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Series One PLCs Series One/One Plus User`s Manual

1. jum o ou 5 55245 gt o E Q eg 9 3 pl bm 5 Incart ima Tn 1 4 Index T a 2 2 Password Protection 1 3 PC Operation 4 1 PC Terminology 1 8 Peripheral Devices 2 9 Peripheral Devices Operation 4 15 Planning a PC System 5 1 Portable Programmer 1 1 1 5 Power Flow 5 17 Power Supply Limitations 3 13 Printer Interface Unit 2 11 4 18 Printer Requirements 4 19 80 132 Column Selection Switch 4 21 External Power Supply Connector 4 21 Hardware Description 4 19 Hardware Features 4 20 Power Supply Select Switch 4 21 Sequence of Operation 4 22 Program Checking 4 7 Programmable Controller Concepts 1 5 Programmer 4 1 Programmer Cable 3 11 Programmer Features 4 2 Address Data Display 4 2 Data Operation Keys 4 6 Editing Keys 4 4 Logic Display 4 2 Logic Keys 4 3 Mode Switch 4 2 Peripheral Jack 4 7 Shifted Functions 4 5 Status Display 4 2 Programmer Functions 5 15 Programmer Mount Assembly 2 4 Programmer Tape Port 2 4 Programming 1 5 Programming Function Compatibility Guide C 5 Programming Fundamentals 5 7 Programming the Data Operation Instructions 5 45 Addition BCD 4 Digit F71 5 53 BCD Binary to BCD F86 5 70 BIN BCD to Binary F85 5 69 CMPR F70 5 52 GEK 90842 Programming the Data Operation
2. sal 21 81 5331 1 al 9287 1 SIT WELL A gt a lt 5 99 89 2 OZ or 0 or 2 75 TOO rar ror car 1 E m nro no Un oO noO 2 ii 2 4 E y d 202 SO 0 20 O a W TE m E Q lt 2 we e 339 Y ui c 3i NE uj Y a l r lt a 5 5 4 lt n A lt gt lt lt 2 a RAE w 4 m gt i 4 2 5 eO 4 O CN OQ gt e o 6663 ai 1 or the appropriate counter Mim 1 ct 1t et la on lt O 4 1 lt es 4 gt xu T gt o A Um q Enable output X4 in fast response mode Disable output X4 in fast response mode Output X4 to field device being controlled DISABLED mode ENABLED fast response mode Dummy contact to put output X4 in fast response mode INPUT NO 00 AA Bo INPUT NO A Mode select for output 4 4 w 5 5 5 lt lt 55 Appl
3. gt N U GEK 90842 D 4 8 Series One Family of Programmable Controllers Compatibility Guide 90842 Table 4 Examples of Valid System Configurations for Points Continued 9 8 Point Series One Series One Model E Series One Plus Series One Plus 3 7K 1 10 Slot Rack 2 8 Point IC610CHS130 Modules 112 610 5134 610 5120 6 16 Point Not used with 112 1C610CHS124 Modules I O Configuration 9 8 Point Series One Series One Model E Series One Plus Series One Plus 3 7K 2 S Slot Rack IC610CHS110 IC610CHS114 2 8 Point Modules 112 6 16 Point Modules Series One Plus 3 7K Series One Plus 1 10 Slot Rack IC610CHS130 134 14 8 Point Modules And 1 5 Slot Rack IC610CHS110 114 Series One Plus Series One Plus 3 7K 3 5 Slot Racks 14 8 Point 610 5110 Modules IC610CHS114 Series One Series One Model E Series One Family of Programmable Controllers Compatibility Guide C 9 90842 Table C 4 Examples of Valid System Configurations for I O Points Continued UO PC and Valid Configuration Points Rack Type Module Type and References 41935 Series One Series One Model E 112 2 10 Slot Racks 14 8 Point IC610CHS130 Modules IC610CHS134 IC610CHS120 IC610CHS124 Series One Plus 6 16 Point Series One Plus 3
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6. the RUN relay is not closed high resistance check the or DC power supply as in step 1 above Adequate AC or DC power and an open relay requires replacement of the rack 90842 240288 7 4 a H y mex 7 E z Figure 7 1 Troubleshooting Indicators General Troubleshooting Procedure Additional procedures depend upon knowledge of the logic installed by the user The following steps are more general in nature and should be modified or adjusted as necessary to meet your specific application There are no better troubleshooting tools than common sense and experience First plug in the programmer and place it in the RUN mode then follow these steps 1 If the Series One or Series One Plus PC has stopped with some outputs energized or basically in mid stream locate the signal input timer coil sequencer etc that should cause the next operation to occur The programmer will display ON or OFF condition of that signal 2 If the signal is an input compare the programmer state with the LED on the input module If they are different replace the input module If multiple modules in an expansion rack appear to require replacement verify the I O cable and its connection before replacing any modules 3 H input state and LED on the input module agree compare the LED status and the input device pushbutton limit switch etc If they are different measure the voltage at th
7. Entering Basic Instructions 5 24 AND STR OR STR 5 24 Basic Relay Logic 5 20 Disabling of Outputs 5 29 Latched Relay 5 26 Master Control Relay 5 27 Normally Closed Input 5 22 Push Down Stack 5 23 Retentive Coils as Latches 5 26 Rung with Parallel Contacts 5 20 Rung with Series Contacts 5 19 Simple Timer Rung 5 20 Error Code Definitions 4 7 Error Codes 4 7 Example of Counters 5 33 Example of Relay Control 2 9 Example of Timer Logic 5 31 Expanded Cable Installation 2 4 GEK 90642 F Fast Response IC610MDL 115 6 56 Faster Scan Rate 1 3 Field Wiring to Modules 6 2 Forcing I O References 5 42 Forcing References 4 15 Fuse List 7 7 G General Specifications 1 3 General Troubleshooting 7 2 Ground Earth 3 10 Grounding Rack 3 3 H Hand Held Programmer 1 1 1 5 Hardware Requirements 2 7 Heat Dissipation 2 2 High Density Module with Removable Connector 6 3 High Speed Counter IC610MDL 110 6 39 History of Programmable Controllers 1 1 I Addressing Switches 3 6 1 O Expansion Cable Connection 3 4 1 O Interface Cable Cross Reference List 6 5 I O Interface Cable Wiring List 6 4 I O Module Capability Compatibility Guide C 3 I O Module Catalog Numbers 6 6 References for 16 Circuit Modules 6 4 I O Simulator IC610MDL 124 6 61 I O Specifications and Wiring 6 1 IC610CHS111 5 Slot Rack UL Listed 6 72 IC610MDL101 24 dc Sink Input 8 Circuits
8. 6 10 IC610MDL103 24 V dc Input Output 4 In 4 Out 6 31 e S e y ON 4 oo lt ND LE 8 Q e gt gt cC w o lt EN pul pal 58 de O pu ve 9 Q jemg in oF ex af y p 5 e M ES 858 v pct R E 2d Q E S22 o e a EL lt e lt IL y y bb E t m 1 23813583 A I 5 2 e fe e A d oO z 5 E O O p 2b eb v b ha 5 9 vO ban a e e 9 s 3 3 544 s 5 uN ay dee qu Q 2 x gt E lt lt e ON N C Q E gt gt gt gt v Y dl J w lt w w a ON N A A 99 A UU OA Y e amp c qa 3 q qj yq pun v ies 5 8 E Q 58788988588 wem wq w omj 994 cole w O Om OU w 5 O O Q O pang mt qum 8 c 9 c en 5 lt 7 45 x A A E a dd 2 e No e Gud 44 ony m e 2 n a A Q gt gt lt lt lt A 105 1 wq 91 o Qvo
9. Instructions cont DeAND DATA AND F75 5 61 DeOR DATA OR F76 5 63 De OUT F60 5 50 DeOUT F61 5 50 DeOUT2 F62 5 51 DeOUT3 F63 5 51 F65 5 52 DeSTR 50 5 47 DeSTR1 F51 5 48 DeSTR2 F52 5 48 DeSTR3 F53 5 49 DeSTRS F55 5 49 Decode F82 5 67 Division BCD 4 Digit F74 5 59 Encode F83 5 68 External Fault Diagnosis F20 5 71 INV F84 5 68 Multiplication X BCD 4 Digit F73 5 58 Shift Left F81 5 65 Shift Right F80 5 65 Special Function Coils 5 46 Subtraction BCD 4 Digit F72 5 56 Programming Introduction to 5 1 PROM Writer Unit 2 12 4 29 Front Panel Features 4 30 Power Supply Select Switch 4 31 Sequence of Operation 4 31 Proper Heat Dissipation 3 2 R Rack Description 2 1 Rack Grounding 3 3 Rack Mounting Dimensions 3 2 Recommended Field Wiring Procedures 3 15 Referencing Sequencer Contacts 5 37 Relay Output 16 Circuits IC610MDL 182 6 29 Relay Output 8 Circuits IC610MDL 180 6 27 Relay Output Module UL Listed IC610MDL 181 6 74 Remote I O 1 8 Removable Connector 6 3 Index 1 5 GEK 90842 Replacement of Components 7 3 Replacing a CPU 7 3 Replacing a Rack 7 3 Replacing I O Modules 7 4 Replacing the Battery 7 4 Requirements Hardware 2 7 Routing of Wiring Typical 3 11 S Safety Considerations 3 15 Search CPU Logic 4 11 Sequencer Operation 5 36 Series One Execution Times 5 3 Series One Model E 1
10. Programmer to Tape Recorder Fuses 2A SB Spiral Element Cable Programmer to Peripberal Fuses 3A FB Cover CPU Connector Fuses 3A SB Cover large DCU PROM Writer Fuses 4A SB Printer Interface Fuses 5 FB Cover small DCU PROM Writer Fuses 10A SB Printer Interface Key Hand Held Programmer Cover I O Terminal Screws PH M3x5 Cover Power Supply Terminal Screws PH M3x7 Cover Rack Dust Screws PH M3x16 Fuses 1A SB Spacer Fuses 2A SB When supporting a Series One or Series One Plus installation it is recommended that spare modules be available on site These are in addition to the Accessory Kit previously discussed As a guide to your requirements the following percentages are presented As a minimum one each of all modules is recommended Depending upon a number of application related conditions location average weekly hours of operation cost of downtime etc more units may be justified Base with Power Supply CPUs Input Modules each type Output Modules each type Programmers Cables Peripheral Devices 7 8 Maintenance 90842 40022 Figure 7 4 Accessory for Series One One Plus Fuse List Table 7 1 is a list of fuses used in Series One I O modules Table 7 1 VO Module Fuse List 1C610MDL103 IC610MDL104 IC610MDL115 1 610 1151 IC610MDLI153 IC610MDL154 IC610MDL155 IC610MDL156 1C610MDL157 IC610MDL158 IC610MDL175 1C610MDL176 1C610MDL180 IC610MDL181 1C610
11. 3 Series One Plus 3 7K 1 3 Series One Plus Program Protection 1 6 Series One Programmable Controllers 1 1 Shift Register 5 38 Operation 5 40 References 5 39 Shift Register References 5 13 Significance Of References 5 7 Spare Parts and Components 7 6 Special Function Coils Use of 5 13 Specifications for Installation 3 1 Summary of I O References for 8 Circuit Modules 5 10 Summary of Programming References C 4 Summary of References 5 8 System Estimating 2 7 T Thumbwheel Interface 1 610 105 6 36 Timer and Counter 5 30 Extending Timer Counter Range 5 34 Programming Counters 5 32 Programming Timers 5 30 Timer Counter References 5 30 Timer and Counter References 5 13 Timer Counter Setpoint Unit 4 32 Example of Using Thumbwheel Inputs 4 34 References for 4 33 Remote Mounting 4 33 Timer Counter Setpoint Unit cont Specifications 4 33 Total Scan Time 5 14 Troubleshooting Aids 7 1 Types of Memory 1 7 CMOS RAM 1 7 PROM 1 7 Typical I O Terminal Configuration 6 3 Typical Rack 2 1 Typical Sequencer Logic 5 37 U UL Listed Products 1 7 6 71 Units of Load 3 13 Units of Load Supplied by Rack 3 13 Units of Load Used by Modules 3 14 3 15 Unlimited use of References 5 18 Use of the Special Function Coils 5 13 Using References for Data Operations 5 44 Data Register References 5 44 Entering a Constant Value 5 44 Entering a Group Reference 5 44 Timer Counter References 5
12. 7K Modules 120 IC610CHS130 And IC610CHS134 3 8 Point Modules TPK A 41936 Series One Plus Series One Plus 3 7K 152 19 8 Point IC610CHS130 IC610CHS134 Series One Plus Series One Plus 3 7K 1 10 Slot Rack 8 8 Point 610 5130 134 Modules And 1 5 Slot Rack IC610CHS110 114 C 10 Series One Family of Programmable Controllers Compatibility Guide 90842 Table 4 Examples of Valid System Configurations for I O Points Continued Series One Plus 3 7K 2 10 Slot Racks 9 8 Point IC610CHS130 Modules IC610CHS134 uii 6 16 Point Modules 1 These examples represent only a sampling of the many configurations of racks and points that are available Configurations depend on the number of points and type of modules 4 8 or 16 points and the units of load used by the modules required for a particular application 2 If modules having only 4 I O points are used in slot the references not used as world are available for use as internal references in the user program 3 The 10 slot racks 1C610CHS130 and IC610CHS134 have 2 bridge connectors on the backplane which must be configured for proper rack addressing Configuration of the bridge connectors is explained in chapter 3 Installation The X a slot means that there is no valid address for that slot for that configuration 1 90842 A
13. EA E uN 5 O S Ha o E Eb 5 E Q 3 Is 3 a 6 15 _ Eggs Index 10 Slot Rack 2 3 115 ac Input Module IC610MDL 129 6 76 115 V ac Input Module UL Listed 1C610MDL 135 6 73 115 ac Input IC610MDL 125 6 7 115 V ac Isolated Input IC610MDL126 6 9 115 V ac Output Module UL Listed IC610MDL 185 6 75 115 230 V ac Isolated Output IC610MDL 176 6 17 115 230 V ac Output IC610MDL 175 6 16 16 Circuit 1 0 Modules with Connectors 6 4 2 230 V ac Input IC610MDL 127 6 8 24 V ac Sink Output 16 Circuits IC610MDL 156 6 19 24 V ac Sink Output 8 Circuits IC610MDL 151 6 18 24 V ac dc Source Input 16 Circuits IC610MDL 1 12 6 14 24 V ac dc Source Input IC610MDL 111 6 13 24 V dc 2 Amp Sink Output IC610MDL153 6 22 24 V dc 2 Amp Sink Source Output IC610MDL154 6 23 24 V de Input Output 4 In 4 Out 1IC610MDL 103 6 31 24 V de Input Output 4 In 4 Out IC610MDL104 6 33 24 V de Sink Input 16 Circuits IC610MDL106 6 11 24 V de Sink Input 8 Circuits IC610MDL 101 6 10 24 V de Sink Load Input 16 Circuits 1 610 107 6 12 24 de Sink Output 16 Circuits IC610MDL157 6 20 24 V de Source Output 16 Circuits IC610MDL 158 6 26 24 V dc Source Output IC610MDL 155 6 24 5 Slot Rack 2 3 5 Slot Rack UL Listed IC610CHS111 6 72 A Accessory Kit IC610ACC120 7 6 Adding Memory 7 5 Adding Racks 2 2 Advantages and Fe
14. OR 605 3 4 605 OR 605 5 OUT 22 4 805 5 DEVICE NUMBER 4 605 23 STR 605 U 2 a 605 OR TE OUT 23 5 Figure 8 5 Event Time Drum Logic Continued 8 6 Applications _ _ _ _ _ _ _ 90842 CE NUMBER pc s1 83 0049 eos DEVICE NUMBER 5 24 O O 9 _ 605 OR 605 OR 605 2 605 OUT 24 5 DEVICE NUMBER 6 605 25 O STR 605 1 1 605 OR 605 OR 605 3 5 605 OUT 25 5 DEVICE NUMBER 7 805 26 OS STR 605 1 605 OR 605 OR 605 3 4 605 OR 605 5 OUT 4 26 605 5 DEVICE NUMBER 8 605 27 69 69 STR 605 2 OR eos 605 OR 5 OUT 27 5 Figure 8 5 Event Time Drum Logic Continued Applications 8 7 90842 Application 4 Cascaded Counters an application requires a counter with presets greater than 9999 multiple counters can be assigned to that function Two counters can record values up to 99 999 999 and three up to 999 999 999 999 etc Additional logic is incorporated to generate a reset signal at 10 000 counts instead of the normal 9999 The following logic uses two counters to record up to 99 999 999 events Counter 601 records the low order values thousands hundreds tens and units and counter 602 the high order values tens of millions millions hundreds of thousands tens of thousands CASCADED COUNTERS 1 83 0050 ONE SHOT 00 340 341 O Om AND NOT 340 OUT 341 00 340 O 8 3
15. tailored for industrial applications the same I O structure including modules racks and cables most of the same CPU modules transportable programs from one model or size to another upward or downward compatibility and the same options Memory and I O capability are listed in Table D 3 Table D 3 Series Six CPU Capacities VO CAPACITY MODEL LOGIC MEMORY INPUTS OUTPUTS REGISTER STORAGE 1000 1000 1024 600 1000 1000 8192 6000 39K 8192 Programming Programs are entered using the LogicMaster 6 software package on the Workmaster industrial computer The Workmaster has 9 CRT display a full travel keyboard integral 3 1 2 diskette drive and full off line stand along programming Programming logic is basically a relay ladder diagram language consisting of relay ladder logic N O and N C contacts counters timers one shots and latches Additional features in the Basic group include Arithmetic add subtract and compare data moves binary and BCD conversion a Master Control Relay function and communication requests The extended Mnemonic group includes the following functions e Data Moves Left 8 Right 8 Block e Signed Arithmetic Double Precision Add and Subtract Extended Add and Subtract Multiply Divide and Greater Than e Table Moves Table To Destination Source To Table Move Table and Move Table Extended e List Add To Top Remove From Bottom Remove From Top and Sort AND OR Exclu
16. the Series One family and Series Three I O Link Remote modules Chapter 1 Connecting the Series Six PC to the Series One or Series Three I O system is an overview of the system configuration and operation Chapter 2 Series Six I O Link Local Module and Programming explains how to install and operate the Series Six Link Local module and how to program the Series Six CPU for Link Local operations Chapter 3 Series One PC YO Link Remote Module explains the installation and operation of the Series One PC I O Link Remote module Chapter 4 Series Three VO Link Remote Module explains the installation and operation of the Series Three PC Link Remote module Chapter 5 Cable Wiring describes cable wiring between the Series Six PC I O Link Local module and the Series One or Series Three PC I O Link Remote module Appendices A B and C provide application information on setting up an example I O chain and using the I O chain status byte GEK 90846Portable Programmer User s Manual The purpose of this manual is to provide information on the functions and features of the Portable Programmer and to instruct the user in installing programming and implementing the Portable Related Documentation A 3 90842 Programmer with the Series One programmable controller family and the Series Three programmable controller This manual contains nine chapters and six appendices Each chapter contains sections to aid t
17. uoo S 43 H dt danke b 855 Bogs gaa age is 8 42 Q E E Ens q c 8 4298 SE dE 3 pum 4 4 2 9 de 4 A 4 ep 1 ic 2 Ar 8 oc 03 2 i a 2 E O E ba E A 9 E T bam iks 8 38239 dg das 8 555446 10 o X ya v 3 3 Y H E E a O t 2 a 4 4 t a esas 57 abb EE PS a Set wer MEE 352 45452 9 E Pos Bae 556 L4 ES 18 98 47 d B E Q Un 3 gt E TEL e d 4 0 a 3 5 E 5 B md _ 0 4 s i 3 3 9 2 5 3 as 3 t a OW R gm Q 2 3 1 3 2 1760290 c o 23 a an s Q un 9 a al Q 2 gt t CY c U d s 1 Y Jj Q E coc V ep 44 Q 8 15448 5555558 5 dog E 658 OE oa e JING gt D 20 E M A t A 2 4 9 Q a lt i 1 x 5 ed 985 FAS gt O 2500 O E FEE 2 OO _ 9 6 2 Related Documentation GEK 90842 GEK 90507 Remote U
18. 09SJR114 IC609SJR120 1IC609SJR 124 IC609SJR 121 000 016 Basic Unit 017 027 Inputs 15 Outputs 9 I O Expansion Units 609 110 IC609EXP120 IC609EXP121 Series One Junior IC609SJR 100 102 IC609SJR110 114 1060957 120 124 IC609SJR121 MEA And One Expansion Rack S or 10 Slot Rack IC610CHS110 114 IC610CHS130 134 IC610CHS120 124 3 8 Point 1 16 Point 40 1 0 NG A A WANA EAS DA EIA ASIA ERR SIE PROCEDA massa Gg PEN TERRE LI E ER Gd FER ENG RE PR RR A A ES e e gt 2 4 2 3 lt C TERES D een g jas NIE co O 828 2 D eed 325 B Eee Je a 49 qaz t dot zx 5 n ERR Wot t amp s 5 Set 2 8 o e 1222 e 8 O ee Q E ds poe e 825 elgeg Web 88 i je ms lees ges pro eses 328 s amp s P gt 2 s 25 ee 1 25 x iL TEM Y IBES sea SPS
19. 10 slot expansion rack 2 One Thumbwheel Interface or one Timer Counter Setpoint unit can be used in a Series One Plus system not both C 4 Series One Family of Programmable Controllers Compatibility Guide ___ _ _ _ _ __ _ __ LL _ Q _ Q___ gt _ _ _ bbQ T 90842 Table 2 Summary of Programming References for Series One Family of Programmable Controllers Memory Type Valid References Octal Decimal Quantity Series One Junior Points 96 total Basic Unit Inputs 000 016 15 Basic Unit Outputs 017 027 9 VO Expansion Unit Inputs 030 047 16 10 Expansion Unit Outputs 058 061 10 Expansion Rack 1 0 030 067 40 130 137 Internal Coils 160 total Non Retentive 140 277 96 Retentive 300 372 59 Set Retentive Coils 373 First Scan Reset 374 1 0 1 Second Clock 375 1 Disable Outputs 376 1 Back Up Battery Status 377 1 Shift Register 140 372 155 total Timers and Counters 600 623 20 4 digit 1 High Speed Counter 624 Sequencers 600 623 20 1000 Series One Series One Model E I O points 000 157 112 total Internal Coils 144 total Non Retentive 160 337 112 Retentive Coils 340 373 28 Initia Reset 374 1 0 1 Second Clock 375 1 Disable Al Outputs 376 1 Back Up Status 377 1 Shift Registers 400 577 128 steps Timer Counters 600 677 64 1 Sequencers 600 677 64 1000 steps Series One Plus Series One Plus 3 7K 10 points000 157 168 total 700 767 Interna Coils 14
20. 4 total Non Retentive 160 337 112 Retentive Coils 340 373 28 Initia Reset 374 1 0 1 Second Clock 375 1 Disable Outputs 376 1 Back Up Battery Status 377 1 Special Purpose Shift Registers 400 577 2 128 steps Timer Counters 600 677 64 1 600 677 64 1000 steps Data Registers 400 577 2 64 16 bit 1 Total maximum number of Timers and or Counters 2 Although shift registers and data register references are the same shift registers operate on individual bits while data registers operate on bytes in t are of memory 3 Unused references can be used as data registers which provides up to 124 16 bit data registers T C references 674 677 are reserved for T C use only Series One Family of Programmable Controllers Compatibility Guide C 5 GEK 90842 Table C 3 Programming Function Compatibility Guide Feature Junior One Plus Plus 3 7K Basic Ladder Diagram Functions STR STR NOT yes yes yes yes yes AND AND NOT yes yes yes yes yes OR OR NOT yes yes yes yes yes SET RST yes yes yes yes yes OUT yes yes yes yes yes SET OUT yes yes yes yes yes SET OUT RST no no no yes yes OR STR yes yes yes yes yes MCS yes yes yes yes yes TMR yes yes yes yes yes STR TMR yes yes yes yes yes STR yes yes yes yes yes AND TMR yes yes yes yes yes AND NOT TMR yes yes yes yes yes OR TMR yes yes yes yes yes OR NOT TRM yes yes yes yes yes CNT yes yes yes yes yes STR CNT yes yes yes yes yes
21. 40 FIRST COUNTER IN CHAIN 0 10000 341 342 3 3 STR 341 CNT AND NOT 342 CNT601 on CNT 601 CNT 601 9999 01 601 BY ONE COUNT 342 341 342 9 STR 342 ORCNT 341 601 CNT601 OUT 342 SECOND COUNTER IN CHAIN 10 000 99 990 000 342 9 5 STR NOT 342 STR CNT 602 1 CNT602 CNT 802 01 Figure 8 6 Sample Cascaded Counter Logic 8 8 Applications 90842 Application 5 Coil 374 Power Up One Shot In industry power loss to machines and process equipment is a frequent event When such an event occurs it creates havoc with automatically controlled equipment and processes The moment power returns may be desirable to place the machine or process in hold state until verification or critical limits position of moving parts and support equipment interfaces are confirmed to be correct by authorized personnel Description of Operation The Series One and Series One Plus PCs have a special function reference internal coil 374 that provides a pulse during the first scan only after powering up the CPU or going from program to run mode Using this pulse in the ladder logic as shown below will place the machine or process in the desired hold state The instant power returns to an automatic machine or process certain phases for instance activating a cylinder starting a motor etc of the automatic cycle need to be inhibited until a correct state is determined allowing the con
22. 45 V Valid System Configurations for I O Points C 6 W Workmaster Industrial Computer 1 1 Fanuc Automation North America Inc Charlottesville Virginia
23. 5 CURRENT COUNT gt PRESET INTIA ONE SHOT TO INCREMENT 01 SHIFT REGISTER Figure 8 15 Programmable CAM Switch Applications 8 15 90842 a40893 00 165 01 162 7 SHIFT REGISTER THAT SR DETERMINES STAGE OF SEQUENCER 162 404 164 160 Figure 8 15 Programmable CAM Switch Continued 8 16 Applications 90842 40893 FIRST STAGE CURRENT COUNT PRESET INITIALLY OUTPUT NO 1 NOT INVERTED OUTPUT NO 1 IN COUNTER MODE OUTPUT NO 2 DISABLED OUTPUT NO 2 IN MANUAL MODE SECOND STAGE CURRENT COUNT PRESET INITIALLY OUTPUT NO INVERTED OUTPUT NO 2 IN COUNTER MODE Figure 8 15 Programmable CAM Switch Continued Applications 8 17 90842 Cut to Length With this type of control application the object is to generate a pulse output every X number of counts In cut to length applications X represents the length of material to be cut in pulses from the encoder The following example pulses output No 1 of the High Speed Counter once every 100 counts The figure below shows the logic diagram for output No 1 while the next figure contains the wiring diagram for this type of application followed by the associated ladder logic a40894 OUTPUT NO 1 CURRENT COUNT 0 100 200 300 400 Figure 8 16 Output No 1 Logic Diagram 1 84 0014 HIGH SPEED COUNTER MODULE B USER LOAD OUTPUT NO 1 Figure 8 17 Wiring Diagram 8 18 Applications
24. 90842 Appendix Series One Family of Programmable Controllers Compatibility Guide ory Memory 700 words CMOS RAM Memory d to 1724 words Memory 3700 words CMOS RAM EPROM non volatile storage Banery Back Scan 0 5 Program imes1 0 Program 1 7 K Program Non Retentive Coils Retentive Coils S Function Coils imers Counters Thumbwheel Interface Module Timer Counter Setpoint Unit Shift Registers Data Registers 12 uencers peed Counter No of I O in Remote Me Programmin Basic Ladder Diag jons g Lan Data Operations and Math I W Hand Held Programmer 10PRG100 IC610PRG105 Hand Held Prog Mount Assembly CMOS RAM memory Series One 6116LP Series One Pius 6264LP 15 low power devices only EPROM mem Serie One Junior amp Series One 2732 Series One Plus 25 Series One Plus 3 7K 27256 25 One Thumbwheel Interface or one Timer Counter Setpoint Unit can be used in a system not both Requires Series One 5 or 10 slot expansion rack Limited to one 16 point module per system See 1 0 Module Compatibility Chart Has limited usefulness Remote stations can be located up to 3300 1Km from the CPU connected by twisted pair cable to Link Local and 10 Link Remote modules P by pur w Fons rae 100 frorn banc ihrough an VO Expansion cable to a basic unit and an 1 0 Applies to Series One Junior only PRG 100 c
25. Chapter 7 7 1 Maintenance Introduction to Maintenance Procedures The Series One and Series One Plus PCs are designed to provide trouble free operation However occasionally situations requiring corrective action do occur and it is important to be able to quickly identify the source of such situations and correct them Many times the need for corrective action originates outside of the PC Troubleshooting Aids The advantages provided by the Series One and Series One Plus PC design are indicators and built in aids to troubleshooting not only the PC but also the overall control system The main diagnostic tool is the programmer that can be easily attached to the PC The programmer provides great insight to the status of the overall control system When troubleshooting a Series One or Series One Plus PC based control system make a habit of having a programmer with you Basic Troubleshooting Procedure The following questions should be asked and appropriate action taken to negative answers At the end of the list of questions are step by step procedures to be followed to replace various modules in a Series One or Series One Plus PC All major corrective action can be accomplished by replacing modules No special hand tools are required except for a screw driver and voltmeter There is no requirement for an oscilloscope highly accurate voltage measurements digital voltmeters or specialized test pro grams Refer to figure 7 1 for locatio
26. GEX 90842 a40005 ONE SHOT TO WRITE PRESET TO HSC WRITE PRESET OF 100 TO HSC OUTPUT NO IN COUNTER MODE OF OPERATION Figure 8 18 Cut to Length Program Measuring a Random Length In measuring the length of moving objects the leading and trailing edge of the object enables and disables the counter which is tied to the encoder At this point the accumulate value of the counter represents the length of the object Unfortunately the accumulate value of the High Speed Counter cannot be moved into the user logic of a Series One or Series One Plus PC Thus an objects length can only be measured relative gt lt to a preset value in the counter Through the use of a shift register and multiple presets the length can be approximated to within two successive presets determine the accuracy a moving objects length can be measured Three parameters must be considered 1 Velocity of Object pulses second 2 Resolution of Encoder inches pulse 3 Scan time of the Series One or Series One Plus CPU seconds These three factors combine in the following manner to determine the accuracy of measurement Accuracy of Measurement INCH PULSE 1 1sc sec PULSE SEC Applications 8 19 gt gt A A ___ _ _ 2 ___ __ _ __ _ _ _z gt gt gt gt gt _ gt _ _ UU _ _ EXE E gt GEK 90842 Sample Calculation Given 1 0 1 inches pulse 2 60 RPM assume 1 pulse degree 360 pulses second 3 Scan ti
27. IIIIAasy h wa x wWA o I WII C TI W K V HI lt YI IIIIO II I I W H IWVIKWGWIK 90842 Application 9 Typical Shift Registers When applying controls to a conveyor system or indexing machine consideration must be given to the object being assembled since it invariably has discrete information pass fail etc associated with it Each time that the object is advanced in the assembly process its discrete information must follow it The shift register function provides this control within the Series One and Series One Plus PCs Referring to the following example the objects undergo a mechanical and visual inspection at stations Number 1 and 3 If either inspection fails the object is rejected at station Number 5 In order to track the pass or fail status of each object two shift registers are required one for the mechanical inspection and one for the visual inspection 51 83 0044 STATION STATION STATION STATION STATION NUMBER 1 NUMBER 2 NUMBER 3 NUMBER 4 NUMBER 5 Figure 8 20 Shift Register Example In this example I O and shift register references are assigned as follows INPUTS OUTPUTS 00 Advance belt shift signal 20 Reject Arm 0 Off 01 Mechanical inspection On pass 1 fail 02 Visual inspection 0 pass 1 fail 03 Reset Shift Register Applications 8 23 90842 Shift Register References 400 First reference in mechanical inspection s
28. MDL182 IC610MDL185 2 P NNN N A AN HD 5 58 5 5 58 8 JL l 9 33 T T _ j ie 01 161 160 161 ON GOING ONE SHOT 01 01 8 2 Applications 90842 Application 2 Flip Flop This logic reverses states ON OFF ON OFF etc each time a control signal is energized In this example the Flip Flop changes state on the OFF to ON transition of the control signal typical timing diagram 15 as follows pc s1 83 0042 939 Figure 8 3 Typical Flip Flop Timing Diagram In the following typical logic input 01 is the control signal and output 20 is the flip flop pc s1 83 0043 ONE SHOT me d AND NOT 161 OUT 160 O STR 01 OUT 161 5 STR 160 AND 20 OUT 162 5 160 20 162 OUT 20 Figure 8 4 Typical Flip Flop Logic Applications 8 3 90842 Application 3 Event Time Drum Many control requirements can be defined as a sequence of established states for each output The decision to shift from one step to another can be based upon time or specific input states To illustrate this concept the following 6 step example is provided The control on incrementing the step is a confirmation of both events for example input 11 and a time value for example timer 601 Each step can have different output states and more or less control can be implemented as the application requires The ladder diagram required to i
29. STR NOT CNT yes yes yes yes yes AND CNT yes yes yes yes yes AND NOT CNT yes yes yes yes yes OR CNT yes yes yes yes yes OR NOT CNT yes yes yes yes yes SR yes yes yes yes yes Data Operations DeSTR Data Store no no no yes yes DeSTR1 no no no yes yes DeS no no no yes yes DeSTR3 no no no yes yes DeSTR5 no no no yes yes DeOUT Data Out no no yes yes DeOUT1 no no no yes yes DeOUT2 no no no yes yes DeOUT3 no no no yes yes no no yes yes COMPARE no no no yes yes D no no no yes yes SUBTRACT no no no yes yes MULTIPLY no no no yes yes DI E Logical no no no yes yes no no no 5 yes De OR _ Logical OR no no no des yes INVERT yes yes BIN BCD To Binary Convert no no no yes yes BCD Binary o BCD Convert no no no yes yes S RIG no no no yes yes SHIFT LEFT no no no yes yes DECODE no no no yes yes ENCODE no no no yes yes EXTERNAL FAULT DIAGNOSIS no no no yes yes 6 Series One Family of Programmable Controllers Compatibility Guide 90842 Table 4 Examples of Valid System Configurations for I O Points VO PC and VO Valid Configuration Points Rack Type Module Type and References 40896 Series One Junior 1C609SJR 100 Basic Unit IC609SJR102 10609SJR110 1C609SJR 114 IC609S7R120 1C609SJR 124 10609SJR 121 Inputs 15 Outputs 9 017 027 41931 Series One Junior IC609SJR100 IC609SJR 102 IC609SJR110 IC6
30. ad the program from tape recorded after initial system programming Check operation of entire system Replacing Modules 1 2 O A t A 10 Turn OFF power from both the rack and the I O system Remove the plastic cover from over the terminals on the 1 0 module to be replaced Only field wiring on the defective module needs to be removed Disconnect field wiring from terminals detach the removable connector or remove connec tor to the I O Interface cable as applicable according to the type of module Label each wire or note installed wire marking for future reconnection Squeeze the I O module at the front top and bottom to release securing tabs Pull the module straight out Insert the new I O module aligning printed circuit boards first into the bottom board guide Rotate the module slightly upwards to engage the top board guide Push the module into the rack until both tabs snap into place Reconnect all field wiring replace the removable connector board or replace the connector then replace the plastic cover Reapply power to the CPU then to the I O system Check operation of the system especially 1 O module that was replaced Replacing the Battery If the CMOS memory back up battery requires replacement refer to the following procedures Figure 7 2 shows the battery location on the CPU location of the battery connector and the battery tie down straps Main
31. annot access data registers data operations or math Up to 124 total if unused Timer Counter references used as data registers 2 Series One Family of Programmable Controllers Compatibility Guide IC610CPU101 UL Listed IC610CPU104 1C610CPU105 1C610CPU 106 Password Protection Available Racks 5 slot IC610CHS101 2X6 yes S glot IC610CHS110 2 yes S slot IC610CHS111 5 yes S slot IC610CHS114 3 yes 10 slot IC610CHS130 2 yes 10 slot IC610CHS134 3 yes 19 Rack Mounting Brackets Data Communications Unit yes 100 Data Communications Unit yes yes yes RevA amp PROM Writer Unit yes Rev amp Timer Counter Setpoint Unit no yes yes 1 Future enhancement with this product 2 Requires 115 230 ac power source 3 Requires 24 V de power source 4 Used with 10 slot rack 5 UL Listed 115 V ac power source only 6 Not expandable GENERAL SPECIFICATIONS Humidity 5 to 95 non condensing Typical Battery Life Operating 2 to 5 Years Shelf Life 8 to 10 Years Operating Power For 115 230 V ac Series One Junior Basic 24 V de Units and all Racks See specifications for each unit or rack for details Series One Family of Programmable Controllers Compatibility Guide 3 90842 Table 1 VO Module Capability Compatibility Guide Feature Junior One Model E Pius Pius 3 7K Input Modules IC610MDL 125 i27 MN yes 1
32. are connected Isolates the CPU from electrical noise Scan A method by which the CPU monitors all inputs and controls all outputs within a prescribed time K An abbreviation for kilo or exactly 1024 in the world of computers Usually related to 1024 words of memory Ladder Diagram A representation of control logic relay systems The user programmed logic 15 expressed in relay equivalent symbology Latch A PC operation that causes a coil to stay on and remain on even if power or the input is removed Referred to as a retentive function 2 Glossary of Terms Logic A fixed set of responses outputs to various external conditions inputs All possible situations for both synchronous and non synchronous activity must be specified by the user Also referred to as the program Memory a physical place to store information such as programs and or data Microsecond ms One millionth of a second 1 x 10 6 or 0 000001 second Millisecond ms One thousandth of a second 1 10 3 or 0 001 second Modules A replaceable electronic subassembly usually plugged in and secured in place but easily removable in case of fault or system redesign Noise Undesirable electrical disturbances to normal signals generally of high frequency content Non Retentive Coil A coil that will tum off when power is removed Optical Isolation Use of a solid state device to isolate the user input and output devices from internal circuitr
33. atures 1 2 Advantages Over Other Control Devices 1 1 Alter One Logic Element 4 11 Analog Input IC610MDL 116 6 62 Analog Output IC610MDL 166 6 67 Appendix A Related Documentation 1 Appendix B Glossary of Terms B 1 Appendix C Compatibility Guide C 1 Appendix D Other Programmable Controllers D 1 Applications 8 1 Application 1 One Shots 8 1 Application 2 Flip Flop 8 2 Application 3 Event Time Drum 8 3 Application 4 Cascaded Counters 8 5 Application 5 Coil 374 Power Up One Shot 8 7 Application 6 Coil 375 10Hz Clock 8 8 Application 7 Start Stop Circuit 8 11 Application 8 High Speed Counter 8 12 Application 9 Typical Shift Registers 8 21 B Basic Instructions 5 19 Basic Ladder Diagram Instructions 5 1 Basic PC Block Diagram 1 5 Basic Troubleshooting 7 1 Bridge Connectors 10 Slot Rack 3 5 C Catalog Numbers 5 Index Central Processing Unit Function of 1 6 Change Contents of a Data Register 4 14 Clear All Memory 4 12 Components Replacement of 7 3 CPU Option Settings 3 8 CPU Programmer Cable 2 4 CPU Scanning Sequence 5 15 D Data Communications 1 3 Data Communications Unit 1 8 2 10 Data Operation Block Diagram 5 43 Data Operation Instructions 5 4 5 43 Data Registers 5 13 DCU 2 10 Delete One Logic Element 4 12 Display a Specific Address 4 13 E Earth Ground Wire 3 10 Enter or Change a Password 4 14 LOG IN 4 14 LOG OUT 4 15
34. d contains instructions for password operation Appendix F Portable Programmer Case illustrates optional carrying case for the Portable Programmer 96662 Logicmaster 1 Programmer Documentor Manual This manual presents the information necessary to use the Workmaster industrial computer with the Logicmaster 1 application software to program a Series One PC The information contained in this manual corresponds to version 02 01 of the Logicmaster 1 Programming and Documentation Software Chapter 1 Introduction introduces the capabilities of the Logicmaster 1 software and also explains how to load and copy it Chapter 2 Workmaster Operation Using Logicmaster 1 Software explains basic operation of the Workmaster industrial computer when using Logicmaster 1 software Sections are included on the keyboard display format and keyswitch positions for the Workmaster computer and Series One PC Chapter 3 Programming the Series One PC explains how to enter programming logic for the Series One PC through the Edit Program function 4 Related Documentation 90842 Chapter 4 Advanced Programming Functions explains how to annotate Series One programs and how to use the Teach function to make programming on the Workmaster computer easier Chapter 5 Logicmaster 1 System Functions explains how to use the scratch pad print programs upload and download programs and use the filing programs Appendix A Menu Tree for Logicma
35. d to store only one piece of information having more than one state for example a one zero ON OFF good bad yes no etc Data that requires more than two states e g numerical values 000 999 will require multiple bits Byte A measurement of memory in the Series One and Series One Plus equal to 8 bits CMOS Acronym for Complimentary Metal Oxide Semiconductor A read write memory that requires a battery to retain its content upon loss of power CPU Central Processing Unit The central device or controller that interprets user instructions makes decisions and executes the functions based on a stored program This program specifies actions to be taken to all possible inputs Counter A function within the PC that records events based upon the on off transition of a signal A coil associated with the counter is energized at a user determined preset value Field Devices User supplied devices typically providing information to the PC Inputs pushbutton limitswitches relay contacts etc or performing PC tasks Outputs motor starters solenoids indicator lights etc Group A series of eight consecutive references such as I O points internal coils etc Inputs A signal typically ON or OFF that provides information to the PC Instruction A word usually an acronym or group of words and numerals that are part of a program entered into user memory Input Output That portion of the PC to which field devices
36. e VuMaster FactoryMaster and Process Master Additional software packages will be available in the future The RPU acts as a switch to transfer control from one Series Six CPU or I O chain to a standby in the event that a failure occurs in the first This provides a method of minimizing downtime in the event of a failure in the PC system The Type 2 Communications Control Module CCM provides 2 independent ports RS 232C RS 422 or 20 for slave communications with computers or similar intelligent devices The Type 2 CCM also has the added function of originating communications to other Series Six CPUs computers or other similar intelligent devices from the user s ladder diagram program The Type 3 CCM also provides 2 ports and the protocol required for interfacing to selected process control systems The OIU is a hand held micro terminal that allows an operator to monitor or modify the register contents and states of a Series Six CPU communicates with a CPU through the Communications Contro module Type 2 The connects to the Series Six through an ASCII BASIC module and provides CRT background screens for the display of status from the CPU User configuration of the screens allows tailoring the screens to fit the application The ProLoop process controllers are a group of analog controllers that can operate independent of but be supervised by a Series Six PC Series Six Plus Programmable Controlle
37. e input module refer to Chapter 6 for typical wiring If the voltage indicates a problem replace the I O device field wiring or power source otherwise replace the input module 4 If the signal is a coil wired to a field device compare its status to the LED on the output module If they are different verify the source of field power to ensure excitation voltage is available If field power is not present examine the power source and its wiring If the proper field power is available but the status is wrong at the I O module s output terminal replace the output module or verify that the rack is providing the proper power to the module 5 If the signal is a coil and either there is no output module or the output is the same as the coil state examine the logic driving the output with the programmer and a hard copy of the program Proceeding from right towards left locate first contact that is not passing power that is otherwise available to it from immediate left Troubleshoot that signal per steps 2 and 3 above if it is an input or 4 and 5 if itis Ensrre Master Control Relays are not affecting operation of the logic Maintenance 7 3 90842 6 If the signal is timer that has stopped at a value below 9999 other than 0000 replace the CPU module 7 the signal is the control over a counter examine the logic controlling the reset first and then the count signal Follow steps 2 through 5 abo
38. e of memory that requires a special method of loading but is retentive upon power loss RAM An acronym for Random Access Memory A solid state memory that allows individual bits to be stored and accessed This type of memory is volatile that is stored data is lost under no power conditions therefore a battery backup is required Read To have data entered into a PC from a peripheral unit Reference number used in a program that tells the CPU where data is coming from or where to transfer the data Register A group of gt nemory locations within a PC used for storage of numerical data Retentive Coil A coil that will remain in its last state even though power has been removed Glossary of Terms B 3 GEK 90842 Rung sequence or grouping of PC functions and instructions that control one coil One or more rungs form a ladder diagram Scan The technique of examining or solving all logic steps specified by the program in a sequential repetitive order from the first step to the last Thumbwheel Switch A rotating numeric switch which can be used for inputting numeric data to a PC Unlatch A PC function that causes an output previously turned on by a latch function to turn off no matter how briefly the function is enabled Word A measurement of memory in the Series One and Series One Plus equal to 16 bits Write To output or transfer data from the PC to a peripheral unit 1
39. ee PC Specifications Size for CPU and 128 VO 18 9 x 10 3 x 6 3 W x Hx D 480mm x 262mm x 159mm Functions Relay including Latches Timers 1 0 0 1 Sec Counters Master Control Relay Shift Registers Add Subtract Compare Multiply Divide Data Moves Subroutine 20 msec for 2K 40 msec for 4K 400 64 Latches 304 Internal Coils 128 Shift Register Stages 128 Timer Counters 4 digit Built In with Keylock Available Types 115 V ac dc 115 230 V ac 2 A Isolated 115 V ac Isolated 115 230 V ac 2A 24 V dc 24 V dc 2 amp 24 V dc 24 V dc 1 Amp 24 V ac dc Source 24 V dc 230 V ac Relay Out Analog Analog 5 12 V dc 5 12 V dc OTHER MODULES High Speed Counter I O Link Local and Remote Twisted Pair and Fiber Optics Data Communica tions 24 V dc In Out 16 16 I O Simulator Other Programmable Controllers D 3 90842 Series Six Programmable Controller The family of Series Six programmable controllers consists of three models 60 600 6000 The capacity for memory and Input Output increases as the model number increases Each model also has internal register storage in varying sizes The family concept allows the use of common features between models The common features include a common programming language featuring a basic extended and advanced set the same reference numbers the same Workmaster industrial computer for programming and running many available programs
40. he user in locating required information Chapter 1 Product Summary presents a product overview and describes the operating modes Chapter 2 Operation explains the installation and operation of the portable Programmer Chapter 3 Introduction to Programming provides general information on programming Chapter 4 Definition and Entry of Instructions explains how to start a new program and contains the instruction sets Chapter 5 Edit Program provides instructions for entering the Edit mode and editing functions Chapter 6 Display Program provides the user with the information for displaying a ladder logic program Chapter 7 On Line Monitor Change covers the On Line Monitor and On Line Change functions available for the Series One Plus and Series Three PCs Chapter 8 Communications explains how programs may be stored on cassette tapes or transferred to the PCs Chapter 9 Print covers the print options and functions Appendix A Series One PC Serial Interface Setup covers the Data Communications Unit and the CPU serial cable Appendix B Series Three PC Serial Interface Setup contains information needed for connecting a Series Three PC with the Portable Programmer Appendix C Port Definition describes the CPU serial port and the printer port Appendix D Compatible Printers contains the necessary information to implement and specifications for selection of compatible printers Appendix E Series One Plus PC Passwor
41. hift register 401 Second reference in mechanical inspection shift register 402 Third reference in mechanical inspection shift register 403 Fourth reference in mechanical inspection shift register 410 First reference in visual inspection shift register 411 Second reference in visual inspection shift register Typical logic using these references is shown in the following ladder diagram SIGNA pc s1 83 0045 00 161 160 O O O iew 100 160 00 161 O O O 161 O 8 78 Z 555 VISUAL SHIFT REGISTER 4 O 8333 529 893 Figure 8 21 Typical Shift Register Logic 4 on gt gt o 9 A 9 4 I 9 2 E E 8 58 Ego e ba 4 om e o ch odi 3655 3 gd 24 p la A A o J 8 5 3 Q 5 9 9 du a et A l Q4 9 Y Y ES Q Q e B 8 4 4 4 it 5 2 Y A 5 EE E 2 09 e 8 2 o 6 Ha Gc 6 5 3 3 a 4 ay 6 9 9 i g amp o yan 0 p amp t 8 Ek ng A i O ee uj 4 z ASE 85 3 2 8 6 e E 9 mn gt 8 A NL ed Q OE EFL Sus E 1 6 8 f 5 4 R E Gh 9 Q 8 E 3 PE c 5 A
42. ications 8 13 2 90842 Application 8 High Speed Counter Applications Three general types of application examples will be covered within this application 1 Programmable CAM Switch 2 Cut to Length 3 Measurement of length In the development of these applications the following system configuration will be used 1 84 0010 4 DIGIT BCD DISPLAY ENCODER Figure 8 13 Application System 8 14 Applications GEX 90842 Programmable Cam Switch The basic concept behind a CAM switch is to enable disable certain devices at various points in the cycle of a machine Using one or more high speed counters this type of control can easily be implemented The following example illustrates this cycling the high speed counter s two outputs at different preset values The timing diagram below shows the output logic with the user program necessary to implement this logic shown on the following pages This example assumes that the encoder 1s resetting the counter once per revolution and that the machine will not travel from one transition point to the next in less than twice the scan time a40023 CURRENT COUNT 0 50 150 250 325 360 PROCESS STAGE FIRST sECOND THIRD FOURTH FIFTH SHIFT REGISTER 400 42 44 OUTPUT NO 771 OUTPUT NO 2 Figure 8 14 Programmable CAM Switch Logic Timing Diagram a40893 RES un
43. me 20 msec PULSE SEC The user logic as shown would implement this type of measurement giving a resolution of 10 counts Definition 111 Photoelectric cell which enables counter 110 Manual Reset Initialize a40895 208 207 210 C MEET SOFT REGISTER ONE SMOT 208 207 00 211 212 G CURRENT COUNT gt 00 211 o 400 e MEASUREMENT INDICATOR DOT REGISTER Figure 8 19 Measuring a Random Length 8 20 oeoooQc Figure 8 19 Measuring a Random Length Continued Figure 8 19 Measuring a Random Length Continued 204 O 206 208 101 20 STOP COUNT ONE SHOT MANUAL RESET ONE SHOT RESET ONE SHOT MITA PRESET VALUE TO HBC WINTE SECOND PRESET VALUE THIRD PRESET VALUE VALUE VALUE WRITE BOTH PREBET VALUE WIETE SEVENTH PRESET VALUE BENTH PRESET VALUE O lt e 9 Ee a 8 q 8 8 8 8 MEE E wx g 1 ii E Q gt R R 9 8 R 751 T 5 to O te ie _ i 310 iO 10 10 005080509 9 30 10 10 10 10 30 10 30 30 aO 8 ce es NN 1 9 9 E PT PT bs WT FS 87 of oim ro J as A O 0 gt 410 A GER U042 manas Q 8 22 Applications __ _ _ _ _ _ __ _ ____ _ _ W KWYII IIIWI KWKI KI IW KI lt KI
44. mplement this function is as follows pc s1 83 0046 STEP NUMBER 1 605 10 TMREOO 340 ST DH o KO 340 on 10 ANO NOT TMR600 OUT 340 STEP NUMBER 2 606 11 TMASO 1 341 STR 605 020 T AND 11 341 OR 341 AND NOT TMAS01 OUT STEP NUMBER 3 805 12 TMABO2 342 OH HA 12 342 OR 342 AND NOT TMAS02 OUT 342 STEP NUMBER 4 805 13 343 sm eos e AND 3 343 OR 343 AND NOT OUT 343 STEP NUMBER 5 005 14 TMA604 3 44 14 344 344 AND TRIRGOS OUT 344 Figure 8 5 Event Time Drum Logic 8 4 Applications 90842 STEP NUMBER 1 51 83 0047 340 TMR600 6 STR 340 TMR 600 1 0 STEP NUMBER 2 341 TMR601 7 O 7 STR 341 TMR 601 1 0 STEP NUMBER 3 342 TMR602 o STR 342 TMR 602 1 0 STEP NUMBER 4 343 TMR603 O 9 STR 343 603 1 0 STEP NUMBER 5 344 TMR604 STR 344 TMR 604 1 0 ADVANCE DRUM TMR600 345 D D STR TMR600 OR TMR601 TMR601 OR TMR602 OR TMR603 OR TMR604 TMR602 OUT 345 TMR603 TMR604 SEQUENCER 345 2 2 STR 345 STR 17 17 CNT 605 Figure 8 5 Event Time Drum Logic Continued Applications 8 5 gi gt s gt C GEK 90842 pc s1 83 0048 DEVICE NUMBER 1 605 20 63 3 STR 805 A 4 605 il ve OUT 20 5 DEVICE NUMBER 2 605 21 T STR de i 605 Oh e OR 805 3 Ms 4 605 OUT 21 4 DEVICE NUMBER 3 605 22 9 5 STR eee Ts OR 605
45. n of the referenced indicators 1 Is PWR Power light ON If not measure power at the input voltage terminals 98 126 V ac or 195 252 ac as appropriate on racks using an source of power For racks requiring a DC power source measure the DC voltage between the 24 and O terminals the appropriate AC or DC power is not present locate the source of the problem external to Series One or Series One Plus PC H the DC power levels are correct but the PWR light is off fuses should be checked then replacement of the CPU rack if necessary 2 Is CPU light OFF If ON check which error code is displayed refer to table 4 1 for error code definitions and take appropriate action 3 Is RUN light ON If not check for the cause such as the programmer in the PRG or LOAD position or programming errors If RUN light is OFF and a programmer is not connected or the programmer in in the RUN mode without an error code being displayed replace the CPU module 4 15 the light ON If yes replace the battery Since the light is only a warning level the program may be unaltered even if the battery is low After replacing the battery examine the program or test the PC operation If a fault is located reload the program from tape recorded at the completion of initial system programming 5 In multiple rack systems if the CPU is operating the RUN relay can be very useful in verifying operation of the other pc supplies
46. nsert the IC into the socket carefully and evenly so as not to bend any leads Visually inspect to ensure that all leads are in place and then push down to firmly seat the 1 If necessary readjust the jumpers and or switch 2 as shown in table 3 2 H the two printed circuit boards that make up the CPU are separated ensure that they are reconnected installed in a base unit and powered up Otherwise logic may lock into a high current drain mode and prematurely drain the battery Reinstall the CPU module following previous instructions Maintenance 2 7 GEK 90842 10 Power up the CPU place the mode switch in the PRG position and perform a Clear All Memory operation CLRSHF348DELNXT The entire memory will now be entirely clear of data Any program previously recorded on tape can now be loaded into the CPU from tape or a new program can be entered Spare Parts and Components To support the Series One or Series One Plus PC an Accessory Kit is available IC610ACC120 This includes commonly needed components that may get damaged or lost in the normal course of operation For a complete list of accessories for the Series One Family of programmable controllers refer to GEP 762 Rather than attempting to place orders for plastic covers fuses audio cables screws etc this kit can be ordered and provides sufficient material to support 3 5 CPUs depending upon their I O count Included in the kit are the following items Cable
47. ppendix Other Programmable Controllers Series One Junior Programmable Controller The Series One Junior programmable controllers are a group of low cost controllers specifically designed for control applications requiring 4 to 60 relays The Series One Junior offers a control package using only 53 square inches of mounting area which is about the same as four 4 pole relays Series One Junior PCs are available in various combinations of voltages Each Series One Junior basic unit has 24 built in IO circuits including 15 inputs and 9 outputs User memory 15 700 words of CMOS RAM or optional EPROM memory If more than 24 points are required expansion is accomplished by one of two methods either add a Series One Junior I O expansion unit or a 5 or 10 slot expansion rack to the basic unit A system can have up to 50 I O points by adding an I O expansion unit which has the same form as the basic unit Up to 96 I O points can be included in a system adding a standard Series One 5 or 10 slot rack to the Series One Junior basic unit Any combination of standard Series One modules can be included in an expansion rack with the exception of the High Speed Counter module or the Thumbwheel Interface Unit The expansion rack can be located up to 100 feet 30 m from a Series One Junior The Series One Junior has a built in high speed counter capable of counting pulses up to 2000 counts per second The programming language is the same ba
48. r The Series Six Plus 15 a cost effective programmable controller that be easily expanded to cover wide variety of applications The Series Six Plus offers in one rack more capability than the Series Six family of programmable controllers which includes models 60 600 and 6000 A Combined Memory module which includes internal memory up to 16K words of user memory and up to 16K of register memory is available in six different configurations as shown below in Table D 4 Table D 4 Series Six Plus Combined Memory Configurations un 79 4 8 4 ea 9 tz q 5 o 2 B Bo 6 7 3 ge o 0 9 SS 5 po d 3 3 a a 4 dE 508 y amp LL 1 85 e q d Q A av gt h 9 lt d d 9 I Of 5 GB a eS X 4 9 2 My A gt g 9 9 35 43 8 q lt lt E us old e m E 4 4 9 2 d 3 A 2 P T gt 2 A E N B B 3 al ba gt O E 8 fa Em D 1d gt 8 gE 20 9248 5 D A B 9 15 4 A oO ob Qf 8 5 fa om O4 Qo dS Q Os gt Pages gt gt D 9 14 0 lt d pij E b 2 A g 2 eas eS a 22 A o 20 4 d
49. s of a second would be accumulated by counter 600 If the time to be measured is anticipated to be larger than 999 9 seconds cascading another counter will increase the range to 9 999 999 9 seconds This technique allows you to measure the duration of an intermittent event that would otherwise reset the standard timer when changing state 1 83 0078 01 375 O CNT 1 01 600 AND 375 02 STR 02 CNT 600 9999 Figure 8 8 Cumulative Timer Example 2 Time of Day Clock In this example the 10HZ clock Internal Coil 375 is used to program a time of day clock with reset capabilities This is a 24 hour time clock with the time format being XX YY where XX hours 0 23 and YY minutes 0 59 The 10HZ clock provides the 0 1 second pulse to counter 603 which in turn produces one pulse every second The remaining three counters 600 601 and 602 keep track of seconds minutes and hours that have elapsed If power goes off and the clock needs resetting the combined use of a 3 position switch and a pushbutton as shown in Figure 8 10 will allow you to set the correct time The lower portion of Figure 8 10 is the ladder logic which resets the clock An I O Simulator module IC610MDL124 could also be used and programmed to reset the clock 90 90842 o LN 8 23 8 zg t hr aml tre 5853 52858 5958 ES ExtEs 8 8 5 30553 nos 8 S gt
50. ser s Manual This manual provides information needed to implement a Remote I O system using the I O of Series One and Series Three PCs Chapter 1 Introduction to Remote I O is a general description of the capabilities of Series One and Series Three PCs Chapter 2 Installation and wiring of the Link modules discusses the hardware used installation wiring and fault detection Chapter 3 Configuring a Remote I O system for the Series One PC describes how to design and implement a Series One Remote J O system Chapter 4 Configuring a Remote I O system for the Series Three PC describes how to design and implement a Series Three Remote I O system Chapter 5 Configuring Mixed Remote systems describes how to design and implement a mixed Series One and Series Three Remote I O system Chapter 6 Timing Considerations explains how to determine the timing delays in the Remote structure Appendix A Power Supply Loading lists the power characteristics of the power supplies and modules used in Series One and Series Three PCs Appendix B Design Worksheets contains handy worksheets for designing Remote I O systems GEK 90825 Series Six PC I O Link Local Module User s Manual This manual describes the link between the Series Six family of programmable controllers and the I O structure for the Series One and Series Three programmable controllers This link is established between the Series Six I O Link Local module and
51. sic ladder diagram functions as is used to program the Series One and Series One Plus Programs can be entered using either the hand held programmer which can be mounted on the basic unit or the LCD Portable Programmer Many programs developed on the Series One Junior PC can be transferred to a Series One or Series One Plus PC Table D 1 Series One Junior Capabilities Number of I O Points Maximum Basic Unit Inputs Basic Unit Outputs Expansion Unit Inputs Expansion Unit Outputs Expansion Rack I O Mixed I O Internal Coils Non Retentive Retentive Special Function Shift Registers Timers Counters High Speed Counter Built In Sequencers 1 Maximum total number of Timers and Counters or a combination of Timers and Counters Optional devices include the Timer Counter Setpoint Unit Data Communications Unit Printer Interface Unit PROM Writer Unit and an audio cassette tape recorder D 2 Other Programmable Controllers 90842 Series Three Programmable Controller The Series Three PC is a compact programmable controller capable of handling applications in the 16 to 400 VO range It offers many of the same outstanding features as the Series One family of program mable controllers such as compact size CMOS or PROM memory hand held programmer and low price Improved capabilities include 4K memory 400 1 O points and four function math Following are specifications for the Series Three PC Table D 2 Series Thr
52. sive OR Invert and Compare e Bit Matrix Bit Set Bit Clear Shift Right Shift Left e Control Do Subroutine Return Suspend I O Do I O and Status The advanced function adds an additional Table Move imstruction Move Table Ex which has the ability to address all 8192 registers in an advanced model 600 or a model 6000 modules available for the Series Six PCs include the following 115 230 V ac dc Inputs and Outputs 115 230 V ac Isolated Inputs and Outputs 12 V ac dc Inputs 24 48 V ac dc Inputs 12 24 48 V dc Sink and Source Outputs 120 V de Outputs e High Density Inputs 32 Inputs e High Density Outputs 32 Outputs 4 Other Programmable Controllers 90842 e Reed Relay Outputs e Analog Inputs and Outputs e Thermocouple Inputs e Interrupt Inputs Axis Positioning Type 1 and Type 2 High Speed Counter ASCU BASIC module 12K or 20K versions Receiver and Transmitter for operation up to 2000 feet 600 meters Remote I O Driver and Receiver for cable operation up to 10 000 feet 3 Km or unlimited distance over a modem link Optional Items Optional items for use with a Series Six PC include a Redundant Processor Unit RPU Communica tions Control Modules an Operator Interface Unit OIU color and amber Operator Interface Terminals OIT ProLoop process controllers and various software packages for use with the Workmaster information center software packages includ
53. stalled that contains a program previously entered into the PROM Maintenance 90842 a40290 e M a ee ae NN m s gt lt L reen teodos Figure 7 3 Location of Extra Memory Socket Before installing additional memory it is recommended that any program currently in memory be recorded on tape If this is not done the program will be lost after memory is added and a Clear All Memory operation is performed Remove the CPU following previous instructions 3 Locate spare memory socket at the rear of the larger printed circuit board in the CPU 4 Obtain the required memory IC either type 6116LP for Series One or 6264LP 15 for a Series One Plus 2K x 8 bit CMOS RAM or equivalent If adding PROM memory obtain an Intel type 2732A 2 for Series One or a 27256 25 for a Series One Plus or equivalent PROMs Ensure that the CMOS RAM or PROM 15 correct for your PC CAUTION When handling CMOS memory ICs always handle by the case and not leads Static electricity on leads can damage internal circuits This damage may not be apparent for several days or weeks of operation 5 Orient the IC so that the notch at one end matches the notch in the memory socket 6 For clearance when installing memory 1Cs it may be necessary to lift the smaller printed circuit board 1 8 3mm Do not separate the boards After the memory IC is installed reseat the smaller board I
54. ster 1 Software provides a map to the function keys throughout the Logicmaster 1 software Appendix B Port Characteristics and Wiring Diagrams provides the information needed to connect the Workmaster computer to the Series One PC or peripherals such as an external disk drive or printer GFK 0075 Logicmaster 1 Family Programming and Documentation Software User s Manual This manual provides the information necessary to use the Workmaster and Cimstar industrial computers with Logicmaster 1 Family application software to program the Series One Model E Series One Plus and Series One Plus 3 7K Programmable Controllers The content of this manual is arranged similarly to GEK 96662 as described above 90842 Appendix Glossary of Terms Address A series of numbers from 0 to 1723 in the Series One and Series One Plus Programmable Controllers assigned to specific program memory locations and used to access those locations AND Logical A mathematical operation berween bits whereby all bits must be a 1 in order for the result to be a 1 AND Function An operation that places two contacts or groups of contacts in series Both control the resultant status BCD Binary Coded Decimal A 4 bit system in which individual decimal digits 0 through 9 are represented by 4 bit binary numerals for example the number 43 is represented by 0100 4 0011 3 in the BCD notation Bit The smallest unit of memory Can be use
55. tenance 7 5 90842 40289 Figure 7 2 Battery Location and Connection 1 Remove the CPU following the previous instructions 2 Cut the plastic tie down straps that secure the battery to the board 3 Disconnect the battery There is sufficient capacitance in the system to retain the CMOS memory contents even without the battery for about 20 minutes The lithium battery should be handled with care DO NOT discard the battery in fire DO NOT attempt to recharge the battery DO NOT short the battery 1f these precautions are not followed the battery may burst burn or release hazardous materials 4 Connect the new battery catalog no IC610ACC150 and place it in its proper position on the printed circuit board S Secure with new tie downs or insulated wire 6 Reinstall the CPU module 7 Verify that the BATT light is OFF 1f necessary reload the CPU from a tape made after initial system programming Then check operation of the entire system 8 If the two printed circuit boards that make up the CPU are separated ensure that they are reconnected installed in a rack and powered up Otherwise logic may lock into a high current drain mode and prematurely drain the battery Adding Memory The following procedure should be followed when adding memory to a Series One or Series One Plus PC Either CMOS RAM memory can be added to increase memory capacity from 700 words to 1724 words or non volatile PROM memory can be in
56. tinuation of the cycle The following program scheme will inhibit those critical outputs from activating field devices until a reset pushbutton is depressed thereby releasing all inhibited outputs and allowing the cycle to continue FIRST SCAN PULSE a40025 374 340 7 6 INHIBIT IN THE BEGINNING YOUR PROGRAM RESET 2 INHIBIT EXTEND 3 CYLINDER RUN 9 CONVEYOR 10 Figure 8 7 Typical Machine or Process Power Up Inhibit Logic The program logic in the above figure is an example you can use to inhibit certain phases of a cycle In this example when power returns to the process 374 will be on during the first scan of the CPU latching 340 referenced NC contact of coil 340 is placed in series with the logic that actuates output coils 200 and 250 Even if the program logic is calling for coils 200 and 250 to tum on they will not until 340 is unlatched The only way to unlatch 340 is to depress the reset pushbutton 1100 allowing outputs 200 and 250 to be turned on Applications 8 9 GEK 90842 Application 6 Coil 375 10Hz Clock The Series One and Series One Plus PCs have a special function reference that continuously provides a pulse every tenth of a second The following two examples use the function of this reference 10 Hz Internal Coil 375 to create a cumulative timer and a time of day clock Example 1 Cumulative Timer In this example when reference 01 is on time in tenth
57. ve Replacement of Components The following procedures provide details on procedures to be followed when replacing components of a Series One or Series One Plus PC system Replacing a Rack 1 2 JA Turn OFF power and remove the programmer if installed Remove the plastic cover and disconnect power wiring from the terminal board on the lower right side of the rack Remove all modules wiring does not have to be disturbed if service loop was provided during the original installation Note the position of each module in the rack for proper reinstallation Remove CPU module if installed and any filler modules Place them aside in a safe location for later reinstallation Remove bottom two bolts holding the rack in place Loosen but do not remove the top bolts Slide base unit up and then pull forward to clear the top mounting bolts Set the rack aside Reinstall the new rack onto the top mounting bolts Insert bottom bolts and tighten all four mounting bolts Install the I O modules in the same slots from which they were removed Placing a module in the wrong slot can cause incorrect and dangerous operation of the control system 10 11 12 Install the CPU and any filler modules that were removed Reconnect power wiring to the terminals on the right side of the rack Reinstall the plastic cover over the power terminals Verify proper power wiring and then tum power ON Carefull
58. y check operation of the entire system to ensure that all 1 0 modules are in their proper locations and the program is not altered Replacing a CPU Module 1 2 3 4 Turn OFF power and remove the programmer if installed Squeeze the CPU module at the front top and bottom to release securing tabs Pull the module straight out from its slot If PROM memory had been installed in the CPU remove the PROM and install it in the new CPU 7 4 Maintenance EHEIZIII II MI IIIIIIII I I I IW I I WI IWKWQ II II I I II I II I II IWIIIII IOW I I I I I I I lt I lt I II I I I IIIII I II IKXIIXIIIII amp lt amp I IEI I H ZII HIIII W Z amp III IVYVI I WI IIIIBII NK XIXI IIOI W Z H W lt I IIIIIKeII I I RIK WWBIVI qYT I I I I I lt WII WK I H III II II II IXI I I IC X lt O OI I I I I II I lt I lt I lt KCW U amp L III IOI II IOHIOIK PTV WHHIyIoILSIIOK IIIIAIIIAIIWSIA IIAII II IIZIzAIyrA 90842 Insert the new CPU module by first aligning the printed circuit boards into the bottom board guide Rotate the module upwards slightly to engage the top board guide Push the CPU module into the rack until both tabs snap into place Reinstall the programmer and reapply power Relo
59. y of an module and the CPU OR Logical A mathematical operation between bits whereby if any bit is a 1 the result will be a 1 OR Function An operation that places two contacts or groups of contacts in parallel Either controls the resultant status Outputs A signal typically ON or OFF originating from the PC with user supplied power that controls external devices based upon commands from the CPU PC or PLC See Programmable Controller Peripheral Equipment External units that can communicate with a PC for example cassette tape recorder Printer Interface Unit or PROM Writer Unit Preset numerical value specified in a function which establishes a limit for a counter or timer A coil will energize when this value is reached Program A sequence of functions and or instructions entered into a Programmable Controller to be executed by the CPU for the purpose of controlling a machine or process Programmable Controller A solid state industrial control device which receives inputs from user supplied control devices such as switches and sensors implements them in a precise pattern determined by ladder diagram based programs stored in the user memory and provides outputs for control of user supplied devices such as relays and motor starters Programmer device for entry examination and alteration of the PC s memory including logic and storage areas Acronym for Programmable Read Only Memory A typ
60. yes yes yes yes ircuits es 1 es 5 es 5 A d 4 Circuits 124 V de Sink 8 Circuits yes 1 yes yes yes yes BE V de Sink Load 16 Circuits yes 1 yes yes yes yes 4 V de Sink 16 Circuits yes 1 yes yes yes yes EPS Source 8 Circuits yes 1 yes yes yes yes IC610MDL 112 1C610Mb Source 16 Circuits yes 1 yes yes yes yes ICCIOMDL 135 UL Listed yes ye 115 V ac Input 6 Circuits yes 1 yes yes yes yes Output Modules 8 Circuits yes 1 yes yes yes yes ac Isolated 4 Circuits yes 1 yes yes yes yes 8 Circuits 1 yes yes yes yes Sink 16 Circuits yes 1 yes yes yes yes IC610MDL153 I 2275 MDL yes 1 yes yes yes yes urce 4 Circuits es 1 es 5 es 5 mM m IC610MDL 158 Soure 16 Circuits yes 1 yes yes yes yes IC6 yes 1 yo yes yes ICSIOMDI BT UL Listed yes 1 yes yes 5 Circuits 1 yes yes yes yes UL Lame Lined 1 yet ye yes Relay Output 8 Circuits yes 1 yes yes yes yes Special Modules BENE 4 Out yes 1 yes yes yes yes IC V de Stak In Rly Out 4 In 4 Out yes 1 yes yes yes yes oe 10 4 2 Out yes 1 yes yes yes yes IC610MDL 124 Simulator 8 Input Circuits yes 1 yes yes yes yes Setpoint Unit yes 1 yes 2 2 yes 2 IC610MDL110 ne yes 2 2 yes 2 Speed Counter no yes yes yes yes 1 Requires 5 or

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