power supply This will ensure that the voltage differential of each power supply DC ground will be at the same level 12 822 The OptilMate Series page 33 Intelligent Peripherals for Control OptilMate Series Configuration Configuration Selections OptiMate panels can be configured for the specific application by using the OP WINEDIT Configuration Editor The OP WINEDIT Editor runs on any IBM PC compatible computer with Windows It allows the user to select the exact functionality to meet application requirements For the OP 620 module the following are important configuration parameters Single Module PLC Based Systems Decision selection Single Multi Choose single panel configuration Module Configuration starting point First time configuration start with defaults for the panel Subsequent configurations can utilize disk files you create PLC Type select appropriate PLC type Protocol select appropriate baud rate data bits stop bits amp parity Note that if 8 data bits and even or odd parity selected only 1 stop bit is available Buttons Select momentary or alternate action as required for your application Messages Define messages as required for application Direct oy Koyo OP 620 home page optimate com Multi Module PLC Applications Uses Communications Master
85. s Technical Support SELV Circuits Environmental Specifications Preventative Maintenance and Cleaning External Fuse Protection for Input Power NOTE Products with CE marks perform theirrequired functions safely and adhere to relevant standards as specified by EC directives provided they are used according to their intended purpose and that the instructions in this manual are adhered to The protection provided by the equipment may be impaired if this equipmentis used in a manner notspecified in this manual Only replacement parts supplied by PLCDirectorits agents should be used A listing of international affiliates is available at our Web site http www plcdirect com If you need technical assistance please call the technical support group at PLCDirect 3505 Hutchinson Rd Cumming GA 30040 U S A at800 633 0405 They are available Monday through Friday from 9 00 A M to 6 00 P M Eastern Standard Time Their Web Site address is http www plcdirect com All electrical circuits connected to the communications port receptacle are rated as Safety Extra Low Voltage SELV Operating 0 to 50 C Storage Temperature 20 to 70 C Operating Humidity 95 non condensing Air COMPOSITION No corrosive gases permitted No preventative maintenance is required To clean the exterior of the panel disconnect
86. s __ 0 Lamp1 PLC Timout Baud Rate Lamp2 Parity ___ Data Stop gt gt lt gt Lamp3 MESSAGE Text Message m T 2 ction ata Type Format Data Type Format Action Data Type Format Action Data Type Format Data Type Format Action Data Type Format Hange Data Type Format Data Type Format Action Data Type Format Data Type Format Page A 19 Installing and Using the Example Programs OP 620 MESSAGE WORKSHEET PAGE MESSAGE Text Message E70 Action Data Type Format Range Data Type Format Data Type Format Data Type Format Action Data Type Format Range Data Type Format Data Type Format No Data Type Format ange 2 JH L E 2 a ction ata Type Format Data Type Format Data Type Format Action Data Type Format Data Type Format Data Type Format Action Data Type Format Range Action Data Type Format Page A 20 Installing and Using the Example Programs OP 620 MENU WORKSHEET MENU Text Message no 111 1111111 Menu Level 11213 Function No no 11 11111 Menu Level Function e vara teva 4 vera toval T 2 o _ e Menu Level 2 3 Function No no 11 1111
87. s only a single sub menu message The second menu level contains two messages both of which are functions The OP 620 configuration for this example is shown in the figure below The base register address is V2000 The first pushbutton F1 is configured for momentary action and the rest for alternate The first pushbutton is the only one used for this example 1 Press Menu 2 Desired Level 3 Adjust then ENTER 4 Actual Level 5 B Arrow Fixed Display Fixed Entry Dane Push Menu Push Fl when Dane 7 Tank 1 Set Fluid Level Display Fluid Lewel Direct oy Koyo OptilMate Series The program implements the following tasks Initializing the display e Mapping the status and control registers to from con trol relay registers setting and Resetting the Menu Enable bit ME e Decoding a function number Implementing a function containing an arrow adjust message Implementing a function containing a data display mes sage e Displaying text messages e Using a function key pushbutton e Using the CLEAR ABORT button to escape from a OP 620 home page optimate com menu or function Resetting the Data Available DA bit using the Data Acknowledge DAK bit BCD ECD Intelligent Peripherals for Control Example Program Rung 1 This rung only happens on the first program scan It places the initial messages onto OP 620 s LCD display It loads mess
88. ssage 15 to the top line message register register to top line data register Adjust then ENTER Load message 16 to the bottom line message register Disable current rung and enable next rung DA FS 7 7 N7 7 Initial value for arrow adjust message Copied from T2 Max Level holding OptiMate Series Direct 1 DA 7 7 When data entry complete DA bit set copy new value from top line data register to holding register for T2 Max Level Disable current rung Energize the ME bit to Re Enable the Menu Since function 15 complete clear the bit that enabled the function Set Data Acknowledge DAK OP 620 page 26 home page optimate com Intelligent Peripherals for Control Example Program using an OP 620 The example program shown in the following 4 pages describes how to implement a program using an OP 620 The program uses the menu tree an arrow adjust message a data display message and text messages Itisacomplete program which will run on an Allen Bradley SLC 5 03 SLC 5 04 or Micrologix PLC The program uses a two level deep menu tree with two menu functions The first menu level contains only a single sub menu message The second menu level contains two messages both of which are functions The OP 620 configuration for this example is shown in the figure below The base register address is N7 0 The first pushbutton F1 is configured for momentary action an
89. that a function has been selected If the function number has been decoded correctly as shown in the previous two rungs then the panel should exit the menu so the program can implement the function The only way to leave the menu is to disable the ME bit If the ME bit is not disabled after a function 1s selected the OP 620 s display will lock up When the ME bit is reset the panel will leave the menu mode and the display will return to PLC program control The program is continued on the next page Direct oy Koyo OptilMate Series OP 620 home page optimate com B3 MOV MOVE 3 Source Dest 7 0 MOVE Source 7 Dest 7 1 B3 L 3 S N78 3 4 FS ME EQU Source A L 6 0 ouceB N7 6 FS ME EQU Source 2 6 Bi Ie ourceB N7 6 FS id B3 L 6 4 page 28 Intelligent Peripherals for Control OptilMate Series Example Program a 1 MOV Continued from previous page MOVE B Source 2 Rung 6 Desi N7 O This rung is the first rung in the logic for function 1 defined in the menu tree as Set Fluid Level When B4 0 is enabled MOVE and B4 3 is not the function begins The second predefined Source N7 20 message Desired Level is loaded into the top line Dest N7 2 N7 0 of the dis
90. ty Data Stop Bits o Lamp3 _System Stopped MESSAGE Text e T RE GPEC EPC EEL Action N A Data Type Format N A Range N A T essage ls N A Action N A Data Text Message EE Action Arrow Data Type Format BCD Range Page A 16 Installing and Using the Example Programs EXAMPLE MESSAGE WORKSHEET PAGE MESSAGE Text Message on fof ote Action Data Type Format BCD Range N A ree Action Keypad Data Type Format Range N A ETSISET E Wem LEE Action N A Data Type Format Range N A TER PEEL EEE Action Keypad Data Type Format Range N A me ole E el TSPETETTET T Action N A Data Type Format Range N A TERT el Action Keypad Data Type Format Range N A mrp Wem LEE EEL Action N A Data Type Format Range N A PEPER ETE Action Keypad Data Type Format pop Range Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Action Data Type Format Page A 17 Installing and Using the Example Programs EXAMPLE MENU WORKSHEET PAGE MENU Text w EjA t
91. ulti panel selection in OP WINEDIT Note When configuring always remember to set Run Pgm to Pgm towards the ON Always wait for the module to reset approximately 2 seconds before configuring the module Specific configuration of the 620 begins with defining the block of PLC register data to be used Next each of the function buttons must be configured for either momentary or alternate action operation Then each of the messages used by the PLC program must be defined Message definition is very straightforward and easily accomplished that 15 necessary is the following sequence e Select the message number to enter e Type the message Up to 20 char acters are allowed Any unused characters will be filled with blanks One numeric field may be defined with caret characters One decimal point or colon may be placed within the field e If the message has a field for nu meric arrow adjustment select ar row adjustment Select and enter minimum and maximum values if they apply page 6 Intelligent Peripherals for Control OptiMate Series Examples of Use with a PLCDirect With this rung placed in the PLC program the status and Register Usage control bits will be control relays The register association is The OptiMate OP WINEDIT software allows you to shown in the figure below configure a module to use a block of registers at a starting value 151413121
92. und 12 Terminal 1 424VDC Plug the terminal block connector into Power receptacle located on the back side of the panel Page A 3 Step 1A Multi Panel Power Supply Connections Optional Installing and Using the Example Programs In multi panel applications if using separate power supplies make sure the electrical ground commons do not have a great potential difference When using a single power supply in multi panel application the power supply must maintain the specified voltage and current consumption for each of the individual units under all conditions including power up See individual panel power requirements Communications to PLC Power OP 9001 5 10 9 9 WI DIC etc qum Oy DE Ground Page A 4 Step 2 Setting the OP Panel PGM RUN DIP Switch to PGM Step 3 Selecting Cables Installing and Using the Example Programs You may generate your OP panel configuration off line To download your configuration the PGM RUN DIP switch located on the back of the OP panel must be set to PGM ON The TERM switch should remain off NOTE You must cycle power to the panel turn power off set DIP switch and turn power back on to activate the new switch settings N RUN 1 PGM Set to 2m TERM For multi panel configurations see the section titled OP 9001 Multi Panel Configurations towards the end of this chapter

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