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1. 6 g 5 Cutout Area 7 Example panel mounting 5 40 0 20 0 50 5 00 m _ 0 60 ge 5 Y 0 16 DIA Dimensions in Inches four places gt 1 00 0 Installation and Specifications Panel Specifications Physical Specifications Environmental Specifications Operating Specifications Weight ects Panel Fasteners Pushbutton Life LED Display NEMA Rating Operating Temperature Storage Temperature Operating Humidity Air Composition Power Consumption Power Power Minimum Maximum Supply Voltage DidQnostiCs s Communication Link 8 ounces Four 6x82 threaded studs 1 000 000 switch cycles 2 line x 20 character STN with LED backlight 5 5mm high x 3 2mm wide character size NEMA 4 when properly installed 0 to 50 C 20 to 70 C 95 non condensing No corrosive gases permitted 0 85W 5 VDC Power On surge of 0 44A for 1 ms Three t
2. E X X 1 4 LCD Display WIngOW zt et rebE REDE TEE tene b eee e ctia es 1 4 About the PUSNDUMONS arches ey DEREN ee X REI RE ner ERES 1 5 EAVOUL Lot saul conde ected Ree e dace aede bara pt ata para Pita ad t 1 5 Serial Communications Port PRAE va TERT 1 5 Power Receptacle i utu ire s BD odd rn it Se Done d eh rar d Mid eed d Hin dnte Bd 1 5 Frequently Asked Questions 0 0 nnm 1 6 Chapter 2 Installation and Specifications Labeling the Pushbuttoris 2 2 Labeling the PushibUltons 13 524 5 eroe Go M bee 2 2 Greating the of cee cg PECIA RE 2 2 Creating Labels Using OP WINEDIT 0000s cece eee III 2 2 Template for Manually Creating Labels 2 4 Dimensions Tor Mounting se se ua lc o de wom Gn ate ete ou dolci o a M ua 2 5 Panel Specifications RU RP Bae ee See NM 2 6 Physical SDecifiCallOriS asit 2 6 Environmental Specifications px Ha taii eg emi d espe 2 6 Operating Specifications rm pate 2 6 Power Supply ConbectionDs eoru ide Ew eC A EIE ge ERU EE I 2 7 Power Supply Connections ees metier tua iw med COOLE eae dit
3. o q Understanding the Features Pushbuttons Pushbutton Operation The OP 420 has four user defined pushbuttons Pushbuttons may be used to begin events or tasks within the PLC such as start stop control This section describes concepts of how to monitor and control the pushbuttons on your OP panel The OP panel pushbutton inputs are monitored for ON OFF conditions in your PLC ladder logic program From a practical point of view we need to control and monitor the bits in the status register on an individual basis The OP 420 pushbuttons are assigned to the first four bits of the Status Register M 6 Examine the highlighted status bits below which show each user definable pushbutton Register Function M 0 Top line message selection M 1 Bottom line message selection M 2 Top line data M 3 Top line data 2 M 4 Bottom line data M 5 Bottom line data 2 p M 6 Status register gt OP 420 Status Register M 6 15 14 13 12 1 10 9 8 7 6 5 4 3 2 1 0 F4 F3 2 F1 Understanding the Features Pushbutton The pushbutton example shown here is using DirectLOGIC PLC address Example references The equivalent instructions for other PLC products supported are shown in Chapter 5 of this manual NOTE In the following example we assume that the OP panel is configured with a base register o
4. Computer System Your personal computer must meet the following Requirements minimum requirements type 386 or above 4X Windows 3 1 or later including Windows 95 or NT 1 meg of hard drive 1 meg of RAM OptiMate OP WINEDIT How to Configure Your Panel Follow these steps to configure your OP 420 operator panel Step 1 Load OP WINEDIT If you are not already using the configuration software or have an older version you must install version 2 3 or later if you are using an older version of OP WINEDIT you can obtain an upgrade at our web site The software is provided on one 3 1 2 inch high density diskette and comes with its own manual Here are brief installation instructions e Place the installation disk into your computer s floppy drive usually either drive A or drive B Open Microsoft Windows 3 1 or above For Microsoft Windows 95 or NT the Start Run program task bar is located at the bottom left portion of your screen For Microsoft Windows 3 x versions select File Run from the Program Manager screen e Select and a pop up window appears Type in the path for the drive in which you have placed the setup disk and designate the file setup Click on OK when you are finished Step 2 Connect Panel to PC Connect the OP 420 to your personal computer using the OP CCBL configuration cable Make sure the OP PS400 5 VDC power supply is connected 4 4 a Conf
5. Status register Programming Examples Displaying The following example uses the configuration shown below and shows two Messages messages being displayed The top line is displaying message 74 The data for the data field is from location N7 54 The bottom line is displaying message 78 OP420 Configuration x Edit Help Pushbuttons PLC Panel a Alternate Momentary Register Close 1 a Address W7 0 5 Labels 3 e 4 Write to Panel Configure Messages Delete Msg Msg Text Action Decimal Format Range Clear List Parts Lefr Display Product Rate Display Tank Lewer Display Good Parts Display Reject Parts Display Count Val a4aaaa v Display Display Process Step 1 OO m N 2 MOVE Selects message 4 for the top display line Source 4 12 Dest N7 0 MOVE Selects message 8 for the bottom display line Source Dest N7 1 LI MOVE Puts data from N7 54 into the top line Source 7 54 data field Dest N7 2 Good Parts Left 235 Process Step 1 Example Address Function N7 0 M 0 Top line message selection 1 to 160 N7 1 M 1 Bottom line message selection 1 to 160
6. Close 5 Labels umm Write ta Panel Configure Messages Ng oe Action Decimal Farmat 1 Parts Left 7 Product Rate A Tank Level Good Parts Reject Parts Gount Val hvgPart Hr AAA RRA ana Process Step 1 BIN BCD BCO BCD BCD BCD Double Display Display Display Display Display Display Display Enter the above messages to run the example programs Floating Point Delete Msg Clear List Range Place the following program rung in the program to copy the status register to memory location V40600 LD V2006 OUT V40600 Register V40600 MSB Bit 15 14 13 12 11 109 8 7 6 5 4 This rung copies the status register to V40600 LSB 3 2 1 0 Status Register 16 15 14 18 12 11 10 9 8 7 6 5 4 3 2 1 C3 C2 C1 C0 F4 F3 F2 Fi As you can see control relays C0 C3 will be associated with pushbuttons F1 F4 Fi F2 F3 F4 4 jl Programming Examples Using a Function The four function buttons will appear as control relay coils in your program Button assuming the register copy rung shown previously is in the program CO Y1 OUT This rung turns on output Y1 when pushbutton F1 is activ
7. OUT v2000 M 0 OP Panel Example PLC Register User Memory M 0 Message request V2000 3 Static Display ud Description Top Line Static Message All supported CPUs use the first Register Function 5 OP panel register for displaying 3 Top line message selection top line stala message med Bottom line message selection Your ladder logic program must M 2 sequence the message being M 3 Top line data 2 displayed by placing an integer M 4 Bottom line data value 1 160 in register 0 For M 5 Bottom line data 2 bottom line static messages USE Mig Status register register M 1 for message selection The OP panel operating system automatically updates the latest top Example Message 3 and bottom line messages according to values placed in the highlighted registers System Running Lad Understanding the Features Dynamic Message You program message numbers 1 160 to be used as dynamic messages One Operation numeric field per line is allowed Dynamic messages may be displayed on either the top or bottom display lines The maximum number of digits which may be displayed is five if binary data format is used four if BCD is used and eight if BCD double is used The figure below demonstrates the OP WINEDIT screens for programming a dynamic message Enter the message text and place the care
8. Count Val 12345678 Process Step 1 Programming Examples D n Displaying Floating Point Numbers Example 1 Displaying Floating Point Numbers Example 2 This example uses a floating point number in the bottom line display The bottom line uses data display message 77 which has been configured as afloating 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 the data to be understandable In this example the data is a constant number 879 56 which is loaded into the bottom line data display registers using an LDR load real number instruction The top line is text message 8 LD This selects message 8 to be displayed in the top line K8 OUT V2000 LD This selects message 7 to be displayed in the K7 bottom line OUT 1 V2001 This puts the floating point value 879 45 into bottom line data field Notice that the displayed LDR value is truncated R879 45 Process Step 1 AvgPart Hr 8 79E 02 TTE This example is similar to the one above except that it gets its value from two PLC registers instead of a constant value The bottom line uses data display message 77 which has been configured as a floating point display message Remember floating point
9. 2 Actio iur Range Data Format ext Message Action Data Format A Application Worksheet 3 OP 420 APPLICATION WORKSHEET PAGE PUSHBUTTONS DESCRIPTION A M Alternate Momentary F1 System Type Panel Type F2 PLC Base Register Addr F3 PLC CONFIGURATION F4 PLC Family CPU Model Protocol PLC Address PLC Timout Baud Rate Parity Data Stop Bits MESSAGE Text Message Action Data Format Action Data Format Data Form Data Format A 4 4 Application Worksheet OP 420 MESSAGE WORKSHEET PAGE MESSAGE Text Message Data Form Action Data Format Action Data Format Data Format Index A Address assignment 3 12 4 5 Application planning 1 4 5 2 worksheets 4 3 Appendix A B BCD Numbers displaying 3 8 5 7 BCD Double Numbers displaying 3 8 5 7 5 13 Back panel layout 1 5 Baud Rate 4 5 Binary Numbers displaying 5 6 5 12 Bit Level Access 3 3 C Communications Cable recommended 2 9 Communications problems 5 14 Computer Requirements 4 3 Configuration address 2 7 3 12 4 5 preparation 4 2 software 4 2 Configuration Cable 2 8 Configuring base register address 4 5 communications 4 4 overview 4 3 panel functions 4 6 Connecting Cables pinouts 2 10 selecting 2 9
10. 11000100 PLC ushbuttons Mu eA Memory Requirements Asi Understanding the Features Status Register Status Register Overview Bit Level Access The OP400 panels communicate to the PLC through user defined PLC data registers The starting or Base register is assigned during panel configuration and automatically occupies seven consecutive 16 bit data registers In this manual the registers are identified as 0 M 1 M 2 thru M 6 Status register M 6 contains bit of word information to monitor individual OP panel functions and features Shown in the figure below base register M 6 must have bit level access by the user control program That means the Status word register memory OP panel Base register must be mapped to a user memory bit register This bit register is referred to as Internal Control Relays such as CO C1 etc The Status bits are monitored and manipulated by the PLC ladder logic For discrete operations such as pushbuttons register M 6 bits are accessed by the PLC control program The figure below shows the fixed definition of the Status register bits These bits are labeled F1 pushbutton 1 thru F4 pushbutton 4 The bits and associated labels are
11. CPU cables 2 9 D Decimal point placement 3 8 Dynamic Message bottom line display 3 7 display 3 6 operation 3 6 top line display 3 7 F Floating Point Numbers displaying 3 9 5 8 5 13 Frequently Asked Questions 1 6 Function Button 5 2 5 9 5 10 L LCD Screen 1 4 Label creating 2 2 installation 2 4 template 2 4 Mapping DL105 205 405 status register 3 15 DL305 status register 3 16 Memory Mapping A B example 5 10 DL105 205 405 example 5 2 DL305 example 5 9 overview 3 12 Message Display examples 5 5 5 9 5 11 operations 3 4 types 3 4 N NEMA Rating 2 6 O OP WINEDIT configuration cable 2 8 configuration software 4 2 documentation 4 2 installation 4 3 overview 1 6 system requirements 4 3 user steps 4 3 P PLC Timeout 4 4 Panel cutout dimensions 2 5 mounting dimensions 2 5 Panel Configuration problems 5 14 Power Receptacle 1 5 Power Supply connections 2 7 requirements 1 6 2 7 Pushbuttons labels 2 2 operation 3 10 overview 1 5 S Serial Port 1 5 Specifications 2 6 communication link 2 6 environmental 2 6 NEMA rating 2 6 power connector 2 6 temperatures 2 6 Static Message display 3 5 operation 3 5 Status Register 3 3 T Template for Labels 2 4 Troubleshooting 5 14 U User Memory overview 3 14 W Web site 1 2
12. DirectLOGIC DL105 DL205 D3 350 DL405 Example Address Function V2000 M 0 Top line message selection 1 to 160 V2001 M 1 Bottom line message selection 1 to 160 V2002 M 2 Top line data V2003 M 3 Top line data 2 V2004 M44 Bottom line data V2005 M45 Bottom line data 2 V2006 M 6 Status register DirectLOGIC DL305 DL340 only Example Address Function ud R400 R401 M 0 Top line message selection 1 to 160 D R402 R403 M 1 Bottom line message selection 1 to 160 S R404 R405 M 2 Top line data ud R406 R407 M 3 Top line data 2 R410 R411 M44 Bottom line data R412 R413 M 5 Bottom line data 2 R414 R415 M 6 Status register Allen Bradley SLC 500 Example Address Function N7 0 M 0 Top line message selection 1 to 160 N7 1 M 1 Bottom line message selection 1 to 160 N7 2 M 2 Top line data N7 3 M 3 Top line data 2 N7 4 M 4 Bottom line data N7 5 M 5 Bottom line data 2 N7 6 M 6 Status register 3 1 Understanding the Features DirectLOGIC User Memory Overview D2 250 D3 350 F1 130 D2 230 D2 240 D3 330 D3 340 D4 430 D4 440 D4 450 V Memory V Memory R Memory R Memory V Memory V Memory V Memor
13. into V2004 M 2 which is embedded in the bot V3001 Loads variable data tomline message The bottom line data value will update as long as X5 is enabled ON M 4 PM OP Panel Example PLC Register User Memory M 1 Message requested V2001 7 4 Bottom line data message V2004 1101 Understanding the Features Displaying Data With a Decimal Point Displaying BCD and Binary Numbers Displaying BCD Double Numbers Bottom Line Dynamic Message Remember your ladder logic Register Function program must select the bottom line M 0 Top line message selection mes sage being displayed by placing M 1 7 Bottom line message selection an integer value between 1 and 160 TE Top line dat message in register M 1 ii M 3 Top line data 2 Example Message 7 M 4 1101 Bottom line data M 5 Bottom line data 2 M 6 Status register Zone2 Temp 1101 The highlighted registers shown in this figure results in displaying this bottom line dynamic message The OP 420 panel allows you to display fixed point numbers which are numeric values that have a known decimal point placement and are simply handled as integer values within the PLC program The only time you see an actual decimal point is on the LCD display An example of a fixed point number is a program that uses temperature as a control variable and within the program all temperatures are scal
14. N7 2 M 2 Top line data N7 3 M 3 Top line data 2 long BCD floating point N7 4 M 4 Bottom line data N7 5 M 5 Bottom line FI BCD floating point N7 6 M 6 ft F4 F3 F2 F1 2 12 Programming Examples Displaying Binary This example is similar to the previous example except that it uses a binary number in the top display The top line uses data display message 1 which has been configured as a binary display message The data for the data field is a constant number 12340 3034 Hexadecimal The data can also be moved tothe data register from another register The bottom line is text message 78 Numbers 2 a E x I 2 MOVE Selects message 1 for the top display line Source 1 12 Dest N7 0 MOVE Selects message 8 for the bottom display line Source Dest N7 1 MOVE Puts binary data 12340 into the top line Source data field amp H3034 Dest N7 2 Parts Left 12340 Process Step 1 Example Address Function N7 0 M 0 Top line message selection 1 to 160 N7 1 M 1 Bottom line message selection 1 to 160 N7 2 M 2 Top line data N7 3 M 3 Top line data 2 long BCD floating point N7 4 M 4 Bottom line data N7 5 M 5 Bottom line m BCD floating point N7 6 M 6 F4 F3 F2 F1 Displaying BCD Double Numbers Displaying Floating Point Numbers Programming Exam
15. 6 Dynamic Message Top 22 utar e sale etm bie eve dle and 3 7 Dynamic Message Bottom Line esee oh ERE CIR RR 3 7 Displaying Data With a Decimal Point 3 8 Displaying BCD and Binary Numbers ennenen rnane 3 8 Displaying BCD Double Numbers re 3 8 Displaying Floating Point Numbers cocer 9 x RR ne 3 9 P shb ttons id Lou Sd ek ed eR oid ae iced aci a ea a ard d 3 10 amp ic Rh EE CES REIP ORE MEER FRU ERE RE RE X 3 10 P shbuttonm EXAample s eene treat sea weedeat Uns d DEPT pas 3 11 Pushbuttons Using Direct Access to Status Register Bits 3 11 Pushbutton LEDS 33 ox ate dot mettus quts Ch EO SERRE I Eee dee sS Un Be 3 11 Memory Mapping PrOGBSS uec os poU ea UT Re aiia EORR M 3 12 OP Base Register Memory Definition c eee eee eee eee 3 12 Operator Panel Base Memory cece ete eee n 3 12 Panel User tatu ct Siete E e ci a eh Se Sek RU an 3 13 DirectLOGIC User Memory Overview 0 ccc cece eee RII Hm nn 3 14 Mapping Operation Sik ee 3 15 Mapping Example DL105 DL205 03 350 and DL405 3 15 DL105 01205 03 350 and DL405 e
16. Floating Point Numbers Nd Understanding the Features When placing a BCD double number in Example BCD Double the display registers the first register 92345678 numerically in the sequence of two Lana registers M 2 or M 4 will contain the four least significant digits of the number The second register in the sequence M 3 or M 5 contains the data for the 9234 must be in register M 3 V four most significant digits of the BCD double number For example to display the number 92345678 on the top line of the display the top line data registers M 2 and M 3 must contain 5678 and 9234 respectively 5678 must be in register M 2 The OP 420 has the capability to display Floating Point or Real numbers if you select the option Float when the display message is being defined in the OP WINEDIT software Floating point numbers can only be used with the D2 250 D3 350 and D4 450 CPUs since they are the only compatible CPUs that support the IEEE 32 bit floating point number format which is where the floating point numbers are stored They always occupy two 16 bit register locations regardless of the size of the number See the PLC User Manual 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 420 will be able to display any number within that range The panel always uses the format to displ
17. described on the following page First examine the figure below to begin understanding the OP panel registers and functions You must structure your ladder logic program to coordinate OP panel functions asynchronously This means the operations are triggered successively not by a clock but by the completion of an operation OP 420 Panel PLC Register Map PLC Register Register Function M 0 Top line message selection M 1 Bottom line message selection M 2 Top line data M 3 Top line data 2 for long BCD and floating point numbers M 4 Bottom line data M 5 Bottom line data 2 for long BCD and floating point numbers he M 6 Status register OP 420 Status Register M 6 15 14 13 12 1 40 9 8 7 6 5 4 3 2 1 0 F4 F3 F2 F1 Register Definition The following describes the function of each of the registers shown in the table Register M 0 When a number from 1 to 160 is placed in this register the predifined message associated with that number will be displayed on the top line of the LCD display Register M 1 When a number from 1 to 160 is placed in this register the predifined message associated with that number will be displayed on the bottom line of the LCD display 3 4 Understanding the Features Register M 2 This contains numeric data associated with the top line display this is describe
18. line The data value v2000_ M 0 in register V3000 let s say 1100 is moved into LD V2002 M 2 which is embedded in the top line V3000 Loads variable data message The top line data value will update as OUT long as X4 is enabled ON v2000 M 2 OP Panel Example PLC Register User Memory M 0 Message requested V2000 5 M 2 Top line message data V2002 1100 Remember your ladder logic Top Line Dynamic Message program must select the message being displayed by placing an register Function integer value between 1 and 160 0 5 Topline message selection message in id M 0 fe 1 Bottom line message selection embedded data for the top line M 2 1100 Top line data message is controlled by loading a 16 bit value into register M 2 M 3 Top line data 2 M 4 Bottom line data Example Message 5 M 5 Bottom line data 2 M 6 Status register Zonei Temp 1100 The highlighted registers 0 and M 2 in this figure result in displaying this top line dynamic message 2 oO EI 0 o 7 Dynamic Message X5 the roe input ae is i the it integer value is placed in Bottom Line ON AE Word register V2001 M 1 requesting message OUT 7 to be displayed on the bottom line The data v2001 M 1 value in register V3001 let s say 1101 is moved
19. office supply store in standard 8 1 2 x 11 sheets It is designed to run through a copy machine or laser printer Creating the The easiest way to create labels is to use the built in label making function of the Labels OP WINEDIT configuration software This is the preferred method and is shown below The labels can also be created manually using the template shown in the next section to help layout the transparency film Here are some ways of manually creating labels e Use a computer graphics program and a laser printer to create the transparency directly or print the labels on paper and photocopy them to a transparency sheet e Use press on letters on a transparency sheet e Use a typewriter or lettering machine or use press on letters to create labels on a paper sheet then photocopy the paper sheet onto a transparency sheet Creating Making labels using the OP WINEDIT configuration software is easy see Chapter 4 Labels Using for information on loading and using OP WINEDIT After loading OP WINEDIT OP WINEDIT follow these steps Welcome To PLE Duect Existing System Exit Software 1 Open OP WINEDIT and select New System Installation and Specifications Optimation Pane Configuration UNTITLED 2 lm Fie Edt Port Help Single Pane System Mukiple Panel System Clase System Titte Configure PLC Link 240 7 Sequence Panel Configaratior Panet
20. 2 Using Function Button oc cts oul ats bb res RE PEDES ber ERR E ees 5 4 Displaying Messages 5 cdi Seven nic MERERI RR E MB CN SIUE D EROR BE MERI S 5 5 Displaying Binary Numbers 5 6 Displaying BCD Double Numbers 5 7 Displaying Floating Point Numbers Example 1 5 8 Displaying Floating Point Numbers Example 2 5 8 Example Using D3 340 Cee ERE E 5 9 Defining the Status Register eee eens 5 9 Examples Using Allen Bradley SLC 5 03 5 04 and Micrologix 5 10 Interfacing to A B Memory ioco cer CR shes Sewers CHEER EO 5 10 Using a Function Buttons xo rper eet er sees INS PETRO EDEN E pp e PERDE 5 10 Displaying Messages 5s abs eol dab ee aru d 5 11 Displaying Binary Numbers qa qs eat ag 5 12 Displaying BCD Double Numbers 0000 c cece eee eee nne 5 13 Displaying Floating Point Numbers 5 13 Troubleshooting the OP 420 Panels 5 14 e EROR EC MM LED I 5 14 Power Supply Problems bees teehee 5 14 Configuration Problems 22 4 2 et Rex etn ee ee ees EP eet 5 1
21. 3 350 DL405 and DCMS 25 pin ports 13 not used 12 not used 112 not used 10 not used 9 not used 8 not used ibs 30 ground used CTS 4 RTS 3 RX 2 TX 1 not used BES net 25 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 c 9 PLC RJ12 Panel 3 4 on svong 1 Panel Connection RJ12 123456 12 Sig ground 2 not used i RX 4 TX 5 5 VDC 6 Sig ground Understanding the Features In This Chapter Learning the Features Status Register Messages Displaying Messages Pushbuttons Memory Mapping Process DirectLOGIC User Memory Overview Mapping Operation Mapping Example DL105 DL205 D3 350 DL405 Mapping Example D3 340 Ed Understanding the Features Learning the Features In this section the subject of how to use the OP 420 features is described The details for using pushbuttons and messages are covered We recommend that you study this chapter before attempting to configure and use the OP panel As you proceed through this chapter relate the topics discussed with how your operator panel may be implemented The concepts discussed in this chapter are applicable to all PLCs Message Operations eMemory Mapping Process Using the Pushbuttons
22. 4 Communication Problems DERE RSEN Ux EE 5 14 Getting Help onto atia tius ud qe 5 14 Appendix A Worksheets Index 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 requirements Technical Support SELV Circuits Environmental Specifications Preventative Maintenance and Cleaning External Fuse Protection for Input Power NOTE Products with CE marks perform their required 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 equipment is used in a manner not specified in this manual Only replacement parts supplied by PLCDirect or its 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 at 800 633 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
23. AC receptacle is available part no OP PS400 This power supply or equivalent but it must have a center negative power jack is required for configuring your panel It is also required for operation unless you are using a DL105 DL205 or DL405 PLC these products supply 5 VDC through the communications cable All other PLCs including D3 340 and D3 350 when used with a D3 05 1 D3 08B 1 or D3 10B 1 base CPUs require the use of an external 5 VDC power supply Q Will the OP panels support graphics animation or color operator display screens A No the OP panels which support display capabilities allow numeric data display and some panels will also allow text message display Installation and Specifications In This Chapter Labeling the Pushbuttons Template for Manually Creating labels Dimensions for Mounting Panel Specifications Power Supply Connections Connecting the Configuration Cable Selecting the Proper Communications Cable Communications Cable Details 2 2 Installation and Specifications Labeling the Pushbuttons Labeling the In any manufacturing environment it is Pushbuttons important to have legible labels on the pushbuttons Labeling the OP 420 MOUSE panel is a relatively simple process that involves removing the bezel and sliding label transparency into a pocket the panel overlay The transparent film can be purchased from almost any
24. Addiers Panel actions Panel Read From Panel Write To Panel PLC Base Register V2000 Address anges VZUDU V4777 40601 For Help press F1 o o ct e 5 3 Select Labels OP420 Label Template Print Pushbuttons 4 The OP 420 Label Template appears Type in the label text for all four pushbuttons Press OK to save the labels 4 2 4 Installation and Specifications om OM420 Label TEMPLATES Printer Pushbutton Template n Start Setup Next Prev 5 Print label on transparent film Transparent Sheet 6 Cut out the block of labels and insert them in the panel Bezel Opt Pocket Start Setup Next Prev Remove the bezel from the module by unsnapping the four plastic tabs which hold the bezel to the module frame Locate the pocket and carefully slide the labels into place Re attach the bezel by snapping the bezel onto the case Template for Manually Creating Labels 0 60 0 69 1 00 1 00 1 00 0 225 ket ee 0 60 px 4 425 Installation and Specifications Dimensions for Mounting
25. Bradley SLC 5 03 5 04 and Micrologix Interfacing to OptiMate panels interface to Allen Bradley SLC 5 03 SLC 5 04 and Micrologix Memory 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 see documentation for information on setting up and using type files NOTE When using an OP 420 with an Allen Bradley PLC always be sure that at least seven words of memory are allocated to allow proper communications All of the examples shown assume the OP 420 has been configured using OP WINEDIT for a file number N7 and base register address 0 With this configuration the status register will be at N7 6 This table relates status register bits to their N7 locations Status Register Using a Function The four function buttons will appear as control relay coils in your program Button N7 6 0 0 C 2 This rung turns on output O 0 5 when pushbutton 1 5 F2 is active Pushbutton F2 Example Address Function N7 0 M 0 Top line message selection 1 to 160 N7 1 1 Bottom line message selection 1 to 160 a N7 2 M 2 Top line data 7 3 M 3 Top line data 2 long BCD floating point X N7 4 M 4 Bottom line data Lu N7 5 M 5 Bottom line data 2 long BCD floating point RRR
26. OP 420 Operator Panel Manual Number OP 420 M WARNING Thank you for purchasing automation equipment from PLCDirect 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 questions
27. P 3CBL 1 D3 340 RJ11 RJ12 8 I IB 123456 RJ11 RJ11 PLC RJ12 Panel 3 not used 1 Sig ground 4 Sig ground 4 1 2 not used 3 RX 1234 4 TX 5 5 VDC 6 Sig ground OP 4CBL 3 DL405 a DB15 53 15 15 Sig ground hot used o 14 Sig ground DB15 PLC RJ12 Panel not used 9 13 Sig ground 2 3 4 Sig ground 12 not used 3 4 3 RX 11 5 VDC 11 5 2 TX 0 10 notused 4 1 1 not used 2 9 notused 13 L 6 ui 14 Pins 15 OP ACBL 3 Allen Bradley DB9 1 1 used 6 notused DB9 PLC RJ12 Panel ae HEP E e 8 3 3 Sig poro o 9 not used 5 1 9 6 Sockets 8 Installation and Specifications The drawings on this page are for cables which are not supplied by PLCDirect Use the drawings to make your own cable We recommend using a 22 AWG or larger shielded cable OP400 Series Communications Cables continued PLC 8 not used 7 Sig ground 6 not used CTS 4 RTS 3 RX 2 TX 1 5 VDC 15 not used 14 not used 13 not used 12 not used 11 not used 10 not used 9 not used apn ANON Mme Rc DB15 PLC RJ12 Panel 3 4 1 5 Make this cable for use with D3 330 w DCU D
28. Problems Configuration Problems Communication Problems Getting Help In this section we explain how to isolate potential problems which may occur while using the OP 420 Because these panels have only a power supply connection and a communications connection no DIP switches or controls to set and cannot be used in multiple panel arrangements troubleshooting is a very straightforward operation Ifthe panel LED display the pushbutton indicators and the RX and TX LEDs on the back ofthe panel do not illuminate the panel is most likely not receiving input power Carefully check your connections to make sure they are tight If this does not help see Chapter 2 and review the input power requirements Remember all PLC s require that you use the OP PS400 5V plug in power supply or equivalent for configuration Some PLC s also require that you use this power supply for operation Make sure that the 120 VAC receptacle you plug the power supply into has power Also if you are using another 5V power supply make sure that it has a center negative connector If using a PLC that supplies 5V for operation through the communications cable check to make sure sure that pin 5 on the lead going into the panel has a 5V signal Make sure that you are using the proper configuration cable OP CCBL and that it is securely connected Check your configuration program and make sure the proper communications port is selected such as COM1 or COM2 Revie
29. S3 General Panel Information LCD Display Window B Ss SSS The OP 420 operator panel provides a man machine interface to your PLC automation system This panel is not designed for applications which demand large amounts of operator data entry The panel communicates with your PLC using RS 232 serial communication Details on configuration software and programming your operator panel are covered in later chapters All OP400 series panels can only be used in a stand alone fashion one panel can be used with each CPU RS232 port They cannot be used in multi panel applications The OP 420 features an LCD display window display user defined messages Up to 160 messages may be configured and stored in the operator panel using OP WINEDIT configuration software The PLC logic program controls which messages are displayed Details on how to enter and use messages are covered in later chapters Backlit LCD Display with 2 lines 20 characters each About the Many applications require operator Pushbuttons panel pushbuttons for controlling the machine or process These pushbuttons are used as input signals to the PLC which start and stop a machine or process The OP 420 has four user configured pushbuttons All four pushbuttons may be freely defined rd RS Fi discrete input signals to the PLC Congue ese as JEJE mo
30. Safety Extra Low Voltage SELV Operating Temperature 0 to 50 C Storage Temperature 20 to 70 C Operating Humidity 9596 non condensing Air Composition No corrosive gases permitted No preventative maintenance is required To clean the exterior of the panel disconnect 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 Getting Started In This Chapter Introduction Conventions Used OP 420 Overview Frequently Asked Questions Introduction The Purpose of this Manual Supplemental Manuals Technical Support Thank you for purchasing an OP 420 OptiMate panel This User Manual shows you how to install configure and V program the 420 Also included ii application examples Be sure to keep OP 420 this manual handy for reference when you run into questions If you understand PLC systems and operator interface units th
31. The PLC Timeout works like rae one a this When the panel sends amessage to the PLC and does not receive a response or does not understand the response it will wait the time out period before resending the message 4 Configuring Your Operator Panel abad You also have several ports which can be used to connect your communications cable Some of these ports have fixed PLC address assignments and some do not The ports which allow configuring the PLC addresses can be set to a unique address ranging from 1 through 90 Refer to your User Manual for specific information on the ports of your PLC NOTE For Allen Bradley you will need to connectto Channel 0 bottom serial port using DF1 full duplex Additionally the Allen Bradley software allows you to set the bottom port to a unique PLC address The software default is PLC Address 1 You must select CRC error detection and make sure the address on the configuration screen matches the address you have assigned This port must also be configured for either 4800 or 9600 baud No other baud rates are supported for communicating between the OP panels and an Allen Bradley PLC Since the Allen Bradley software uses a default baud rate of 1200 you must change the settings Step 6 PLC Model Port Baud Rates Parity Stop Bit DL105 230 240 Top 9600 Odd Bottom Bottom DL240 only 1 9600 19 2k Odd None DL250 Top 9600 Odd Non
32. a Slice I O panels OP 4CBL 3 TI305 325 07 PPX 325 07 Requires DCU SIMATIC 335 37 PPX 335 37 Phone Jacks OP 3CBL 1 If DCU is used see note below 11405 425 CPU PPX 425 CPU OP 4CBL 3 SIMATIC 1405 PPX 430 CPU Top port 15 pin OP 4CBL 3 1305 gt 330 37 330 37 Requires DCU see note below 325S 07 or 325 w Stage Kt Requires DCU see note below 330 37 PPX 330S 37 Requires DCU see note below 430 435 CPU PPX 435 CPU Top port 15 pin Bottom port 25 pin SLC 500 5 04 Allen Bradley MicroLogix Note Pre assembled cables for connecting to these ports are not supplied by PLCDirect however you can use the cable pinout diagrams in the following section to make your own cables 2 10 Installation and Specifications Communications Cable Details The drawings on this page are for cables which are supplied by PLCDirect Use this page if you need to make your own cables We recommend using 22 AWG shielded cable OP400 Series p Communications EZ Cables 2 Panel OP 2CBL 2 DL105 DL205 m nt D3 350 D4 450 1 Sig ground RJ12 RJ12 PLC p 2 Panel 2 5VDC 1 3 RX 2 g 4 TX 3 4 5 not used 4 3 p TE a Connection RJ12 O
33. alternate ON OFF Momentary pushbuttons remain ON as long as they are pressed while Maintained pushbuttons retain their status ON or OFF until the next time they are pressed e Messages Enter all messages using the Configure Messages window OPAD Coetguiatan Edi Hep Pashbutions PLO Mamesary a oc Select Configure 4 Messages NE 6 Contigere Messages Action Address yooen e r 1 Parts Left 4048 Dis play 2 Product Flare Dis play 3 Level sees lt Dis play 4 Good Parts Dis play Reject Parts Dis play Dr a 5228048 Dis play 2 hwgParir Dis play Haarieg Point 8 Process Step 1 5 10 11 12 Hey Massage Number 1 4 Qui 9 Text Parts Loft Decimal Point Position Varveble Point count 17 For example Em curser by the 1 Cong ay Only area and double click Format This screen appears BLO Double allowing you to enter the message Select OK when message is written iin Sat o m USA Furepean Character Set available on Panele with sta codes of 11 97 20 Er Step 8 Download and Save Connecting the OP CCBL configuration cable places the panel in configura
34. as worksheets that you can use to help setup your OP panel Conventions Used Sk Key Topics for Each Chapter When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note The word NOTE in boldface will mark the beginning of the text When you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases The word WARNING in boldface will mark the beginning of the text The beginning of each chapter will list the key topics that can be found in that ifitroduction chapter 4 OP 420 Overview Plan your System PLC Pushbuttons Let s look at the OP 420 operator panel and its individually supported features As you continue through this manual try to relate the examples to your Operator Panel application The application worksheets located in Appendix A will be helpful during the design and configuration of your system It is important to read and understand all topics discussed before installing configuring and programming your application You should plan your system with all operator interface requirements in mind TEE Memory Requirements
35. ay 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 three significant digits The OP 420 truncates the remaining digits so you always see the true number The two examples below showthe data contained in the PLC registers and the corresponding value displayed on the panel in its format Notice how the data is truncated The configuration of a floating point number message is similar to any other Example Floating Foint Numbers message First you select the message then od type in the text using Ee Registers nine caret symbols as a place holder 12301 789 1 23E 04 for each of the nine floating point number symbols Next select the Float option for 123 96783 1 23 02 the data format Let s say you wanted to configure message 58 to display a floating point number Inthe OP WINEDIT software select OP 420 as the module type and then select message 58 with the mouse in the following message Float Pt and 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 appropriate message number into the corresponding top or bottom line message selection register For example if you display the number 632 15 in message 58 it will be displayed as Float Pt 6 32E 02 m 5
36. ays are used within the ladder logic program for monitoring pushbuttons and coordinating data entry control SP1 always ON maps OP register V2006 to 40600 0 C17 n SP1 Mapping the STATUS word LD g ON 2006 OUT V40600 Internal OP panel Control Register Relays V2006 V40600 M 6 Status register M 6 CO C17 OP 420 M 6 PLC Program User Memory 15 14 18 12 11 109 8 7 6 5 4 3 2 1 0 C17C16C15C14C13 C12C11C10 C7 C6 C5 C4 C3 C2 C1 CO F4 F3 F2 F1 F4 2 1 Understanding the Features Mapping Example D3 340 DL305 Family Let s look at mapping the D3 340 CPU belonging to the DL305 family Unlike the DL105 DL205 D3 350 and DL405 mapping examples the DL305 uses 8 bit words It therefore takes two 8 bit words for each mapped memory location because each mapped memory location needs sixteen consecutive bits We will assume that R400 was used as the base register address and we want the mapping to start at R16 for the status register This figure demonstrates how the OP panel status word is mapped to ladder program user memory for bit manipulation In this figure notice that the two 8 bit status registers M 6 are loaded into the Internal Control Relays R16 R17 These control relays are used within the ladder logic pr
37. 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 PLCDirect 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 PLCDirect 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 Micros
38. d in more detail later Register M 3 This is used for long BCD and floating point data only Register 4 This contains numeric data associated with the bottom line display this is described in more detail later Register M 5 This is used for long BCD and floating point data only Register M 6 This is the status register Bits O thru 3 monitor the status of pushbuttons F1 thru F4 These bits are set to 1 when the pushbuttons are active Messages Displaying Messages on the LCD Screen Static Messages Dynamic Messages Through the OP WINEDIT software up to 160 predefined messages can be entered and stored in the OP 420 These messages are 20 characters long and can include a field for the display of numeric data Any predefined message can be displayed on either the top or bottom line The messages entered during configuration are numbered 1 thru 160 To display a particular predefined message on the display simply place that message s number in the message selection register For example let s 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 respectively we would simply need to put the number 16inregister M 0 and 22 register M 1 If any number other than 1 thru 160 is placed in a message selection register the associated line will not change Example Message Mar
39. e COEUR Pao ee 2 8 Connecting the Configuration Cable eseeeeeseee n n nh 2 8 Contiguration Cable Sows teu oce ed D E Ro Demet ro ERE e IS EDEN 2 8 Selecting a Communications Cable cee cece eee eee eee nn nnn 2 9 Communications Cable Details 2 000 cece cece eee eee I nn nh 2 10 OP400 Series Communications Cables 2 10 Chapter 3 Understanding the Features Learning the Features 250 eoa voee ik Rte oc Sig ac Ro DS dca ele Mt ata a 3 2 Status Register acetate ets Laat di ups ect DI 3 3 LN Table of Contents Status Register Overview tesi Qut aetati e 3 3 BitE vel ACCESS 1032 5 WSs bd e aos dec add eds RR UES fes eid a 3 3 Register Definition s dace seek eee ee cea ie ed ex Face Ete S Ve eres 3 3 MeSSaQGS rrr 3 4 Displaying Messages on the LCD Screen 3 4 Static Messages vetere ts cete E TRE SUCRE RR DUE EE ora ed E 3 4 Dynamic Messages xe eR Reales ERI a ede ERES IA REDE Uere EXIT EYES 3 4 Displaying Messages ws iu EE EAR E ERRARE RR EX RUE EE EO X RR REO RR RO KO E 3 5 Static Message Operation See eee eee exu 3 5 Static Display t 3 5 Dynamic Message Operation eee eee eens 3
40. e FA C1 Y2 OUT This rung turns on output Y2 when pushbutton F2 is active F2 C2 Y3 OUT This rung turns on output Y3 when pushbutton F3 is active F3 C3 Y4 OUT This rung turns on output Y4 when pushbutton ET F4 is active eee E x nm Displaying Messages Programming Examples a The following example shows two messages being displayed The top line is displaying message 4 and the bottom line is displaying message 8 C100 LD K4 OUT V2000 ij LD OUT V2001 LD V3000 OUT V2002 This selects message 4 to be displayed in the top line This selects message 8 to be displayed in the bottom line This puts data from V3000 235 in this example into the top line data field Good Parts 235 Process Step 1 TIE V2000 Top line message selection V2001 Bottom line message selection V2002 Top line data 2003 Top line data 2 for long BCD amp floating point V2004 Bottom line data V2005 Bottom line data 2 for long BCD amp floating point V2006 Status register Programming Examples Displaying Binary This example is similar to the previous example except that it uses a binary number D x n Numbers in the top display The top line uses data d
41. e 1 Bottom 9600 19 2 DL330 DCU only 4800 9600 19 2k Odd None 1 DL340 Bottom amp 4800 9600 19 2k Odd None 1 DL350 9600 Odd 1 4800 9600 19 2K Odd None DL430 440 Top Top 9600 Odd 1 Bottom 9600 19 2k Odd None DL450 0815 9600 Odd DB25 9600 19 2k Odd None 1 RJ12 9600 19 2k Odd None These ports do not supply 5VDC You must use the OP PS400 external power supply Select the Base Register Address This step is very important because it establishes the link in your PLC memory to the panel Chapter 3 Understanding the Features describes the mapping process Once you are familiar with the mapping process and you know which memory block in your PLC to use refer to the user manual for your PLC enter your selection If you choose Allen Bradley as your PLC Type you must enter the PLC File Number in addition to a Base Register Address You must expand the memory map in the Allen Bradley PLC to include all registers being used by the OP panel The panel will only recognize integer file types N7 and user defined file types N9 through N255 Enter the number only and not the prefix N The Base Register Address is any number between 0 and 255 Li Configuring Your Operator Panel Step 7 Configure the Panel Features These features are discussed in detail in Chapter 3 but they include Pushbutton Configuration The pushbuttons can be configured as either Momentary or Maintained
42. ed in tenths of a degree The values are integer so a temperature of 73 5 degrees would be 735 in a data register For the convenience of the operator you would want the LCD display to include the decimal Fixed point numbers are handled by Example Message 47 simply placing a decimal point or period Temperature 73 5 in the message field during configuration For example let s say you want display the message E Place 47 register M 0 Temperature 73 5 on the top line and inessage is Temperature the message is 47 Enter message 47 during To display this 735 must configuration be in register M 2 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 form or between 0 and 9999 in BCD form For these type numbers register M 2 is used for the numeric value for the top line and M 4 is used for the bottom line The OP 420 will handle large numeric numbers If you select the option BCD Double when the display message is being defined your display can handle numbers between 0 and 99 999 999 The panel will use data in the register pair M 2 and M 3 for the top line and use M 4 and M 5 for the bottom line The data must be in BCD LDD Notice that double registers are used pil V UTD V M 2 amp M 3 Displaying
43. ee es 3 15 Mapping Example 03 340 cease ce id cee ee A RR EORR XR RACER OK Fn n RR n 3 16 DLIZOS FAMI uude Des ats etm ct nc ti meinte Dind 3 16 Chapter 4 Configuring Your Operator Panel Preparing for Configuration 4 2 OP WINEDIT Seem re o 4 2 More about OP WINEDIT este pe x EARS tee 4 2 HELP Screen ness csi eve IR Eee E ee IDCM IRE 4 2 Application Worksheets IRR EE E ER He ADS chee bho ERE ed 4 3 Computer System Requirements cece eee en 4 3 How to Configure Your Panel eee eee eee nnn nnn nnn 4 3 pec be ee eee 4 3 cos OPE 4 3 Step S opu LU ree te DN cao LU 4 4 lor Mec ecc och th E Dae Sake a hl cen Dnt 4 4 Step O 4 4 Step O cease odes ptas 4 5 SUB duet esee dar t us Edel ved Unos dee net dad eee eee epe d 4 6 Table of Contents BL Chapter 5 Programming Examples Examples Using PLCDirect PLCs ccc eee eee eee reece eee n n nnn 5 2 Register Usage She MESI oak eee dee Se nie hee site 5 2 Examples Using DL105 DL205 03 350 and 01405 5 2 Defining the Status Register estero 185 Shea ees Pas ee Rae ca EE adage d acus 5
44. erminal DC power plug center negative 5 VDC external power supply required for configuration on all panels required for operation on all PLCs except DL105 DL205 and DL405 5 VDC only LED Status RS 232 4800 to19200 baud 6 pin RJ12 phone jack type connector Installation and Specifications Power Supply Connections OP400 series panels require 5 VDC input power An optional 5 VDC external power supply that plugs into a standard 120 VAC receptacle is available part no OP PS400 This power supply or equivalent is required for configuring your panel It is also required for operation unless you are using a DL105 DL205 or DL405 PLC these products supply 5VDC through the communications cable All other PLCs including D3 340 350 and Allen Bradley 5 03 5 04 and Micrologix require the use of an external 5VDC power supply during operation NOTE Only use a5 VDC power supply that has a center negative DC power jack Configuration 5 VDC Power Supply Required For Configuring All CPUs 5 VDC Power Supply Part No OP PS400 oO ie ch 5 6 OP CCBL Configuration Cable Operation Using a D3 340 D3 350 D3 350 w DCU Bottom Port of DL405 or Allen Bradley CPU 5 VDC Power Supply Required Operation Using a DL105 DL205 or Top Port of DL405 CPU 5 VDC Power Supply Not Required Communications Cable Supp
45. f DirectLOGIC address V2000 In this case status register M 6 is V2006 which we will assume has been mapped to V40600 the DirectLogic internal control relay memory Mapping details are discussed later in this chapter In this example CO represents the pushbutton i C50 No 1 F1 viathe mapping process When push ouD button No 1 is pressed CO is true and Coil C50 ON is energized Status Register M 6 V40600 CO C17 D2 250 D3 350 D4 450 Only Direct bit register 8 V2006 0 H 1 00 ON Status Register PLC Program User Memory Bit 0 F1 V40600 M 6 Status Register M 6 C17 OP 420 Status Register M 6 15 14 13 12 41 40 9 8 7 6 5 4 3 2 1 0 F4 F3 F2 Ft Pushbuttons Using The DirectLogic D2 250 D3 350 D4 450 CPUs and the Allen Bradley SLC 5 03 Direct Access to and 5 04 support instructions which provide individual status bits access This is Status Register called Bit of Word capability For example in the figure above the ladder logic for Bits the D2 250 D3 350 D4 450 monitors the first bit of the status word directly Once again our example assumes that we configured the OP panel with a starting base address of V2000 Pushbutton LEDs There are LEDs located on each of the user defined pushbuttons These LEDs indicate whether the pushbutton status condition is ON or OFF You may choose the pushbutton
46. iguring Your Operator Panel wx e Q Step 3 Step 4 Step 5 Weltvome PLE Ducat Select New System Select Single configuration as Open OP WINEDIT Select New System Start Configuring Your Panel Start by filling in these parameters Optimstion Panel Configuration UN TITLED2 Panel System im Ed Pot Xx spes Enter a title that C Sine Panel Multiple Pandi System you will save this S Configues PLC Link DiractLogic 240 Sequence Panal Configuration Panel actions Panel Tepe Verily Panel Select OP420 PLC 2000 Head From Panel Addio IRanges V2 V3777 VAOSBO 40617 Write To Ponol d For Help press F1 Select Configure PLC Link Here 15 El where you define protocol items such as PLC address baud rate and parity PLE Eamiy Kov Z pw Enter the appropriate parameters for PLC Model Lamm your PLC The following table provides DirectLogie 240 the necessary information for MOSt g swrssmenss PLCDirect controllers For other PLC families reference that product s user Communications manual to determine the port PLC Addes 2 communications capabilities PLC Limeout in 1 00 During configuration make sure that your address and communications Baud Raie parameters match the PLC port settings
47. ill out and return the Suggestions card that was shipped with this manual Chapters Getting Started Discusses pushbuttons and the LCD display Also provides The main contents of this manual are organized into the following five chapters Introduces the physical and functional characteristics introduction to planning your system Installation and Shows how to prepare for system installation including Specifications specifications and mounting instructions Includes connecting cables part numbers and specifications Understanding the Explains the features and functions of the OP 420 Teaches concept of how data is exchanged between the panel and Appendices A 3 3 3 3 Features the PLC Also discusses the function of the status register Shows how to use the OP WINEDIT configuration software to Configuring the configure your panel Shows how to load the software on your Operator Panel personal computer call up the screens you will need and how to download the configuration program to your panel Provides example programs for using the standard functions and features These examples include ladder logic for implementing Programming pushbuttons and messages using DirectLOGIC compatibles and Examples Allen Bradley SLC 5 03 5 04 and Micrologix CPUs Also includes troubleshooting information Additional reference information is in the following appendices Worksheets H
48. is manual will provide all the information that you needto get and keep your panel up and running 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 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 panel We realize that even though we strive to be the best we may have arranged our information in such a way that you cannot find what you are looking for First check these resources for help in locating the information Table of Contents chapter and section listing of contents in the front of this manual e Quick Guide to Contents chapter summary listing on the next page Appendices reference material for key topics near the end of this manual You can also check our online resources for the latest product support information e Internet the address of our Web site is http www plcdirect com If you still need assistance please call us at 800 633 0405 Our technical support group will be glad to work with you in answering your questions They are available Monday through Friday from 9 00 A M to 6 00 P M Eastern Standard Time If you have a comment or question about any of our products services or manuals please f
49. isplay message 1 which has been configured as a binary display message The data for the data field is a constant number 12340 V3034 The data can also be moved to the data register from another register The bottom line is text message 8 a a LD This selects message 1 to be displayed in the top line K1 V2000 j LD This selects message 8 to be displayed in the K8 bottom line OUT V2001 LD This puts binary value from V3034 12340 in this I 4 3034 example into the top line data field OUT V2002 Parts Left 12340 Process Step 1 Programming Examples End Displaying BCD This example is similar to the previous example except that it uses a BCD Double Double Numbers number in the top line display The top line uses data display message 6 which has been configured as a BCD Double display message The data for the data field is from V3002 and V3003 V3002 contains the four least significant digits while V3003 contains the four most significant digits The bottom line is text message 78 LD This selects message 76 to be displayed in the top line OUT V2000 LD This selects message 8 to be displayed in the K8 bottom line OUT V2001 LDD This puts BCD Double number from V3002 V3002 12345678 in this example into the top line data field OUTD V2002
50. isplay messages Order the software from PLCDirect using part number OP WINEDIT The OP 420 panel requires version 2 3 or later HELP Screens The OP WINEDIT software provides Help windows which supply instructions for performing all necessary configuration tasks Should you have problems understanding how to program your panel refer to these built in Help windows To access the Help windows point and click on the Help menu and choose Using help or click on the icon located near the top of the main configuration window Poet ator lof HELP Screen argumen Menu Contorts Seach Back History Glossy I Welcome to the Optimation Panel Configuration Help wx e Q Table of Comente 4 Getting Stared Panel System Cosliguratien PLC Configuration Help System Scope ned Other Belerences OP 486 Larmrp Pushbulton Panel PengiDescnptan Memory e Dialog Other OP 413 Lamp Pushbutton Panel PanolDoscripion Other Topics 4 Configuring Your Operator Panel Application To prepare your application use the Worksheets Application Worksheets which are regs provided in Appendix A of this manual TM The example worksheets will help you configure the 420 panel The blank T worksheets can be photocopied and pp cm used in planning your own applications es a
51. lies 5 VDC Input Power E e Installation and Specifications Power Supply 400 Connections Power Supply Insert power supply connector into receptacle Serial Port Receptacle Connecting the Configuration Cable Configuration You will need two cables to use your OP panel A configuration cable part number Cable OP CCBL and acommunications cable Connect the configuration cable between the serial port on the rear of the OP panel and the serial port of the personal computer The panel may then be configured using the OP WINEDIT configuration software The figure below shows configuration cable connectors and wiring specifications The wiring diagram refers to the cable connectors not the communication ports This cable is disconnected after configuration 5 VDC Power Supply OP CCBL Configuration Cable Computer Panel SSSA 1 not used r 6 12 Sig ground 2 RX 6 not used 5 2 Cfg mode 3 TX 7 not used 2 3 RX 4 not used 8 not used 4 TX 5 Sig ground 9 not used 2 5 not used 123456 5 e _ 1 6 Sig ground Sockets Installation and Specifications Selecting a Communications Cable After configuration connect the communications cable between the OP panel and the PLC Use the following table to select the proper communications cable am CPU or oth vice DL105 preesse
52. mentary or alternating to best fit your Pushbuttons operator interface application You may create custom text labels for the pushbuttons Back Panel Layout The back side of the OP 420 contains a serial communications port with transmit TX and receive RX LEDs and a power receptacle A Product of Optimation Inc PLCOirect Complimentary Product Serial Comm 4 RSTXERX 1 Power Receptacle LED Display Intensity TXLED RXLED RJ12 Connection Location Adjustment Control Red Green Serial The serial communications port is a 6 pin RJ12 connector which supports RS 232 Communications _ interface wiring This port is used for communications between the OP panel and Port PLC as well as for programming your panel configurations The OP 420 can also draw 5VDC input power through this port through the communications cable when using a DL105 DL205 or DL405 PLC In this case the OP PS400 power supply is only needed for configuration Power Receptacle The center negative connector is located on the side of the panel and is used to connect the OP PS400 power supply This power supply is used when configuring the panel It is also used to power the panel when the panel is connected to any CPU that does not supply 5VDC from the communications port Frequently Asked Questions Q What is required to get started using the OP 420 in my application A You must read this manual and unde
53. numbers require two 16 bit registers In this example the data is loaded from V3010 and V3011 using an LDD load double number instruction to the bottom line display registers V2004 and V2005 LD K8 This selects message 8 to be displayed in the top line OUT V2000 ij LD This selects message 77 to be displayed in the K7 bottom line OUT V2001 LDD This puts the floating point value from V3010 V3010 V3011 into bottom line data field OUTD V2004 Example Using D3 340 Defining the Status Register Programming Examples aA The following example assumes that the OP 420 is configured for a base address of R400 R401 When configuring the panel enter the messages shown in the previous section for the DL105 DL205 D3 350 and DL405 examples DirectSOFT DSTR F50 First Scan MR K1 DOUT F60 R400 DSTR F50 R500 DOUT F60 R404 DSTR F50 First Scan ee K2376 DOUT F60 R500 DSTR F50 R414 DOUT F60 RC200 Displaying Messages This rung displays message 1 and R500 value in the top display line This rung loads an arbitrary value 2376 to be displayed Pushbuttom Status This rung remaps the status register R414 R415 to control relays C200 C217 L 92 10 Programming Examples Examples Using Allen
54. oft Corporation OPTOMUX and PAMUX are trademarks of OPTO 22 Copyright 1998 PLCDirect Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of PLCDirect Incorporated PLCDirect 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 OP 420 Operator Panel User Manual Manual Number OP 420 M Original Cover Copyright Original Issue Contents 1 1 1 6 2 1 2 11 3 1 3 16 4 1 4 6 5 1 5 14 A1 A4 11 12 Table of Contents Chapter 1 Getting Started InIrOdUC HOT eod eevee ard bienes ck hd ww M entertains tate Hee Mean De mrad Cd eat 1 2 The Purpose of this ve dece t beu bee ode MOL ek Ponds da DA uidet da 1 2 Supplemental ated eoa uaa dod eR 1 2 Technical SUIS DORE sd i Pope Ludus Moe Ma 1 2 Ghaplers Seer ee ihe D SERE Ie E e ure niet etuer v b suede vtt ve 1 3 Apperidices cuti bue prece tee nt 1 3 Conventions ERR ERRARE ERR 1 3 Key Topics for Each bid EDUC 1 3 OP 420 ERE 1 4 Plan your System ur od Os arate eem T utin M duong ho 1 4 General Panel 1
55. ogram for monitoring pushbuttons and coordinating data entry control Not C374 always ON after first scan maps OP register R414 R415 to R16 R17 Note that DSTR and DOUT are 16 bit instructions C374 Mapping the STATUS word Vt DSTR ON R414 DOUT R16 Register Relays R414 R415 M 6 Status register M 6 R16 R17 OP 420 M 6 PLC Program User Memory 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 C176 C174 C172 C170 C166 C164 C162 C160 4 2 1 4 1 C177 C175 C173 C171 C167 C165 C163 C161 Configuring Your Operator Panel In This Chapter Preparing for Configuration How to Configure Your Panel 4 Configuring Your Operator Panel Preparing for Configuration OP WINEDIT The OP 420 is configured with software running on a personal computer This Software software is available through PLCDirect and is referred to as OP WINEDIT configuration software Welcome To PLC Direct More about The OP WINEDIT configuration software allows you to configure OP panel OP WINEDIT applications as well as download write to panel and upload read from panel the configurations Use this software to configure your communication link select pushbutton control and enter operator d
56. ples 2 13 Allen Bradley PLCs do not have an easy way of handling long BCD numbers so this feature of the OP 420 will not be commonly used Inthis example register N7 54 and N7 55 contain an eight digit BCD number with the most significant four digits in register N7 55 The data is moved into the top display registers using a MOVE instruction BCD long data can also be displayed on the bottom line by simply moving the data to the bottom line data registers The bottom line is text message 8 MOVE Selects message 6 for the top display line 6 12 Dest N7 0 MOVE Selects message 8 for the bottom display line Source 8 Dest N7 1 L MOVE Puts BCD data from N7 54 N7 55 into the Source 7 54 top line data field Dest N7 2 MOVE SourceN7 55 Dest N7 3 Count Val 12345678 Process Step 1 p Example Address Function N7 0 M 0 Top line message selection 1 to 160 N7 1 M 1 Bottom line message selection 1 to 160 N7 2 M 2 Top line data N7 3 M 3 Top line data 2 long BCD floating point N7 4 M 4 Bottom line data N7 5 M 5 Bottom line data 2 long BCD floating point N7 6 M 6 F4 F3 F2 F1 Allen Bradley SLC PLCs do not have a means of handling floating point numbers 4 Programming Examples Troubleshooting the OP 420 Panels D n Troubleshooting Power Supply
57. rstand the OP panel requirements and application concepts You must have programming knowledge for the PLC product you re using the PLC serial communications capabilities which are available as well as hook up and connecting cable data How do configure the OP 420 operator panel A Using the OP WINEDIT configuration software available from PLCDirect This software allows you to configure the OP panels in a Microsoft Windows environment You may configure your programs offline upload and or download them to your OptiMate panel The OP WINEDIT software is provided with installation documentation and Help screens NOTE OP WINEDIT version 2 3 or later is required when using OP400 series panels Q Can the OP 420 be used with other PLC products A Yes The OP400 units do support Allen Bradley SLC 5 03 SLC 5 04 and Micrologix Can connect more than one OP 420 panel to one PLC CPU A Yes but only if the CPU has more than one communications port OP400 series panels can only be used in a stand alone fashion that is one panel can be used with one CPU port OP600 and OP1000 series panels can be used in multiple panel applications even if the CPU has only a single communications port with an OP 9001 communications panel Q What are the power supply requirements for the OP 420 A The OP400 series panels require 5 VDC input power A 5 VDC external power supply that plugs into a standard 120 V
58. s the programmer must define seven 16 bit registers for PLC interface Below is a figure showing memory layout for DirectLOGIC DL105 DL205 DL405 PLC s and uses V2000 V2006 for the OP 420 panel See the next page for other PLC product memory usage examples You must reserve 112 bits seven 16 bit registers or fourteen 8 bit registers CPU User s memory which are used to process data between the Panel and your PLC You must V2000 16 bits configure the Base register for the V2001 16 bits OP panel This base register address is V2002 16 bits stored in the OP panel memory V2003 16 bits P y V2004 16 bits V2005 16 bits V2006 16 bits Total 112 bits Understanding the Features OP Panel User Let s examine the different address conventions for PLCDirect and Allen Bradley Memory For example the PLCDirect address references are octal and the Allen Bradley is decimal The DirectLOGIC DL105 DL205 D3 350 DL405 OP panel address uses V memory registers which are 16 bit registers The DL305 family uses reference assignments with 8 bit registers This means that the DL305 will require fourteen 8 bit registers for data handling The Allen Bradley memory is defined with a reference which Nx represents the memory area and n which defines the word within the memory area Please referto the appropriate CPU User manual for the PLC product you are using
59. t symbol s depending on the number of digits you would like to display The value range which may be displayed is 0 65 535 integer 0 9999 BCD or 0 99999999 BCDD Choose binary BCD or BCD double format and fixed point decimal placement For dynamic messages which require fixed decimal point placement within the value you must use the OP WINEDIT to perform parameter placement type For fixed position decimal points you must enter the decimal directly into the message text such as Zone1 Temp For example let s say message 36 is Example Message 36 widgets sold Let s also say that 465 widgets have been sold today To widgets sold 465 display the current number of widgets sold on the bottom line of the display you would place 36 in register 1 465 lace 36 in register 1 message is widgets sold register M 4 The bottom line would then display widgets sold 465 To display this 465 must be in register M 4 Examples of dynamic messages Notice the caret symbols which is where data will be when the message is displayed Understanding the Features aa Dynamic Message T In this example if the PLC s input signal X4 is Top Line ON the 16 bit integer K5 value is placed in ON es ms uM Word register V2000 M 0 selecting message OUT i 5 to be displayed on the top
60. tion mode Select Write to Panel to download the configuration to your panel When the program is finished downloading wait a few seconds before disconnecting the configuration cable Disconnecting the cable returns the panel to run mode When downloading to OP panels which have already been configured first clear the message list Clear List before loading the new configuration This removes old messages which may reside within the OP panel s memory Remember to save your configuration program before closing OP WINEDIT Programming Examples In This Chapter DL105 DL205 D3 350 DL405 Application Examples D3 340 Application Example Allen Bradley Application Examples Troubleshooting 9 2 _ Programming Examples Examples Using PLCDirect PLCs 2 a E P3 LLI Register Usage The OP WINEDIT configuration software allows you to configure a panel to use a block of registers at a starting value that you define For a DL105 DL205 D3 350 or DL405 CPU the recommended memory to use is the general purpose data words starting at V2000 For the 305 family except the D3 350 the recommended memory is the registers beginning at R400 Any block of registers within the data word range can be used The first six PLC registers in the block used by the OP 420 panel are used for numeric information and this makes them ideally suited for the general purpose data registers The seventh register uses individual bits for p
61. type while configuring your OP panel There are two different operator controls alternate or momentary which will determine the LED response when the pushbuttons are pressed In the case of an alternating configured pushbutton the LED will change state each time the pushbutton is pressed With momentary configured pushbuttons the LED is ON only as long as the pushbutton is being pressed 2 EI 0 en 7 a le Understanding the Features Memory Mapping Process OP Base Register Memory Definition Operator Panel Base Memory Each OP 420 is assigned 112 bits of PLC user memory which will be used as the OP panel database The ladder logic program must access this assigned OP panel memory Let s take a closer look at this user memory and how it relates to the OP panel features As discussed earlier regardless of which PLC product you are using the base registers address M 0 through M 6 are formatted the same In this manual when the terms M 0 through M 6 are used this identifies which base register s are affected for the topic being covered Base Address Manual Reference Function Description M 0 Top line message selection M 1 Bottom line message selection M 2 Top line data M 3 Top line data 2 M 4 Bottom line data 5 Bottom line data 2 M 6 Status register PLC user memory is assigned to each panel with the OP WINEDIT configuration software For new OP panels and add on application
62. ushbutton status making it 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 register to a control relay register we show you how to do this later The following table lists the control relay register addresses for CPUs F1 130 V40600 V40617 DirectLOGIC DL205 D2 230 V40600 V40617 D2 240 V40600 V40617 D2 250 V40600 V40677 D3 340 R016 R037 and R100 R106 D3 350 V40600 V40677 DirectLOGIC DL405 04 430 V40600 V40635 D4 440 V40600 V40677 D4 450 V40600 V40777 DirectLOGIC DL305 D3 330 D3 330P not applicable to OP 420 Examples Using DL105 DL205 D3 350 and DL405 Defining the Status Register The following examples assume that the OP 420 is configured for a base address of V2000 When configuring the panel use the configuration data and messages shown in the following figure NOTE The Example Worksheet in Appendix A also has the configuration data and messages needed for these examples The example uses an F1 130 CPU but enter the PLC parameters for your PLC The example shows how you can use the worksheets to help plan your configurations Programming Examples 97 0 420 Configuration Edit Help Pushbuttons PLE Panel Alternate Momentary Register Address y2000 9799
63. w your configuration settings to make sure they are correct Remember the OP WINEDIT Help screens provide a lot of valuable information Observe the RX and TX LEDs on the rear panel They should be steady flashing or glow depending on the baud rate If not make sure that you are using the proper communications cable and that it is securely connected Review your configuratiion settings and make sure that the communications information for your PLC address number baud rate protocoltype etc is correct Checkthe user manualfor your PLC for the proper settings See Technical Support in Chapter 1 for additional information Appendix A Worksheets In This Appendix Example Application Message Worksheet Blank Application Message Worksheet A 2 Application Worksheet EXAMPLE WORKSHEET PAGE PUSHBUTTONS LAMPS DESCRIPTION OP 420 Demo M Alternate Momentary System Type Single Panel F1 ix OP 420 Panel Type F2 X PLC Base Register Addr _ 2000 F3 x PLC CONFIGURATION FA x PLC Family PLCDirect by Koyo CPU Model DirectLOGIC DL105 K Sequence Protocol PLC Address 1 PLC Timout _3 Baud Rate 9600 ODD Parity Data Stop Bits d E Data Format BCD Double Range Tex hes Action Display Data Format BCD Double Range Action Displa Text Mo
64. y R16 R16 R37 R37 En V1400 V1400 V1400 V2000 V2000 V2377 R400 R400 R563 R563 R700 R767 4377 40600 te V40617 V7377 V7377 V7377 V10000 V10000 EH M V40600 V40635 V17777 User Data Space available for OP panels V40600 V40677 Internal Relay Memory 40600 DirectLOGIC PLCs use octal addressing as indicated by the shaded areas 40777 Understanding the Features a Mapping Operation We explained earlier that the PLC and OP panel must exchange data on a bit level basis For DirectLOGIC controllers the OP panel status register M 6 must be mapped into internal control relays such as CO C1 etc This allows direct access to the Status bit register You must execute mapping every CPU scan in order to update data between the OP panel and PLC The following examples assume the OP panel starting base register M 0 is assigned to word register V2000 For example the DL105 DL205 D3 350 and DL405 CPUs have internal control relays starting at register V40600 They are designated as CO C1 etc Mapping updates status data M 6 into base register V2006 each PLC scan Mapping Example DL105 DL205 D3 350 and DL405 DL105 DL205 This figure demonstrates how the OP panel status word is mapped to ladder 03 350 and 01405 program user memory for bit manipulation In this figure notice the sixteen bits in the status register are loaded into the Internal Control Relays CO C17 These control rel
65. y had a little white fleeced lamb To display message 16 here place 16 in register M 0 Y To display message 722 here place 22 in register M 1 There are two types of messages which may be displayed on this panel Static and Dynamic messages Static messages are text displays which have no embedded data The static messages may be displayed when an event or condition becomes true You enter the messages during configuration Dynamic messages are text messages which include embedded data These messages are used to present the operator with important PLC data This data is information which helps the operator closely monitor and control the machine or process Example Static Message SYSTEM RUNNING Example Dynamic Message Zone1 Temp Data Value update from PLC register Understanding the Features ad Displaying Messages The logic required to display the configured message is quite simple Simply put the message number 1 160 in memory location M 0 for the top line message or M 1 for the bottom line message The figure below demonstrates an example of a Static message with the panel configured for a starting address of V2000 Static Message T In this example if the PLC s input signal X3 is Operation ON the 16 bit integer K3 value is placed in ON E RO DESEE Word register V2000 M 0 selecting message P 3 to be displayed on the top line

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