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M4020 user`s manual - Sea

1. INTERRUPT INPUTO 10 30VDC INTERRUPT INPUT1 10 30VDC FAULT INTERLOCK OUTPUT 100mAMP SINK ROTOR POWER INPUT 24 7 POWER INPUT 24vDC RESOLVER STATOBS d E 2 o fp INT RPM O2 2 V O2 ros Ro 03 4 L m 94 _ 04 lojs los H 2 O6 Joje s1 97 4 97 H O10 r 32 gu FUT O11 H 55 O2 ig o2 Ld 54 913 913 U 914 4 914 15 SER O15 RESOLVER 0116 pfe INPUT O7 ou o h H 1 AC 2 2 10 30V0C Pos RPM 3 3 L DIGITAL 4 4 INPUTS 8EA 1s 1 5 5 2 5 2 6 C 4 5 4 7 7 HHHH 8 s 8 CAN 10 9 io E STRB DGTO DO 1 RPM POSITION STRB DGTI D1 1 DISPLAY STRB DGIZ 02 13 ORUN 13 emae 4 DIGIT BCD DISPLAY 1KPPR OCOMM FT OUTPUTS 1AMP STRB 0073 D3 14 OFLT 14 eens RPM SELECT INPUT RP 15 C 15 REMOTE ENABLE INPUT EN 16 16 POWER INPUT 17 Lj tr 24VDC l ggr c Alc CHAN 20 128PPR 1 0 4020 8IN 80UT PLC 16 CHANNEL PLS SYSTEMS ELECTRONICS GROUP S J 10 30VDC TIMING CHANNEL OUTPUTS 100mAMP 16EA 8IN
2. logical OR equal assignment 2 Statements program statements equations conditional program execution if else if else program looping for while and do while loops unconditional program jumping goto user function calls ufuncXX subroutines system function calls sfuncXX I O operations 5 1 3 ASSEMBLY The Assembly language conforms to the Intel MCS 51 instruction set The assembler syntax conforms to the UNIX system V assembler syntax M4020 User s Manual SYSTEMS Electronics Group 24 SECTION 5 PLC PROGRAMMING REFERENCE 5 2 SYSTEM FUNCTIONS System functions provide the user with a means to perform extended functions such as communication on the serial network etc A summary of the system functions available in the M4020 module is as follows sfunc04 ASCII string load sfunc07 general external address read sfunc08 general external address write sfunc09 system fault routine sfunc10 USER PORT receive sfunc11 USER PORT transmit sfunc13 serial network communications System functions are entered in high level blocks as text Each system function has a parameter list associated with the system function call which defines such things as the address to read write to the number of bytes to send receive etc In addition some system functions return with an error code or function status which can be used to determine if the system function was successfu
3. 40 SECTION 7 PLS PROGRAMMING 8 Select PLS Program Select PLS program is used to change to a different existing PLS program or to create a new program once PLSdev has been invoked When the selection 1 entered the main development menu is cleared and the cursor is placed at the Program Name prompt Enter the desired program name as was done when PLSdev was initially invoked 9 File Utilities The PLSdev program allows you to back up restore make a new directory and to copy the current program to another program name all while inside PLSdev Selecting File Utilities brings up a sub menu with the following choices 1 Back up Program This allows the current program to be backed up on a diskette in drive A Install the back up diskette in drive A and press any key when ready This copies all the files associated with the program to the root directory of the A drive Note The files will be stored at the root directory of the diskette not within a sub directory This selection provides a convenient way to back up your program 2 Restore Program This copies the current program name from the root directory of the A drive to the drive and directory specified with the current program name Install the diskette with the program on it in the A drive and press any key when ready This copies all the files associated with the program name on the drive to the path specified with the program name Note The program files
4. Trouble shooting 1 Perform the hardware confidence test on the M4020 module It may be desirable to remove the suspect module from the system and to install another module to get the application being controlled back up and running See section 11 for details on the test 2 Basedon the results of this test return the module for repair or re install the module in system M4020 User s Manual SYSTEMS Electronics Group 63 SECTION 9 RPM POSITION OUTPUT CONNECTOR 10 4 SERIAL NETWORK COMMUNICATION ERRORS Unlike the system faults the serial network communication errors do not cause the M4020 module to shut down but instead are simply logged into the Current and Last comm error registers with user program execution continuing The Current comm error represents an error that 1 present at the time the fault codes are viewed while the Last comm error represents the last comm error detected The comm error codes are viewed from the Sdev fault display see section 10 2 for more details The error codes saved in the Current and Last comm error registers are the same error codes returned from the sfunc13 call The return values from the sfunc13 calls should be saved in separate B variables such that when a comm error occurs the slave that it occurred with can be determined 10 4 1 SERIAL NETWORK COMM ERROR CODES The following is a list of the detected serial network communication errors Code Description 00H No n
5. Compensation Enable Window This is a window in degrees in which is allowed to move in order to compensate for brake wear This allows the user to place a limit on the amount of compensation the M4020 will perform If no limit is to be placed on the compensation of enter 000 000 for the enable window In addition to the above parameters the REMOTE ENABLE input is used to enable the brake wear compensation The adjustment of is performed when the press is stopped RPM 0 and the REMOTE ENABLE input is high If the REMOTE ENABLE input is low when the press is stopped is not altered regardless of the stopping location This allows the algorithm to be by passed for inch and single modes as well as emergency stops M4020 User s Manual SYSTEMS Electronics Group 5 SECTION 8 BRAKE WEAR COMPENSATION 8 2 OPERATION OF THE BRAKE WEAR COMPENSATION ALGORITHM If the brake wear compensation algorithm is to be used CH00 must be used as the TDC timing signal should be wired to an input on the PLC that controls the press with this input used in conjunction with other user logic to declutch the press for TDC stops The REMOTE ENABLE input on the M4020 must also be controlled such that it is high when the press is stopped for TDC stops but is low when an emergency non TDC stop is activated or when in any other non TDC stop clutch mode such as inch or bar is used It
6. In addition to the four digit RPM POSITION display built into the M4020 an RPM POSITION output connector is provided to drive a remote RPM POSITION display or for interfacing to a PLC allowing the PLC to read the RPM or POSITION 9 1 RPM POSITION OUTPUT CONNECTOR DESCRIPTION OF OPERATION The connector contains eight outputs and two inputs The eight outputs are 24VDC sinking true low outputs which multiplex the data for the four digits using four outputs for the digit data and four outputs for the individual digit strobes Figure 9 1 is a timing diagram of a typical remote display update For each digit 1 s 10 s 100 s and 1000 s the digit data is placed on the digit outputs 175 2 4 s and 8 s and held for a data set up time The respective strobe output STRB DGTO 1 2 3 is then activated low for a data strobe time The strobe is then released and the digit data is held for a data hold time Note The digit data is always valid when the digit strobe is low this is when the digit data lines should be sampled and read in Each digit of the remote display is updated starting with the 1 s digit until all digits are updated at which time the entire process is then started over The remote display is thus updated automatically and continuously this way DIGITAL DATA 1 S DIGITAL DATA 2 S 4 X GITAL DATA 8 5 STRB DGT3 S EN STRB DGT3 5 _
7. SECTION 12 INSTALLATION 12 5 WIRING 10 30VDC DIGITAL OUTPUTS The digital outputs are 10 30VDC sourcing true high which are used to interface to the application outputs such as solenoids lamps PLC inputs etc Each output is rated at 1 amp DC continuous with an inrush pulsed current drive capability of 5 amps for 100msec The outputs do not contain output fusing or short circuit protection therefore external fusing should be provided Power for the digital outputs is wired to the power and common or return terminals on the output connector Be sure to observe the proper polarity of the power and wiring otherwise damage to the module may occur Note The outputs are optically isolated thus the 10 30VDC power applied to the output connector does not have to be commoned with the 24VDC power used to power the module Figure 12 3 shows an example of the typical output wiring M4000 OUTPUT OPTIONAL TO OTHER CIRCUITS 10 30VDC 6AMP TO INTERNAL OUTPUT S 0 17 2 1AMP L TO OTHER CIRCUITS S RETURN Figure 12 3 Typical Output Wiring M4020 User s Manual SYSTEMS Electronics Group 76 SECTION 12 INSTALLATION 12 6 WIRING THE FAULT INTERLOCK The fault interlock is a 24VDC sinking true low output which can be interfaced to an external relay or PLC input to indicate a fault condition with the M4020 module The output is capable of sinki
8. M4020 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 12 LED STATUS INDICATIONS The following four status LEDs are located on the front of the M4020 PWR RUN COMM and FLT The definitions of these LEDs are as follows PWR On when 24VDC power is applied to the M4020 RUN On steady when the M4020 is running a valid user s application program when an internal fault is detected or when a valid user s program has not been loaded The RUN led is flashed during program download and also when the hardware confidence test is executed COMM This LED is flashed every time an access to the serial network is made by any board or module on the network If the LED is on solid continuous communications is occurring on the network If the LED is off no communications is occurring This is not a fault LED but simply an indication of activity on the serial network FLT On when an internally detected fault has occurred in the M4020 See section 10 for more details on the fault routines and error codes M4020 User s Manual SYSTEMS Electronics Group SECTION 2 PLC PROGRAM STRUCTURE The PLC section of the M4020 is programmed with SYSdev The SYSdev programming language is a combination of Ladder High level subset of C and Assembly MCS 51 AII the files shown in the following are programmed in the same language format Each file can be written in any combination of the language t
9. STRB DGT1 5 DGT1 STRB STRB DGT2 6 DGT2 STRB STRB DGT3 7 DGT3 STRB RPM SEL REM EN 424VDC t aie 24VDC C CUT C L 4 RETURN PLC OUTPUTS 24 0 74 0 RPM SEL Figure 9 3 RPM Position Output Connector Wired to PLC M4020 User s Manual 58 SYSTEMS Electronics Group SECTION 10 FAULT DETECTION The M4020 contains comprehensive fault detection routines which verify the proper operation of the module at all times If the module detects a fault condition the FLT LED on the front of the module is illuminated and the fault routine is executed The sources of these faults range from a hardware failure of the module to an error in the user s program infinite loop etc 10 1 FAULT ROUTINE EXECUTION When a fault is detected the following fault routine is executed User program execution is suspended If possible all outputs in the system are disabled FLT LED on the front of the module is illuminated RUN LED is extinguished Fault interlock is opened Fault code representing the detected fault is saved in internal memory of the module for viewing with SYSdev The first step in correcting a fault condition FLT LED in the M4020 is viewing the fault code saved inside the module with SY Sdev 10 2 VIEWING FAULT CODES WITH SYSDEV When a fault occurs an IBM PC or compatible running SYSdev c
10. 11 5 Interactive Interface 71 M4020 User s Manual SYSTEMS Electronics Group iii CONTENTS 12 Installation o 73 12 1 Mounting the M4020 73 12 2 Wiring Input Power 73 12 3 Wiring 10 30VDC Digital Inputs 74 12 4 Wiring Interrupt Inputs 75 12 5 Wiring 10 30vdc Digital Outputs 76 12 6 Wiring the Fault Interlock 77 12 7 Serial Network Installation 77 12 7 1 Wiring the Serial Network 78 12 7 2 Setting the Network Addresses 80 12 8 Resolver Interface 80 12 8 1 Resolver Wiring 81 12 8 2 Resolver Reference Voltage Selection 81 12 9 Wiring the RPM Position Output Connector 83 12 10 Wiring Timing Channel Outputs 83 12 11 Wiring the 128PPR and 1KPPR Outputs 84 12 12 Power Up Sequence of M4020 Module 85 LIST OF FIGURES Figure 9 1 Typical Remote Display Update 55 Figure 9 2 RPM Position Output Connector Wired to Remote Display 57 Figure 9 3 RPM Position Output Connector Wired to PLC 58 Figure 12 1 Typical 4000 Input Wiring 74 Figure 12 2 Typical Interrupt Wiring 75 Figure 12 3 Typical Output Wiring 76 Figure 12 4 Typical Fault Interlock Wiring 77 Figure 12 5 Typical Network Wiring 79 Figure 12 6 Alternative Serial Connector Wiring 79 Figure 12 7 4020 40 41 Resolver Interface stand alone 82 Figure 12 8 M4020 40 41 s Slaved to One Resolver 82 Figure 12 9 Typical Channel Output Wiring 84 Figure 12 10 Typical 128ppr 1Kppr Output Wiring 84 APPENDICES Programming Examp
11. 9 147 187 054 10 093 133 003 11 093 133 011 12 090 130 008 13 090 130 032 14 090 130 035 15 090 130 311 16 139 179 352 17 147 187 358 M4020 User s Manual New Set Point 180 220 180 220 173 213 173 213 no change no change advanced by 7 no change pore Rr 157 197 advanced by 16 157 197 no change 147 187 advanced by 10 147 187 no change 093 133 advanced by 54 093 133 no change 090 130 fully advanced 090 130 fully advanced 090 130 fully advanced 090 130 fully advanced 139 179 retarded by 49 147 187 retarded by 8 147 187 no change SYSTEMS Electronics Group 53 SECTION 8 BRAKE WEAR COMPENSATION In all cases above normal TDC stops were performed with the REMOTE ENABLE input high Note In the above chart when the stopping location was within the allowed error 5 degrees or less no change was made in the set point Also once the set point was set to 90 130 that no further compensation occurred even though the press still stopped outside the allowed error This is because the compensation window was set at 90 270 degrees The algorithm only programs the set point within the compensation window If no limit on the amount of compensation is desired simply set the compensation window to 000 000 This allows to be reprogrammed anywhere M4020 User s Manual SYSTEMS Electronics Group 54 SECTION 9 RPM POSITION OUTPUT CONNECTOR
12. F2 Prev Chan key F3 Select Chan Used to select any channel number for editing When selected the current channel number will be cleared and the cursor will be placed in the CHANNEL field Simply type in the desired channel number in octal and press Enter lt CR gt to accept The set points and data for that channel will then be displayed F4 Doc Chan Used to enter the channel description or name in the DESCRIPTION field This is a user definition of the channel and will be associated with the channel at all times print outs etc Up to 20 printable characters can be entered in this field Once the name is entered press lt gt to accept F5 Pulse Train Used to program the channel as a pulse train See section 7 4 for details F6 Fine Tune Used to fine tune increment or decrement the selected set point See section 7 4 for details M4020 User s Manual SYSTEMS Electronics Group 44 SECTION 7 PLS PROGRAMMING F7 Clear SetPnt Clears the currently selected set point set point designated with cursor No other set points are affected by this command F8 Clear Chan Clears all the set points in the channel Also used to clear the channel and reset the pulse train mode to when a channel has been programmed as a pulse train F9 Set Offset Used primarily in the on line mode to electronically zero the resolver shaft at the machine zero To set the offset locate the machine at machine z
13. Press any key to return to the main development menu and try the download again M4020 User s Manual SYSTEMS Electronics Group 38 SECTION 7 PLS PROGRAMMING 5 Upload Channels from PLS This selection uploads the set points for each channel from the M4020 and saves it in the channel data file of the currently selected program Note The configuration data is not uploaded from the M4020 To upload the data form the M4020 perform the following 1 With both the PC running PLSdev and the M4020 powered up connect COMI on the PC to the CHAN port on the M4020 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the upload press ESC otherwise press any key to start the upload 3 While the upload is in progress the channel number which is currently being uploaded will be displayed Once all channels are uploaded an upload complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 Ifthe computer was unable to initiate the upload to the M4020 a message stating this will be displayed Verify the RS 232 cable connections between COMI on the computer and the CHAN port on the M4020 Press any key to return to the main development menu and try the upload again M4020 User s Manual SYSTEMS Electronics Group 39 SECTION 7 PLS PROGRAMMING 6 Print
14. Select Perform Test from the Test Functions Menu to start the test Once the test is initiated all tests enabled will be executed repeatedly starting with test1 thru the last enabled test until any key is depressed If no faults are detected the tests will continue to execute repeatedly displaying test passed messages after the successful completion of each test If a fault does occur the test will stop and display the following Fault Code XX test fault code and description Address of fault memory address or I O address where fault occurred Actual data at fault data actually obtained at address of fault Expected data at fault data that should have been obtained at address of fault Diagnostics test number for factory use only Once a fault occurs exit back to the Main Test Menu and re initiate the test to reset the fault code Once testing is complete exit back the Main Development Menu The user application program will now have to be re downloaded to the M4020 module M4020 User s Manual SYSTEMS Electronics Group 69 SECTION 11 HARDWARE CONFIDENCE TEST 11 4 PERFORMING THE PLS HARDWARE CONFIDENCE TEST WARNING The hardware confidence test should not be performed in an M4020 installed in a users control system Unpredictable output states may result while the test is being performed 11 4 1 EQUIPMENT REQUIRED In order to perform the M4040 41 hardware confidence test the following is requi
15. pee I O I O output input5 16 X010 5 Y011 6 I O output input6 17 X010 6 Y011 7 SYSTEMS Electronics Group APPENDIX PROGRAMMING EXAMPLE M4020 User s Manual SYSTEMS Electronics Group APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN block 4 Ladder This block implements a flasher circuit which flashes output Y11 0 off for 1 second and on for 75 seconds Note that F003 is only on for one scan since the off timer is reset as soon as F003 is a 1 which resets the on timer turning F003 back off on the next scan F003 is then used as the ck input to the counter in the next rung Note that the input to ck on the counter is a single shot if this was not the case the counter would down count once each scan that the ck input is a 1 which is generally not what is desired The counter resets itself as soon as it down counts to 0 since F004 is set to a 1 which resets the counter setting F004 back to a 0 on the next scan I O flasher output reset Timer 10 F003 4 Y011 0 Qi 4 4 r 00100 0 01 100 flasher flasher Timer reset off F003 T accum gt E 4 t P 40
16. 1 Key Depressed Set point Field 2 22 0 20 020 4 020 4 _ 0 020 40 Enter lt CR gt 020 040 M4020 User s Manual SYSTEMS Electronics Group 48 SECTION 7 PLS PROGRAMMING Example 2 The following example programs the entire channel by specifying both the and off parameters to 000 Key Depressed Set point Field 0 pel Enter lt CR gt 000 0 000 0 Enter lt CR gt 000 000 7 4 2 FINE TUNE SET POINT COMMAND The fine tune set point command allows the user to increment or decrement by one the on or off parameter of an already existing set point The fine tune command is executed by selecting F6 Fine Tune from the channel edit menu When this is done the fine tune menu is displayed This menu contains the following commands F1 On Setpnt This is used to select the on parameter of the set point When selected the cursor will move to the least significant digit of the parameter F2 Off Setpnt This is used to select the off parameter of the set point When selected the cursor will move to the least significant digit of the off parameter F3 Inc This command increments the selected parameter either or off whichever was selected with the On Setpnt or Off Setpnt commands by one F4 Dec This command decrements the selected parameter either or whichever was selected with the On
17. 4 DIGITAL OUTPUTS The eight digital outputs are 10 30VDC sourcing true high which are used to interface to the application outputs such as solenoids lamps PLC inputs etc Each output is rated at 1 amp DC continuous with an inrush pulsed current drive capability of 5 amps for 100msec The sum of the current must not however exceed 6 amps All outputs are optically isolated and contain a transient suppression circuit to protect the output when driving inductive loads The outputs do not contain output fusing therefore external fusing should be provided 1 5 RESOLVER INTERFACE The M4020 can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc A dip switch accessible through an access hole on the lower left side of the module selects the desired resolver reference voltage either 1 45 VRMS 3 70VRMS For Autotech and Gemco resolvers the reference should be set at 1 45 VRMS for C amp A at 3 70VRMS For other resolvers refer to the manufactures specifications to determine which reference should be selected See section 12 8 1 for details on wiring the resolver to the M4020 and selection of the resolver reference voltage M4020 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 TIMING CHANNELS The M4020 contains 16 timing channels Each timing channel can be progra
18. 51 8 1 Brake Wear Compensation Parameters 51 8 2 Operation of the Brake Wear Compensation Algorithm 52 8 3 Brake Wear Compensation Example 53 9 RPM Position Output Connector 55 9 1 RPM Position Output Connector Description of Operation 55 9 2 Remote RPM Position Display Interface 57 9 3 Interfacing the RPM Position Output to a PLC 58 10 Fault Detection 3 59 10 1 Fault Routine Execution 59 10 2 Viewing Fault Codes with SYSdev 59 10 3 Fault Codes 61 10 3 1 Watchdog Timer Timeout 40H 61 10 3 2 IBM PC to M4000 Communications Failure 42H 62 10 3 3 Invalid Program Faults 5cH and 5dH 63 10 3 4 User Program sfunc09 System Fault Call 45H 63 10 3 5 Internal M4020 Faults 43H 44H 59H 5bH 63 10 4 Serial Network Communications Errors 64 10 4 1 Serial Network Comm error Codes 64 10 4 2 No Response from Slave 04H and 05H 65 10 4 3 Serial Network Integrity error 03H O6H OeH 10H 65 10 4 4 Address Outside Range 0fH 65 10 5 PLS Section Fault Codes 66 10 5 1 8807 Invalid Scale Factor 66 10 5 2 8808 Invalid Offset 66 10 5 3 8809 Timing Channel Output Short Circuit 66 11 Hardware Confidence Test 67 1 Tests Performed PLC Section 67 2 Tests Performed PLS Section 68 3 Performing the PLC Hardware Confidence Test 68 11 3 1 Equipment Required 68 11 3 2 Executing the PLC Test 69 11 4 Performing the PLS Hardware Confidence Test 70 11 4 1 Equipment Required 70 11 4 2 Executing the PLS Test 70
19. 8OUT PLC 16 CHANNEL PLS MODULE M4020 User s Manual SYSTEMS Electronics Group C l
20. Channels Both the PLS configuration data and channel set points data can be printed out through PLSdev When this selection is made a printer selection menu is displayed Select the appropriate printer to be used Once this is done the print outs selection menu is displayed The selections are 1 Print PLS Channel Set points This selection prints the set points for all the channels For each channel the following is printed CHANNEL number DESCRIPTION users documentation PULSE TRAIN yes no ON OFF START SET POINTS ON OFF 1 etc The above is the set points data for the respective channel as entered through the channel edit menu 2 Print PLS Configuration This selection prints the configuration parameters as entered in the PLS configuration menu 3 Enter PLS Program Title This selection allows the user to enter a title for the program This title is printed at the top of each page of both the PLS Channel Set points print out and the PLS Configuration print out The title can be up to 60 characters long and can be composed of any printable characters When entry of the title is complete press Enter lt CR gt to save the title If the title or changes to the title are not to be saved press ESC 7 PLS Hardware Confidence Test This selection is used to invoke the hardware confidence test of the M4020 See section 11 fora complete description of the test M4020 User s Manual SYSTEMS Electronics Group
21. SPEED WINDOW If CH17 is to be used as a speed window it must be enabled in the PLS configuration If enabled the following additional parameters must be set LOW SPEED THRESHOLD If the speed is below this threshold CH17 is off HIGH SPEED THRESHOLD If the speed is above this threshold CH17 is off The two thresholds above define a window such that if the speed is between or equal to the low and high thresholds CH17 is If the speed is below the low or above the high threshold CH17 is off Both thresholds are defined in RPM If the CH17 speed window is disabled CH17 will function as a standard timing channel 7 4 CHANNEL SET POINT PROGRAMMING COMMANDS Three channel set point programming commands are available through PLSdev These are single set point programming set point fine tune and the pulse train programming command The single set point command allows the user to simply type in the complete set point both on and off parameters at the currently selected set point The fine tune command allows the user to either increment or decrement by one the or off set point parameter of the currently selected set point The pulse train programming command allows the user to program the entire channel with a pulse train of a fixed and off duration through out M4020 User s Manual SYSTEMS Electronics Group 47 SECTION 7 PLS PROGRAMMING 7 4 1 SINGLE S
22. STRB DGT3 5 L5 STRB DGT 10 1172173 1 Set up lime 2 Strobe lime T3 old Time T1 T2 T3 Strobe Time Figure 9 1 Typical Remote Display Update M4020 User s Manual SYSTEMS Electronics Group 55 SECTION 9 RPM POSITION OUTPUT CONNECTOR The two inputs on the RPM POSITION output connector are 12 30VDC sourcing true high inputs labeled REMOTE ENABLE and RPM SELECT If REMOTE ENABLE is low RPM or POSITION is selected locally via the RPM POSITION toggle switch on the M4020 If REMOTE ENABLE is high POSITION is displayed when RPM SELECT is a low and RPM is displayed when RPM SELECT is a high When REMOTE ENABLE is high the strobe time of the digit strobe outputs can be user programmed from 2 5msec to 640msec in 2 5msec increments This allows the user to match the output strobe time to the device the remote output connector is interfaced to If REMOTE ENABLE is low no remote display connected the digit strobe times are in microseconds and would be ineffective in driving a remote device Thus if a remote device is connected to the M4020 REMOTE ENABLE should be high The strobe time is set in the PLS configuration see section 7 3 3 Note When REMOTE ENABLE is high the RPM POSITION toggle switch on the M4020 has no effect either on the remote display or built in display Also the data placed on the digit data lines is the binary equivalent of the digit nu
23. Setpnt or Off Setpnt commands by one The fine tune command is primarily used in on line mode to fine tune set points while the machine is in operation M4020 User s Manual SYSTEMS Electronics Group 49 SECTION 7 PLS PROGRAMMING 7 4 3 PULSE TRAIN COMMAND The pulse train command is used to program a channel with a fixed on and off duration through out the entire channel in one simple command To program a channel with a pulse train perform the following 1 Select F5 Pulse Train from the channel edit menu 2 The cursor is located in the ON field of the channel edit menu Enter the on duration in degrees and press Enter lt CR gt 3 The cursor is located in the OFF field of the channel edit menu Enter the off duration in degrees and press Enter lt CR gt 4 The cursor is now located in the START field Enter the location that the pulse train will be initially started at in degrees and press Enter lt CR gt 5 The entire channel will be programmed with the and off duration through out the entire channel starting at the start location The first 50 set points or less will be displayed in the set point array Note The set point cursor will not be displayed since the single set point and fine tune commands are not valid if the channel is programmed as a pulse train M4020 User s Manual SYSTEMS Electronics Group 50 SECTION 8 BRAKE WEAR COMPENSATION
24. The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm of the M4020 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear 8 1 BRAKE WEAR COMPENSATION PARAMETERS The brake wear algorithm is implemented in and can be enabled or disabled in the PLS configuration see section 7 3 4 When disabled CHOO functions as a standard timing channel When enabled the following parameters set by the user are used to implement the algorithm Desired Stop Location This is the location in degrees that the press is desired to stop at 1 0 degrees TDC Allowed Stopping Error This is the plus or minus allowed deviation in degrees from the desired stopping location that the press will be allowed to stop before the algorithm adjusts the timing signal to compensate for brake wear Timing Signal Width This is the width in degrees that the algorithm will program the timing signal Note The algorithm assumes the leading off to on transition of the timing signal is used to declutch the press for a TDC stop
25. bit and no parity 6 2 1 RECEIVING THROUGH THE USER PORT sfunc10 Using sfunc10 from 1 to 250 consecutive bytes can be received from the USER PORT in one command System function 10 is a simultaneous function such that once it is initiated program execution continues without waiting for the sfunc to complete Subsequent calls of sfunc10 result in a return value of BUSY until the sfunc completes return DONE or an error occurs return ERROR CODE Since sfunc10 is a simultaneous function the impact on the user application program scan time is negligible when an sfunc10 is executed The device connected to the USER PORT must send the data to the M4020 within a certain time period once sfunc10 is initiated in order to avoid a return value of TIME OUT In most applications software handshaking will be required between the M4020 and user RS 232 device in order to assure the proper number of bytes is sent at the proper time Note The M4020 as the bytes are received through the USER PORT they are stored directly into the byte addresses specified in the sfunc10 call there is not an intermediate buffer Therefore the return value of sfunc10 should be monitored to determine when all the bytes have actually been received The parameters specified in sfunc10 are the number of bytes to receive and the starting address of the stack to store the bytes at See Section 5 2 6 for the general form parameter list and return values of sfunc
26. following steps are performed by the sfuncl3 2 The master sends 2 words W080 and W082 to the slave at network address 2 storing these two words at W120 and W122 respectively 3 The master then receives 2 words W110 and W112 from the slave and stores these two words in W084 and W086 of the master 4 Note that the sfuncl3 is a simultaneous system function such that once it is initiated program execution continues without waiting for the sfuncl3 to complete Subsequent calls of the sfuncl3 will result in a return value of BUSY 1 DONE 2 or an error code 3 10H By examining this return value it can be determined whether the sfuncl3 completed and whether it was successful return DONE or failed return error code 5 In this example once the sfuncl3 is complete it is simply called again such that communications occurs continuously and indefinitely until disabled B67 set to 0 0 if B67 0 enable serial comm T 2 B65 sfunci3 2 2 W80 W120 2 W110 W84 yes communicate with 38 if B65 1 slave 2 4 B66 B65 52 if B65 gt 3 error code return value 6 B68 B65 yes save error code in B68 as 8 B065 Eee comm return value B066 comm return value B067 serial comm enable B068 comm error code 19080 master send stack W082 WOSA
27. on the diskette in drive A must be at the root directory This selection along with the back up selection above provides a convenient way to copy programs from one computer to another 3 Make new directory This provides a way to make a new user program directory while inside PLSdev Enter the drive and directory name following the MS DOS conventions of directory names M4020 User s Manual SYSTEMS Electronics Group 41 SECTION 7 PLS PROGRAMMING 4 Copy program to another program name This provides a way to copy the current program name to any disk and directory while also allowing the user to copy to a different program name Enter the drive directory and new program name using the MS DOS conventions for directory and file names Do not enter an extension with the program name This copies all the files associated with the program to the different directory and program name This selection can be used to copy the current name to another drive and directory when the program name entered is the same as the current program name This is also used to copy the program to a new program name For instance when one program is similar to another completed program simply copy the old program to the new program name and edit as required 7 2 2 Channel Edit Menu This menu is invoked for both off line and on line programming and provides a mechanism to enter and edit the set points for the channels The menu contains both information
28. process i e loading file etc OFFSET The current resolver offset of the selected program This is entered using the F10 Set Offset command PULSE TRAIN Defines whether the channel is programmed as a pulse train YES or not NO The channel defaults to NO until the F5 Pulse Train command is executed Once programmed as a pulse train the channel must be cleared using the F8 Clear Chan command to reset PULSE TRAIN to NO See section 7 4 for details of the pulse train command ON On duration in degrees of the pulse train OFF Off duration in degrees of the pulse train START Starting location of the pulse train The Channel will be programmed through out with the and off durations starting at the Start location M4020 User s Manual SYSTEMS Electronics Group 43 SECTION 7 PLS PROGRAMMING The function key commands of the channel edit menu are defined as follows F1 Next Chan Selects the next highest numbered channel for editing When selected the channel number will increment by one and the set points and data for that channel will be displayed The PgDn key also performs the same function as the F1 Next Chan key F2 Prev Chan Selects the next lowest numbered channel for editing When selected the channel number will decrement by one and the set points and data for that channel will be displayed The PgUp key also performs the same function as the
29. select the 1 45 VRMS reference set both switches down the side that reads 1 45VRMS To select the 3 70VRMS reference set both switches up on the side that reads 3 70VRMS Note The proper reference voltage level must be selected for the specific resolver used otherwise erroneous operation may result M4020 User s Manual SYSTEMS Electronics Group 81 SECTION 12 INSTALLATION M4020 40 41 RO RI R2 S1 2 55 54 SH RESOLVER STATORS Figure 12 7 M020 40 41 Resolver Interface Stand Alone M4020 40 41 RO R2 RO RI R2 S1 S2 S3 S4 SH ROTOR RESOLVER STATORS M4020 40 41 SLAVE RO RI R2 S1 2 S3 S4 SH Figure 12 8 M4020 40 41 s Slaved to One Resolver M4020 User s Manual SYSTEMS Electronics Group 82 SECTION 12 INSTALLATION 12 9 WIRING THE RPM POSITION OUTPUT CONNECTOR The RPM POSITION output connector is provided to drive remote RPM POSITION displays or to interface with a PLC The connector consists of eight 10 30VDC true low outputs capable of sinking 100milliamps and two 12 30VDC sourcing inputs See section 9 for examples of wiring this connector 12 10 WIRING TIMING CHANNEL OUTPUTS The timing channel outputs are 10 30VDC t
30. selecting Y from the Enable Fixed Scan or Timed Interrupt prompt then selecting 0 Fixed Main Scan from the following prompt Note Both the fixed scan mode and timed interrupt cannot be enabled at the same time M4020 User s Manual SYSTEMS Electronics Group 10 SECTION 3 PLC SYSTEM CONFIGURATION 3 6 TIMED INTERRUPT If the timed interrupt file is to be used it must be enabled in the system configuration The timed interrupt interval must also be selected as 0 5 1 0 or 10 0 milliseconds The timed interrupt file will be called at these intervals thus the user must create the timed interrupt file The timed interrupt file is created and executed just as any other file with the exception that it is executed at the specified interval by interrupting the main program In addition all outputs are updated at the beginning of the timed interrupt as well as the inputs being read and stored at special function variables B62 B64 these are used as the immediate inputs for the timed interrupt Note The actual timed interrupt execution time must be less than the selected timed interrupt time otherwise a main program scan watchdog time out will occur The timed interrupt is enabled by selecting from the Enable Fixed Scan or Timed Interrupt prompt then selecting 1 TIMED INTRPT from the following prompt Note Both the fixed scan mode and timed interrupt cannot be enabled at the same time M4020
31. the PLS configuration menu See section 7 3 When PLSdev is initially invoked and the program name entered does not exist the PLS configuration menu is automatically activated This selection allows the user to modify the system configuration at any time 4 Download Channels to PLS This selection downloads both the PLS configuration and channel data files for the selected program to the M4020 module To download the data to the M4020 perform the following Note Each channel is cleared prior to downloading the set points for that channel thus machine operation should be ceased prior to initiating the download 1 With both the PC running PLSdev and the M4020 powered up connect COMI on the PC to the CHAN port on the M4020 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the download press ESC otherwise press any key to start the download 3 While the download is in progress the channel number which is currently being downloaded will be displayed Once all channels are downloaded a dump complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 If the computer was unable to initiate the download to the M4020 a message stating this will be displayed Verify the RS 232 cable connections between COMI on the computer and the CHAN port on the M4020
32. thus when the input is P32 will be 0 When input0 is off P32 will bea 1 P33 interrupt input Just as with interrupt inputO interrupt inputl is mapped to port pin P33 Input functions identically to input M4020 User s Manual SYSTEMS Electronics Group 15 SECTION 4 PLC VARIABLE TYPES MEMORY 4 1 5 Inputs X Input variables are bytes that contain the data read from the M4000 inputs during the main program update One X byte is allocated for each input byte thus the M4020 module has three X bytes allocated for it one byte for timing channel inputs 00 thru 07 one for timing channel inputs 10 thru 17 and one byte for digital inputs 00 thru 07 The input bytes reside in the I O image table of data memory and can only be accessed using the X variable designation The format for the input byte is Xaab where aaisthe two digit I O address 00 02 and b is the byte at the slot 0 or 1 Note The X must be a capital letter and that the I O address must be two digits add leading zero Also X variables can only be referenced for inputs that are actually available in the module Any reference to input variables that do not correspond to existing inputs will result in a compiler error As with byte variables individual bits within the X variable can be referenced These bits correspond to the respective I O point of the input byte The form of thi
33. total wire length of the network cannot exceed 1000 ft if the network baud rate is set to 344KBPS 2000 ft for 229KBPS 4000 ft for 106KBPS See section 3 2 for details on setting the network baud rate 3 The maximum number of nodes connected to one network is limited to 32 nodes 4 The shield of the cable should be carried through the entire network using the shield tie points on the interface connectors to achieve this The shield tie points on the connectors are not internally tied to anything they are strictly tie points One of these tie points should then be tied to earth ground 5 The two extreme ends of the network should be terminated with 150 ohm resistors as shown in figure 12 5 6 The network wiring should be isolated from other high voltage wiring by routing the network in a separate conduit dedicated to the network 7 The network should be wired directly to the network comm port connectors No intermediate terminations or splices should be used The network should be wired in a direct connect topology as shown not in multi drop or cluster topologies Note The network comm interface connectors contain two sets of and terminals The two sets of terminals are tied together internally on the module to to and are provided as tie points to ease wiring Communications across the network will continue even if one of the nodes has failed provided all the connectors are installed in their respective module
34. 0075 TB 0 01 A B101 flasher W on LU 2 accum 4 t flasher counter reset Counter reset F003 F004 pee H H H H H P 00010 A B102 counter reset F004 en counter 4 accum M4020 User s Manual SYSTEMS Electronics Group 8 APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN block 5 High level The following block is an example of an if else if else instruction in a high level block which simply compares the current value of the counter accum from the previous block and sets Y11 2 and Y11 3 to various states based on the current value Also note the inter block comments in the high level block with are separated with the and comment delimiters The compiler ignores all text after the beginning delimiter until it detects the ending comment delimiter This allows any amount of comments to be entered in the block Don t forget the ending delimiter once you hav ntered the beginning delimiter or else subsequent high level instructions will not be compiled being viewed simply as comments by the compiler 0 if B102 gt 8 counter accum greater than or equal to 8 Is 2s yll 2 Le yes set output 12 on and 3e 11 3 0 outpu
35. 0VDC PLC TO INTERNAL OUTPUT Q k TO OTHER CIRCUITS e RETURN Figure 12 9 Typical Channel Output Wirin M4020 40 41 DIGITAL TACH ETC 128PPR OR 1KPPR OUTPUT 4 4 DIFFERENTIAL MM88C30 INPUT FROM INTERNAL CIRCUITRY Figure 12 10 Typical 128ppr 1Kppr Output Wirin M4020 User s Manual SYSTEMS Electronics Group 84 SECTION 12 INSTALLATION 12 12 POWER UP SEQUENCE OF M4020 MODULE Once all connectors are wired and re installed in their respective sockets apply 24VDC power to the module The power sequence occurs as follows 1 Atinitial power up the module is reset for approximately half a second During this time the fault interlock will be and the FLT RUN and PWR LEDs will all be Note During this time the outputs of the module may also be or off randomly This is because the processor of the module has not started execution of the program yet and thus has no control of the outputs If this is a problem power for the outputs can either be supplied to the outputs from a separate source which is not activated until after the module is powered up or by using a time delay relay which supplies power to the outputs a time delay one second or so after power is applied to the module During the reset cycle the RPM POSITION display will show arbitrary data decimal points
36. 10 M4020 User s Manual SYSTEMS Electronics Group 33 SECTION 6 SERIAL NETWORK COMMUNICATIONS Example 1 Receiving through the USER PORT Main program B080 sfunc10 20 B100 execution The above receives 20 bytes from the USER PORT and stores them in B100 thru B119 The return value of sfunc10 is stored in B080 When the sfunc10 is first called the return value will equal BUSY 080 1 Subsequent calls of sfunc10 will result in a BUSY 080 1 return value until all 20 bytes have been received at which time a return value of DONE 080 2 is obtained If the device connected to the USER PORT does not send any or all of the 20 bytes a return value of TIME OUT 080 3 is obtained after a certain time period 6 2 2 TRANSMITTING THROUGH THE USER PORT sfunc11 Using sfuncl1 from 1 to 250 consecutive bytes can be transmitted out the USER PORT in one command System function 11 is a simultaneous function such that once it is initiated program execution continues without waiting for the sfunc to complete Subsequent calls of sfunc11 result in a return value of BUSY until the sfunc completes return DONE Since sfuncll is a simultaneous function the impact on the user application program scan time is negligible when an sfuncll is executed The parameters specified in sfuncl1 are the number of bytes to transmit and the starting address of the stack of bytes that will be transmitted See Section 5 2 7 for th
37. 4 1 7 Constants Constants are used as fixed numbers in High level arithmetic and conditional statements as well as for presets in timer counters in ladder blocks In High level blocks constants can be represented in decimal or hex If the number is decimal the constant is simply entered as the number to be referenced No prefix or suffix is specified If the number is hex the suffix is added immediately following the hex number Examples of both are 25 decimal 25657 decimal hex f000H hex The hex letters a b c d e f are case sensitive and must be typed as lower case letters The hex suffix is also case sensitive and must be typed as a capital letter H constants are unsigned integers When the variable class is byte the range of values is 0 to 255 decimal or 0 to hex If the variable class is word the range of values is 0 to 65535 decimal or 0 to ffffH hex In ladder blocks the only constants allowed are in timer counter presets In this case they are specified in decimal and preceded with the prefix 4 2 DATA MEMORY MAP The M4020 module contains two distinct data memory spaces 200 bytes of volatile non battery backed data memory and 2K bytes of non volatile battery backed data memory The flag F byte B and word W variables as described previously are located in the 200 bytes of volatile data memory The 2K bytes of non volatile data memory can only be accessed using sfu
38. BLE RS 232 PROG PORT AS USER PORT When F104 is 0 the PROG port on the M4020 is used to download the user program perform online monitoring and in general to interface with the PC running SYSdev in the normal PROG port mode When F104 is set to 1 the PROG port now functions as a user port executing the sfunc10 and sfunc11 user port read and write commands see section 6 2 In this mode the port can be used to interface to an ASCII operator interface or any other device that can accept ASCII data sent via serial RS 232 Note When F104 is a 1 the PROG port will not respond to any commands sent from SYSdev F104 must be 0 in order to download programs or perform on line monitoring with SY Sdev Thus it is highly recommended that an X input point is used to set F104 to a 0 or 1 When the PROG port is to be used to download the program or perform on line monitoring the X input would be turned off setting F104 to a 0 and enabling PROG port mode When the PROG port is connected to the user ASCII device the input would be turned setting F104 to a 1 and enabling the USER port mode M4020 User s Manual SYSTEMS Electronics Group 20 SECTION 4 PLC VARIABLE TYPES MEMORY 4 4 2 B62 B64 TIMED INTERRUPT IMMEDIATE INPUT VARIABLES When the timed interrupt is enabled B62 through B64 are used as the input image bytes of the CHAN inputs and I O inputs At the beginning of the time
39. ET POINT PROGRAMMING COMMAND The single set point command is used to enter unique set points in a channel when that channel is not programmed as a pulse train PULSE TRAIN NO Note When the channel is programmed as a pulse train the single set point command cannot be used to modify individual set points in the channel To program a single set point locate the set point cursor large block cursor at the set point to be modified the large cursor will always be located in the parameter of the set point Enter the set point as follows 1 Type in on parameter in degrees cursor will change to the small data entry cursor 2 Press Enter lt CR gt or to enter the on parameter 3 Type in off parameter in degrees 4 Press Enter lt CR gt to enter the off parameter 5 The cursor will change back to the large set point cursor and automatically advance to the parameter of the next set point The set point has now been entered 6 Ifan invalid set point number is entered a message stating this will be displayed in the message field of the channel edit menu Re enter a proper set point value or press ESC to abort the set point entry Note The set point values entered must be less than the scale factor Set points are also not allowed to overlap any existing set points already entered in the channel Example 1 The following key sequence enters the set point 020 040 at set point number
40. However if a connector is pulled from it s module communications to the modules downstream will be lost the internal tie point will be broken If it is desired this situation can be avoided by wiring the connector as shown in figure 12 6 M4020 User s Manual SYSTEMS Electronics Group 78 SECTION 12 INSTALLATION M4000 M4000 MODULE MODULE BELDEN CABLE 9182 OR EQUIVALENT NOTE SHIELD TIED TO EARTH GROUND AT ONE BOARD ONLY 3012 S3014 1 W SPB3012 1 TO OTHER S3012 S amp S3014 S TOTAL OF 32 MAX 150 ohm TERMINATING RESISTOR USED AT EXTREME ENDS OF NETWORK Figure 12 5 Typical Network Wirin M4000 MODULE TO OTHER S3012 S amp 3014 S UPSTREAM TO OTHER S3012 S amp S3014 S DOWNSTREAM Figure 12 6 Alternative Serial Connector Wirin M4020 User s Manual SYSTEMS Electronics Group 79 SECTION 12 INSTALLATION 12 7 2 SETTING THE NETWORK ADDRESSES Each M4000 module on the network must be set with a unique network address between 1 and 32 This is how the modules can distinguish one node from another To set the network address for a particular module perform the following 1 Connect an IBM PC or compatible running SYSdev from COM1 on the PC to PROG port on the module using the RS 232 interface cable see appendix B 2 From the SYSdev Main Development Menu select Target Board Interface 3 From the Target board Interface Menu selec
41. M4020 User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 02 2004 M4020 User s Manual Copyright 1991 Systems Engineering Associates Inc Revision 2 1993 All Rights Reserved M4020 User s Manual CONTENTS 1 General Description 1 1 4 Programming 1 1 2 Digital Inputs 2 1 3 Interrupt Inputs 3 1 4 Digital Outputs 3 1 5 Resolver Interface 3 1 6 Timing Channels 4 1 7 Interface Ports 4 1 8 Display Output Connector 4 1 9 Brake Wear Compensation 5 1 10 Motion speed Output 5 1 11 Diagnostics Fault Detection 5 1 12 LED Status Indications 6 2 PLC Program Structure 7 3 PLC System Configuration 9 31 Target Board 9 3 2 Network Baud Rate 9 3 3 InputO Interrupt Enable 9 3 4 Input1 Interrupt Enable 10 3 5 Fixed Scan Time Mode 10 3 6 Timed Interrupt 11 4 PLC Variable Types Memory Map 13 4 1 Variables 13 4 1 1 Flags 13 4 1 2 Bytes B 13 4 1 3 Words W 14 4 1 4 Port Pins P 15 4 1 5 Inputs X 16 4 1 6 Outputs Y 16 4 1 7 Constants 17 4 2 Data Memory 17 4 2 1 Volatile Data Memory 18 4 2 2 Non Volatile battery backed Data Memory 19 4 3 Image Addressing 19 4 4 Special Function Variables 20 4 4 1 F104 Enable RS 232 Prog Port as User Port 20 4 4 2 B62 B64 Timed Interrupt Immediate Input Variables 21 SYSTEMS Electronics Group CON
42. Refer to appendix C for the pin outs of the various connectors on the M4020 module 12 1 MOUNTING THE M4020 The M4020 module was designed for back panel mounting The module should be mounted using 2ea 8 32 screws and lock washers A lugged earth ground wire should be installed on one of the mounting screws to insure that the module is grounded 12 2 WIRING INPUT POWER The M4020 module is powered with 24VDC 10 power This power is wired to the power and common or return terminals of the input interrupt connector and to the power and common or return terminals of the RPM POSITION output connector Note Both sets of these power input terminals must be wired to provide power to both the PLC and PLS sections of the M4020 This provides power to the internal circuitry of the module The current required is less than 0 8 AMPs Be sure to observe the proper polarity of the input power otherwise damage to the module may occur Input fusing of 2AMP or so should be provided for the input power M4020 User s Manual SYSTEMS Electronics Group 293 SECTION 12 INSTALLATION 12 3 WIRING 10 30VDC DIGITAL INPUTS The digital inputs are 10 30VDC sourcing true high inputs which are used to interface to sourcing application inputs such as proximity sensors push buttons etc The inputs are internally mapped to terminals on the input connector numbered with the corresponding input number
43. SECTION 6 SERIAL NETWORK COMMUNICATIONS The serial network provides a means for multiple S3012s S3014s or M4000 modules hereafter referred to as nodes to communicate with each other The network operates in a master slave topology One S3012 S3014 or M4000 module acts as the master node and controls all communications on the network The remaining nodes act as slaves and simply respond to communications requests from the master The master can send up to 120 consecutive words and receive up to 120 consecutive words from a slave in one command If data is to be sent from one slave to another slave it must be done through the master i e the master reads the data from the first slave and then sends it to the second slave Up to 32 530125 S3014s M4000 modules or other S3000 network compatible boards can be installed on one network These 32 nodes consist of the one master and up to 31 slaves Each node on the network is assigned a unique network address This number is a number between 1 and 32 The network address is used to specify which slave the master is communicating to The network address is set in the M4000 module from the SYSdev Target board Interface menu and is downloaded directly to the module from the IBM PC or compatible running SYSdev See section 12 7 2 6 1 COMMUNICATING ON THE NETWORK sfunc13 System function 13 is used to execute the communications command to the slave The parameter list of sfunc13 contains 1 Sla
44. Sdev shell PLSdev is invoked when M4020 PLS is selected as the target board See SYSdev Program Development Manual See section 7 for details on the PLS programming commands and PLSdev features 1 2 DIGITAL INPUTS The eight digital inputs are 10 30VDC sourcing true high which are used to interface to the application inputs such as proximity sensors push buttons etc The input is 1 when the input voltage exceeds 10VDC and is off 0 when the input voltage is below 5VDC Individual LED status indication is provided for each input All inputs are optically isolated and provided with an input filter delay nominally 1 0 milliseconds M4020 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 3 INTERRUPT INPUTS The M4020 contains two interrupt inputs which allow hardware interrupts to be implemented in the user s program The inputs are 12 30VDC differential inputs which can be enabled as interrupts or disabled and used as standard inputs When enabled as interrupts an off to on transition of the enabled input activates an interrupt call to a user programmed file ufunc00 for inputO and ufunc01 for input1 This suspends the main program file until the interrupt file execution is completed at which time program execution resumes at the place in the main file where the interrupt occurs This mechanism allows ultra fast through puts to be implemented if required 1
45. TENTS 5 PLC Programming Reference 23 5 1 Instruction Set 23 5 1 1 Ladder 23 5 1 2 High Level 24 5 1 3 Assembly 24 5 2 System Functions 25 5 2 1 System Function Types 25 5 2 2 sfunc04 ASCII String Load Command 26 5 2 3 sfunc07 General External Address Read 27 5 2 4 sfunc08 General External Address Write 28 5 2 5 sfunc09 System Fault Routine 28 5 2 6 sfunc10 USER PORT Receive 29 5 2 7 sfunc11 USER PORT Transmit 29 5 2 8 sfunc13 Serial Network Communications 30 6 Serial Network Communications 31 6 1 Communicating on the Network sfunc13 31 6 2 User Port PROG port Communications 33 6 2 1 Receiving through the User Port sfunc10 33 6 2 2 Transmitting through the USER Port sfunc11 34 7 PLS Programming 35 7 1 Introduction to PLSdev 35 7 1 1 Features of PLSdev 35 7 1 2 System Requirements 36 7 1 3 Installing PLSdev 36 7 1 4 Executing PLSdev 36 7 2 Menus 37 7 2 1 Main Development Menu 37 7 2 2 Channel Edit Menu 42 7 3 Configuration 45 7 39 1 Number of PLS Channels 45 7 3 2 Scale Factor 46 7 3 3 Remote Display Strobe Time 46 7 3 4 Brake Wear Compensation 46 7 39 5 CH17 Speed Window 47 7 4 Channel Set Point Programming Commands 47 7 4 4 Single Set Point Programming Command 48 7 4 2 Fine Tune Set Point Command 49 7 4 3 Pulse train Command 50 M4020 User s Manual SYSTEMS Electronics Group diis CONTENTS 8 Brake Wear Compensation
46. User s Manual SYSTEMS Electronics Group 11 SECTION 3 PLC SYSTEM CONFIGURATION This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group 12 SECTION 4 PLC VARIABLE TYPES MEMORY 4 1 VARIABLES Three classes of variables are used in the PLC section of the M4020 They are bits bytes and words Bits are a single bit in width and can have a value of 0 or 1 Bytes are 8 bits in width and can have a value between 0 and 255 decimal or 0 and ffH hex Words are 16 bits in width and can have a value of 0 to 65535 decimal or 0 to ffffH hex numbers values in variables and constants are unsigned integer values No signed or floating point numbers are supported Numbers can be represented as decimal or hex suffix following number Six different variable types are available in the M4020 flags F bytes B words W port pins P inputs X and outputs Y 4 1 1 Flags F Flags are single bit variables which are generally used as internal coils or flags in the user program Flags can have a value of 0 or 1 The M4020 module contains 104 flags The format of the flag variable is Fzzz where zzz is a three digit flag address 000 to 103 Note The leading must be a capital letter and that the flag address must be three digits include leading zeros as necessary Examples F000 F012 F103 etc 4 1 2 Bytes B Byte variables are 8 bit varia
47. ables in the user program Words can have a value between 0 and 65535 decimal or 0 and ffffH hex Word variables are used as arithmetic variables in the High level language The M4020 module contains 100 W variables The format of the word variable 15 Wzzz where zzz is the three digit word address 032 thru 230 Note The leading W must be a capital letter and that zzz must be a three digit address include leading zeros as necessary Also word addresses are always an even number divisible by 2 Examples W034 W100 W076 etc M4020 User s Manual SYSTEMS Electronics Group 14 SECTION 4 PLC VARIABLE TYPES MEMORY 4 1 4 Port Pins P Port pins are single bit variables that map directly to specific hardware functions on the M4020 module These can be input or output hardware functions as defined by the specific port pin see the following The format for port pins is Paa where aa is the two digit port pin 10 17 or 30 37 Note The P must be a capital letter and that the port pin address must be two digits Port pins can only be referenced in high level blocks The following port pins on the M4020 module are mapped to the respective hardware functions P32 interrupt inputO The state of interrupt inputO is mapped to this port pin If interrupt inputO is not enabled as an interrupt it can be used as a standard non interrupt input Note The state of interrupt inputO is true low logic
48. an be connected to the PROG port of the module to view the fault codes To view the fault codes perform the following 1 Connect IBM PC COM1 port to M4020 PROG port using the appropriate cable see appendix B 2 Initiate SYSdev from the DOS prompt and select the user program currently loaded in the module 3 From the main menu select Target Board Interface 4 From the Target Board Interface menu select Target Board Fault Codes Status M4020 User s Manual SYSTEMS Electronics Group 59 SECTION 9 RPM POSITION OUTPUT CONNECTOR The SYSdev fault display reads the fault codes from the module and displays the following Target Board Internal Fault Code 1 Curr Fit 2 Last Fit 3 Co cpu slot 4 Corrective action Communications Network Error Codes 5 Current comm error 6 Last comm error Curr Fit This is the M4020 fault code corresponding to the current detected fault along with a short description of the fault This fault code is cleared at power up or optionally by the user after it is displayed in the SYSdev fault display Last Flt This is the last M4020 fault code detected shown just as the Curr is shown Unlike the Curr Flt this fault code is not cleared at power up This field retains the last detected fault even when power to the module is cycled This fault code can only be cleared after it is displayed in the SYSdev fault display Co cpu slot Not used by the M4020 module Correct
49. arbitrary digits etc The timing channel outputs may also be randomly on or This is normal 2 Once the reset cycle is complete the module will begin to execute the program previously loaded The fault interlock will turn on sink true low and the FLT LED will extinguish The outputs will then be activated in the states as controlled by the user program If the timing channels have previously been programmed the offset value previously set will be displayed for approximately 2 to 3 seconds The module will then proceed to normal operation with the RPM POSITION display showing either the RPM or position whichever is selected 3 user program has not been loaded new module or module which the confidence test has just been executed the FLT LED will stay on and the RUN LED will extinguish Download the user program and data files to the module The RUN LED will flash while the user program is downloading When the download is complete the FLT LED will extinguish and the RUN LED will turn If the FLT LED turns after the download is complete read the fault code in the M4000 module see section 10 See the SYSdev program manual for details on downloading programs to the M4000 modules If the timing channels have not been previously programmed new module it may show either the invalid scale factor fault code 8807 or invalid offset fault code 8808 on the RPM POSITION disp
50. ate the only and will incorporate just one Return Value none Type suspended Valid Files Initialization Main Program and user functions Examples 1 sfunc04 B100 example 1 The above example will load the following byte addresses with the corresponding ASCII codes numbers 100 101 101 code for 101 120 120 code for 102 97 97 ASCII code for B103 109 109 ASCII code for m 104 112 112 code for p 105 108 108 code for l 106 101 101 code for e 107 32 32 code for space 108 35 35 code for B109 49 49 code for 1 2 sfunc04 B150 The above example will load B150 with 58 which is the ASCII code for M4020 User s Manual SYSTEMS Electronics Group 26 SECTION 5 PLC PROGRAMMING REFERENCE 3 sfunc04 1a00H MOTORY on The above example incorporates double quotes in the string and uses the back slash to designate that these double quotes are part of the string and not the string delimiters The characters are stored in non volatile memory as follows 1 00 77 77 code for M 1 01 79 79 code for O 1 02 84 84 ASCII code for T 1a03H 79 79 ASCII code for O 1a04H 82 82 code for R 1 05 32 32 ASCII code for space 1a06H 34 34 code for 1 07 111 111 ASCII code o 1 08 110 110 ASCII code fo
51. bles used as general purpose variables in the user program Byte variables can have a value between 0 and 255 decimal or 0 and ffH hex Byte variables are used as arithmetic variables in the High level language timer counter presets and accumulators as well as shift register bytes in the ladder language The M4020 module contains 200 variables The format of the byte variable is Bzzz where ZZz is the three digit byte address 032 thru 231 Note The leading must be a capital letter and that zzz must be a three digit address include leading zeros as necessary M4020 User s Manual SYSTEMS Electronics Group 13 SECTION 4 PLC VARIABLE TYPES MEMORY Examples B032 B150 B201 etc Individual bits within the byte can also be referenced by simply appending a followed by the bit number 0 7 to the byte address The form of this is Bzzz y where zzz is the byte address and y is the bit 0 7 This allows any bit in the entire data memory to be referenced just as a flag is referenced These byte bit variables can be used in ladder blocks as contact and coil variables as well as in the High level blocks Execution times for instructions that use bits within a byte are longer than execution times for instructions using flags Keep this in mind when using byte bit references Examples B080 0 B100 7 B072 4 etc 4 1 3 Words W Word variables are 16 bit variables used as general purpose vari
52. can time is negligible when executed This is also true for the responding slave Reception and transmission on the serial network occurs concurrently with program execution no significant increase in the scan time of the slave occurs when a slave is communicated with The sequence of events in a serial network comm event are as follows 1 Master node initiates comm event by executing an sfunc13 Program execution in the master proceeds concurrently with the transmission of the words to the slave 2 The slave receives the words from the master concurrently with it s program execution Once all words are received from the master the slave starts transmission of the words that are to be sent from the slave to the master This also occurs concurrently with the slave program execution 3 The master receives the words sent from the slave concurrently with it s program execution Once all the words from the slave have been received the subsequent call to sfunc13 results in a return value of DONE Until this step calls to sfunc13 would have resulted in a BUSY return value See section 12 7 for details on installing and wiring the network Example 1 Communicating from the master to a slave Master M4000 main program B070 sfunc13 4 10 W080 W100 5 W090 W1 10 execution The above command transmits 10 words W080 thru W098 in the master to the slave at network address 4 storing the data in W100 thru W118 The slave then transmit
53. ceeds 100 milliseconds The cause of this fault ranges from an error in the user program unintentional loop entered in the user program unintentional indirect access to program memory to a hardware failure of the M4020 module Trouble shooting 1 Check the program for any unintentional loops These are loops where the exit condition of the loop can never be satisfied This can occur in for while and do while loops Also check for any goto jumps that cause the program to jump to a previous location in the program with no condition to stop executing the jump 2 Check for any loop instructions that may take longer than 100 milliseconds to execute a large number of iterations through the loop M4020 User s Manual SYSTEMS Electronics Group 61 SECTION 9 RPM POSITION OUTPUT CONNECTOR 3 When the 40H fault code is displayed in the SYSdev fault display a field is displayed that reads PC xxxxH The is a four digit hex number which equals the address program counter that the program was at when the watchdog timed out If the program was in an infinite loop this would give an indication of where the loop was To see which block this address is in add an assembly block at the end of the program with just the one word test typed into it and then compile the program The program will compile with no errors but will assemble with one error no hex file created The compiler will create a file named as
54. constant 1900H thru 1fefH srce The variable where the value that will be written is stored Variable types Return value sfunc08 returns with the value written to the external address Type suspended Valid files Initialization Main Program and User functions Example sfunc08 W100 B105 With W100 1905H the above writes the data in B105 to non volatile data byte address 1905H 5 2 5 sfunc09 system fault routine System function 09 provides a means for the fault routine to be called in response to a software detected fault from the user application program The fault routine is executed as described in section 10 1 The fault code will be set to 45H sfunc09 generated fault Note This function should only be called when a complete system shutdown is desired due to the fact that program execution will cease General form 09 Parameters none Return value none Type non returning Valid files Initialization Main Program and User functions M4020 User s Manual SYSTEMS Electronics Group 28 SECTION 5 PLC PROGRAMMING REFERENCE 5 2 6 sfunc10 USER PORT receive System function 10 receives a consecutive number of bytes from the USER PORT PROG port used as USER PORT F104 set to 1 See Section 6 2 1 for a detailed description of the use of sfunc10 General form sfunc10 rcve dest Parameters rcve The number of bytes to be received thru the USER PORT Variable types consta
55. d interrupt the corresponding inputs are read and the data from these inputs is stored at these variables in the same fashion that the X variables are updated at the beginning of the main scan Thus bytes B62 through B64 should be used as the input image bytes inside of the timed interrupt file instead of the X variables Note The X variables are still updated at the beginning of the main scan even when the timed interrupt is enabled The I O of the M4020 module is mapped to the B62 B64 variables when the timed interrupt is enabled as follows Input Image Function B62 CHAN inputs 0 7 B63 CHAN inputs 10 17 B64 inputs 0 7 M4020 User s Manual SYSTEMS Electronics Group 21 SECTION 4 PLC VARIABLE TYPES MEMORY This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group 22 SECTION 5 PLC PROGRAMMING REFERENCE The following sections provide an overview of the SY Sdev instruction set and the system functions available in the M4020 module See the SYSdev Programming Manual for more details on the SYSdev programming language and the operation of the SYSdev software package See appendix A for an example of an M4020 program 5 1 INSTRUCTION SET 5 1 1 LADDER The ladder language is generally used to implement the boolean logic of the user program Networks of virtually any form including nested branches can be implemented Ladder blocks are implemented as a 7 ro
56. dware tests embedded in the module to verify the proper operation of the M4020 This is the same test used by the factory to verify the module at completion of manufacturing M4020 User s Manual SYSTEMS Electronics Group 35 SECTION 7 PLS PROGRAMMING PLSdev is provided as a stand alone program or with the SYSdev shell To install or execute PLSdev from the SY Sdev shell refer to the SYSdev Programming Manual for details To install or execute PLSdev as stand alone program refer to the following sections 7 1 2 SYSTEM REQUIREMENTS PLSdev will run on any IBM PC or compatible with the following minimum system requirements 1 DOS 3 1 or greater 2 512K or more RAM 3 Hard disk not required but recommended 4 One 3 5 or 5 25 diskette drive 5 COMI RS 232 port 7 1 3 INSTALLING PLSdev PLSdev consists of two executable files PLSdev exe and S4040T exe To install PLSdev simply install the PLSdev disk in the A or B floppy drive and copy PLSdev exe and S4040T exe to the desired directory on the hard drive 7 1 4 EXECUTING PLSdev To execute PLSdev switch to the directory on the hard drive that PLSdev was installed and type gt PLSdev program lt CR gt where program is the path and name of the PLS channel program to be edited The format of program should be drive directory name where drive the drive letter of the drive your channel program will be stored on directory the user or
57. e general form parameter list and return values of sfunc11 Example 1 Transmitting out the USER PORT Main program B080 2sfunc1 1 30 B 120 execution The above transmits the 30 bytes between B120 and B149 out the USER PORT The return value of sfunc11 is stored in BO80 When the sfunc11 is first called the return value will equal BUSY 080 1 Subsequent calls of sfunc11 will result in a BUSY 080 1 return value until all 30 bytes have been transmitted at which time a return value of DONE 080 2 is obtained Note Program execution is not suspended while sfunc11 is executing Once initiated program execution continues with subsequent calls of sfunc11 determining when all 30 bytes have actually been transmitted The time it takes for sfunc11 to complete is a function of the number of bytes to be transmitted M4020 User s Manual SYSTEMS Electronics Group 34 SECTION 7 PLS PROGRAMMING 7 1 INTRODUCTION TO PLSdev PLSdev is a DOS based software package used to configure and program the timing channels of the M4020 PLS section An RS 232 cable connected to COMI of the IBM PC or compatible running PLSdev is used to interface with the CHAN port of the M4020 module for on line programming program upload download etc No other additional hardware is required 7 1 1 FEATURES OF PLSdev PLSdev incorporates the following features Offline Channel Set point Programming set points for each channel can be ent
58. e main development menu will be displayed Select 1 Edit program On line Funcs and then the F1 Main Prog to view the program M4020 User s Manual SYSTEMS Electronics Group 1 APPENDIX PROGRAMMING EXAMPLE M4020 PLC program Example SYSS51 System Configuration M4020E1 LCF System Configuration Target Board Network Baud Rate InputO Interrupt Enable Input Interrupt Enable Fixed Scan Time Mode Fixed Scan Time M4020 User s Manual M4020 8 Input 8 Output Intelligent PLS Module 344K BPS SYSTEMS Electronics Group A 2 APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN The following is an example of an 4020 PLC program The program provides various examples of ladder rungs high level instructions and communications on the serial network plus some of the documentation capabilities of SYSdev including inter block comments and variable annotation block 1 Ladder The following block generates both a leading edge single shot F000 and a trailing edge single shot F001 on the timing channel 00 input from the PLS section of the M4020 Flag F000 is on for one scan when CHOO goes from off to on Flag F001 is on for one scan when CH00 goes from on to off Timing Timing Timin
59. each system function M4020 User s Manual SYSTEMS Electronics Group 25 SECTION 5 PLC PROGRAMMING REFERENCE 5 2 2 sfunc04 ASCII string load command System function 04 is used to convert the characters in an ASCII string to their equivalent ASCII codes and store these codes in consecutive byte addresses in variable memory Bxxx variables or external non volatile memory addresses 1900H 1fefH System function 04 is typically used in conjunction with the USER PORT sfuncl1 transmit system function to send ASCII strings to operator interfaces etc General form sfunc04 dest string Parameters dest The address where the first ASCII character of the string will be stored The remaining ASCII characters will be stored in consecutive byte addresses following the first byte address Variable types B or constant 1900H 1fefH string The string is from one to 60 printable characters These characters will be converted to their equivalent ASCII codes and stored in consecutive byte addresses starting at the dest byte address Note The string must be enclosed with double quotes as shown these double quotes are not stored as part of the string but are simply used as delimiters for the string Any printable character can be incorporated in the string with the exception of the double quote or back slash If these two characters are to be incorporated in the string they must be preceded with the back slash i e will incorpor
60. ed as a standard input by reference P32 see section 4 1 4 M4020 User s Manual SYSTEMS Electronics Group SECTION 3 PLC SYSTEM CONFIGURATION 3 4 INPUT1 INTERRUPT ENABLE If the Inputl interrupt is to be used it must be enabled in the system configuration The input interrupt calls ufunc01 when activated thus the user must create ufunc01 The ufunc01 file is created and executed just like any other user function file with the exception that it is called when the input interrupt input makes an off to transition instead of being called from the main user program If the inputl interrupt is disabled interrupt inputl can be used as a standard input by reference P33 see section 4 1 4 3 5 FIXED SCAN TIME MODE When enabled the fixed scan time mode allows the user to set the main program scan to a fixed time either 0 5 milliseconds 1 0 milliseconds or 10 0 milliseconds This allows the main program scan to be used as a high speed time base for either fixed rate sampling or high speed timer time bases when scan time base timers are used Note The actual main program execution time must be less than the selected fixed time otherwise the scan time will equal the actual scan time rather than the fixed scan time If the fixed scan time mode is disabled the scan time will be a function of the length of the user program and vary as a function of the true false state of the logic The fixed scan mode is enabled by
61. ed stopping location for all TDC stops REMOTE ENABLE high when press reaches zero speed As brake wear occurs over time the press will overshoot the desired stopping location Once it stops past the allowed error the algorithm calculates the difference and re programs the set point advancing it by this difference The press will than stop at the desired location again The set point is programmed with the width specified in the PLS configuration however the algorithm assumes the leading off to on transition is used to actually declutch the press M4020 User s Manual SYSTEMS Electronics Group 52 SECTION 8 BRAKE WEAR COMPENSATION 8 3 BRAKE WEAR COMPENSATION EXAMPLE In the this example the algorithm is implemented on a press which normally requires 180 degrees to stop 1 2 stroke The parameters are set as follows Brake Wear Compensation Enabled Desired Stop Location Allowed Stopping Error Timing Signal Width Compensation Enable Window yes 090 270 The following chart shows the automatic reprogramming of set point by the algorithm as a function of the actual stopping location of the press Note These are not consecutive stops but instead a sampling of stops over a period of time Actual Stop CH00 Stopping Example Set Point Location 1 180 220 003 2 180 220 005 3 180 220 007 4 173 213 359 5 173 213 016 6 157 197 000 7 157 197 010 8 147 187 001
62. ered with easy to use set point programming commands and saved on disk for download to the M4020 at a later time This allows the channel programming to be implemented without having an M4020 present Online Channel Set point Programming using the same set point programming commands and menus used with the off line channel programming the user can alter channel set points in the M4020 module directly using an RS 232 cable which connects the CHAN port of the M4020 module to COMI of the IBM PC or compatible running PLSdev This allows machine timing to be altered while in operation PLS Configuration the configuration of the PLS section is set using PLSdev This includes defining the number of PLS timing channels in the module scale factor remote display strobe time brake wear compensation enable and parameter setting CH17 speed window enable and parameter setting Download Channels to PLS this allows channels edited in off line mode or previously uploaded channels to be downloaded to the M4020 module This feature allows quick replacement of an M4020 module by eliminating the need to reprogram the channel set points by hand Upload Channels from PLS uploads channel set points and configuration parameters from the M4020 module to disk files Print outs the set points of all channels as well as the PLS configuration can be printed out to provide hard copy documentation PLS Hardware Confidence Test Allows the execution of har
63. ero Read the resolver shaft position from the front of the M4020 select F9 Set Offset and enter the position into the offset field The actual offset number required to make this the zero position will than be calculated by PLSdev and downloaded to the M4020 The actual offset which may not equal the entered position will be displayed in the offset field and the M4020 will then display zero as the position 7 3 PLS CONFIGURATION The PLS configuration is used to define the following PLS parameters in the M4020 number of PLS channels scale factor remote display strobe time brake wear compensation parameters and CH17 speed window parameters The parameters are all set through the Edit PLS Configuration menu selection 7 3 1 NUMBER OF PLS CHANNELS This is the number of PLS timing channels available in the specific module being configured The number of channels should be set as follows for M4020 set number of channels 16 M4020 User s Manual SYSTEMS Electronics Group 45 SECTION 7 PLS PROGRAMMING 7 3 2 SCALE FACTOR The scale factor is the desired number of divisions per revolution This is programmable from 2 to 512 For 360 degrees per revolution the scale factor should be set to 360 7 3 3 REMOTE DISPLAY STROBE TIME The remote display strobe time 15 the time that the strobe outputs on the remote display connector are activated to strobe the respective digits for the remote display The nu
64. est will stop and display the following Fault Code XX test fault code and description Address of fault memory address or I O address where fault occurred Actual data at fault data actually obtained at address of fault Expected data at fault data that should have been obtained at address of fault Diagnostics test number for factory use only Once a fault occurs exit back to the Main Test Menu and re initiate the test to reset the fault code 11 5 INTERACTIVE INTERFACE The interactive interface menu contains selections to read the fault code same as displayed when a fault is detected perform diagnostics routines for use by the factory only and to read and write via the RS 232 ports to any address in the module In general all these selections are for factory use and are of little significance to the user M4020 User s Manual SYSTEMS Electronics Group zs SECTION 11 HARDWARE CONFIDENCE TEST This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group 72 SECTION 12 INSTALLATION The following sections provide information on mounting and wiring the M4020 module as well as a description of the power up sequence Note wiring is implemented with removable field wiring connectors The connectors are removed by gently pulling the connectors from the socket Install the connectors by firmly seating the connector to the socket observing the proper polarity of the connector
65. etwork comm error 03H More than one bus master detected 04H sfunc13 xmitt timeout no response 05H sfunc13 receive timeout no response 06H Invalid command received from master 07H Receive overflow 08H Receive collision detected 09H Receive alignment error bad frame Receive CRC error OBH Unknown undefined error OCH Transmit no acknowledge Transmit underrun error OEH Transmit collision detected OFH Address error outside data memory 10H Unexpected slave responding M4020 User s Manual SYSTEMS Electronics Group 64 SECTION 10 FAULT DETECTION 10 4 2 NO RESPONSE FROM SLAVE 04H and 05H The no response errors occur when the master executes an sfunc13 addressed to a particular slave but receives no response from that slave For every execution of sfunc13 the slave will always respond to the request even if no data 1 to be sent from the slave to the master This verifies that the slave did in fact receive the data sent to it Trouble shooting 1 Verify that the network continuity is good between the master and the slave This can be done by observing the COMM LEDs on the network interface boards Every time sfunc13 is executed the COMM LEDs will flash or be on solid for continuous communications 2 Verify that the master and all slaves on the network are set to the correct network address they have been assigned For each node on the network the address must be a number between 1 and 32 and mu
66. fields and function key commands The information fields are defined as follows CHANNEL This is the number in octal of the currently selected and displayed channel When the channel edit menu is initially invoked channel number 00 is selected and displayed The F1 Next Chan F2 Prev Chan and F3 Select Chan commands are used to select a different channel number DESCRIPTION This field contains the user entered description or channel name which is associated with the channel number The F4 Doc Chan command is used to enter or edit this description PROG MODE This field displays the program mode either OFFLINE or ONLINE depending on whether the channel edit menu was invoked from the Offline or Online selection of the main development menu SET POINTS This a 10 row by 5 column 50 element array where the set points are entered using the various set point programming commands Note If the channel is not programmed as a pulse train PULSE TRAIN NO that up to 50 unique set points can be entered in the channel If the channel is programmed as a pulse train PULSE TRAIN YES up to the scale factor divided by two number of set points ON 1 OFF 1 can be programmed in the channel In this case only the first 50 set points would be displayed in the channel however the channel would be programmed through out with the and off duration specified See section 7 4 for complete details on the set point pr
67. g CHOO CHOO CHOO input bit L E S S X000 0 F002 F000 0 Timing Timing Timing CHOO CHOO CHOO input bit T E S S X000 0 F002 FOOL 1 E Timing Timing CHOO CHOO input bit 000 0 F002 2 t 4 H H H H H H E M4020 User s Manual SYSTEMS Electronics Group 3 APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN block 2 Ladder The following block implements a 28 bit shift register As can be seen by cascading the shift register instructions any number of shifts can be generated Note that the input to the shift register ck is a leading edge left edge scan single shot one bit single shot was not used the shift register that ck input was a 1 which is generally Each register can be referenced in the program following the shift register instructions as was Shift ck4 F000 1 1 B090 2 B091 3 B092 I O input0 X010 0 si Zu shift reg byte 1 so si so shift reg bit 4 B090 4 very scan that the ck input is a 1 byte of the shift register is worth 7 shifts The shift register shifts all the bits of the register Thus if a leading would be clocked every not what is desired Any bit within
68. h the even byte address as the low byte lower 256 significance of the respective word and the odd byte address as the upper byte upper 256 significance of the word as shown B032 W032 low byte B033 W032 high byte 4 2 2 NON VOLATILE BATTERY BACKED DATA MEMORY The memory map for the non volatile battery backed data memory is shown below Note These memory locations are not referenced as user variables F B and W but instead are accessed using sfunc07 and sfunc08 Address Valid Variable References 1900H 1901H thru thru thru thru 1feeH 1fefH These variables are battery backed and will retain data when powered down This memory space provides a non volatile data space for user variables such as timer counter presets etc This memory space is not cleared at power up 4 3 IMAGE ADDRESSING The I O of the M4020 module is mapped to the following I O image bytes Image Function X000 CHAN inputs 0 7 X001 CHAN inputs 10 17 X010 I O inputs 0 7 Y011 I O outputs 10 17 M4020 User s Manual SYSTEMS Electronics Group 19 SECTION 4 PLC VARIABLE TYPES MEMORY 4 4 SPECIAL FUNCTION VARIABLES The following variables are used as special function variables These variables should not be used as general purpose variables within the user program but only for the purposes described below 4 4 1 F104 ENA
69. inputs are commoned to the common or return terminal of the connector Note The inputs are optically isolated thus the common of the input voltage does not have to be commoned with the 24VDC power used to power the module Figure 12 1 shows typical input wiring APPLICATION M4000 INPUT INPUT SOURCING 0 17 410 30VDC oo SV ANY C RETURN TO OTHER CIRCUITS Figure 12 1 Typical M4000 Input Wiring M4020 User s Manual SYSTEMS Electronics Group 74 SECTION 12 INSTALLATION 12 4 WIRING INTERRUPT INPUTS Interrupt inputO and inputl are 12 30VDC differential inputs which can be wired as sourcing true high sinking true low or as true differential inputs driven by a differential output Each input 1 provided with a and terminal Figure 12 2 shows wiring examples of all three types of input configurations APPLICATION M4000 INPUT SOURCING INTERRUPT INPUT 12 30VDC oO S ANN RETURN S 12 30VDC M4000 INTERRUPT INPUT APPLICATION INPUT SINKING RETURN oO S w DIFFERENTIAL LINE DRIVER M4000 INTERRUPT INPUT E Sw vor vor INTERRUPT INPUT WIRED FO SOURCING INPUT INTERRUPT INPUT WIRED FOR SINKING INPUT INTERRUPT INPUT WIRED FO DIFFERENTIAL INPUT Figure 12 2 Typical Interrupt Input Wiring M4020 User s Manual 235 SYSTEMS Electronics Group
70. ion The test is resident in all modules and is initiated through SYSdev and PLSdev The hardware confidence test is the same test used at the factory to initially test the production M4020 modules and therefore provides the same 100 hardware test as provided at the factory The test 1 provided to the user to verify whether the module hardware is functional or not Not as a tool to repair the modules If a fault is detected the module should be returned to the factory for repair Any attempt to repair an M4020 module will void the warranty 11 1 TESTS PERFORMED PLC SECTION The following is a list of the tests performed in the PLC section by the hardware confidence test Micro controller RAM test Internal Fault detection test RAM memory test Serial network interface test RS 232 PROG PORT test Tests 1 3 and 4 not optional and are always performed Test 2 is normally disabled but be enabled if desired Note If test 2 is to be performed the FLT interlock output must be wired to the terminal of both the interrupt inputO and input inputs The terminals of both interrupt inputO and input must be wired to the terminal of the power input 24VDC Test 2 uses these two inputs to verify the FLT interlock output Failure to connect these inputs as described will result in a fault detected when test 2 is performed Test 5 is optional and may be disabled if desired All tests are a
71. ion 6 1 for details on the use of sfunc13 and a description of the serial network General form sfunc13 slave Zsent s srce s dest frcve r srce r dest Parameters slave Address of node to communicate with This is the network address of the slave each slave has a unique address Variable type constant 1 32 B or indirect B sent Number of words to send to slave Variable types constant 0 120 B or indirect S srce Address of send stack master which will be sent to slave consecutive number of words sent will be sent to the slave starting at this address Variable type W or indirect W S dest Starting address of stack in slave where words sent from master will be stored Variable type W or indirect W rcve Number of words received from slave Variable type constant 0 120 B or indirect B r srce Starting address of stack in slave where words will be sent from slave to master Variable type W or indirect W r dest Starting address in master where words sent from slave will be stored Variable type W or indirect W Return values 0 NOT BUSY READY 1 BUSY 2 DONE comm with slave successful 3 10H ERROR CODE see section 10 4 1 for serial network communication error code descriptions Type simultaneous Valid files Initialization and Main Program only M4020 User s Manual SYSTEMS Electronics Group 30
72. is suggested that a 24VDC sourcing output from the PLC controlling the press be wired to the REMOTE ENABLE input with the appropriate PLC logic controlling this output as described above To enable the CH00 brake wear compensation answer to the 0 Brake Wear Compensation enable prompt in the PLS configuration see section 7 3 4 Enter the desired stopping location allowed stopping error timing signal width and compensation enable window Initially must also be programmed with TDC timing signal This set point is used to stop the press after the brake wear compensation is enabled for the first time Note The press may or may not stop at the desired location the first time the brake wear compensation is enabled If the press does not stop within the allowed stopping error of the desired stopping location the algorithm will automatically advance or retard timing set point by the difference between the actual and desired stopping location At the next TDC stop the press should than stop at the desired location Note CH00 will only be advanced or retarded within the compensation enable window and further If the set point is advanced to the leading edge of the enable window it will not be advanced any further thus no further compensation for brake wear will occur In normal operation the algorithm verifies that the press always stops within the allowed error of the desir
73. ive action This field contains a short description of the action which can be taken to correct the particular fault that was detected Current comm error This field displays the current serial network comm error along with a short description describing the error This field is cleared as soon as the current comm error clears Last comm error This field displays the last error displayed in the Current comm error field Unlike the Current comm error this field retains the error code even after the error condition clears This provides a history of the last comm error to occur The user has the option of clearing the fault codes when exiting the SYSdev fault display M4020 User s Manual SYSTEMS Electronics Group 60 SECTION 10 FAULT DETECTION 10 3 FAULT CODES The following is a list of the fault codes and descriptions as displayed in the SYSdev fault display detected by the module Code Description 00H No internal fault has occurred 40H Watchdog timer timeout 42H Cannot communicate with target board 43H RAM battery low program corrupted 44H Program memory checksum error 45H User program system fault sfuncO9 call 59H Program execution out of bounds 5AH Address out of program memory range 5BH Invalid interrupt 5CH Program invalid execution suspended 5DH Program dump timeout program not sent 10 3 1 WATCHDOG TIMER TIMEOUT 40H The watchdog timeout fault occurs when the main program scan time ex
74. j STROBE 1000 S NOTE DISPLAY PROGRAMMED FOR D P STROBE 1 TRUE LOGIC LEVEL 24VDC LOAVDC 2 Figure 9 2 RPM Position Output Connector Wired to Remote Display M4020 User s Manual SYSTEMS Electronics Group 57 SECTION 9 RPM POSITION OUTPUT CONNECTOR 9 3 INTERFACING THE RPM POSITION OUTPUT TO A PLC Figure 9 3 shows the M4020 RPM POSITION output interfaced to a typical PLC Programmable Logic Controller This is an example of how a PLC can read the RPM or POSITION from the M4020 The digit data and strobe outputs of the M4020 are wired to PLC inputs while the REMOTE ENABLE input is tied high and RPM SELECT input is wired from a PLC output This allows the PLC to read either the RPM or the POSITION In this case the digit strobe time would have to be set to a time greater than or equal to the following strobe time gt PLC input filter delay time max worst case PLC scan time X 2 Setting the strobe time to the above guarantees that each digit will be read by the PLC The PLC logic would than clock in the data for each digit when the corresponding digit strobe is low Once the 1000 s digit strobe occurs the equivalent RPM or POSITION whichever is selected by the PLC can be determined from the individual digits strobed in PLC INPUTS 24VDC M4020 40 41 go 1 5 1 5 26 1 2 5 45 2 45 8 3 8 S C STRB DGTO 4 DGTO STRB
75. l busy etc 5 2 1 SYSTEM FUNCTION TYPES Two types of system functions exist suspended and simultaneous Suspended system functions actually suspend program execution while they are executed Thus they are performed just as any other type of instruction in order of sequence in which they occur Simultaneous system functions are executed simultaneously to program execution By their nature simultaneous system functions may take multiple main program scans to execute These are basically back ground tasks which are executed while the user application program is executing with insignificant impact on the user program scan time The simultaneous system function returns with one of four types of return values when called Not Busy Busy Done or an error code representing a fault in the execution of the function When the function is first executed a return value of Busy is returned This indicates the function is executing and is no longer available for use until it has completed Subsequent calls to the same system function will result in a return value until the function has completed At that time a call to the system function will result in either a Done return value or an error code value representing a failure of the function to execute The system function is now available to execute again See the individual system function formats following for more details on the return values and error codes pertinent to
76. lay indicating that the scale factor and or offset has not been set yet Download the configuration and channel data to the 4020 using the 4 Download Channels to PLS selection of PLSdev See section 7 for details on setting the configuration programming the channels and downloading the channels to the M4020 M4020 User s Manual SYSTEMS Electronics Group 85 SECTION 12 INSTALLATION This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group 86 APPENDIX PROGRAMMING EXAMPLE The following is an M4020 program example The program contains various examples of ladder and high level blocks The name of the program is M4020E1 and it was copied into a directory named EXAMPLES which is a sub directory of SYS51 by the installation program when SY Sdev was installed on your hard drive To view the program SYSdev perform the following 1 From the root directory of the drive you installed SYSdev on type SYSDEV and press ENTER SYSdev will be invoked displaying the directories and programs in the root directory of the current drive 2 Select the SYS51 directory using the Select Dir command 3 Select the EXAMPLES directory also using the F3 Select Dir command 4 The programs the EXAMPLES directory will be displayed in the Program Selections menu Select the M4020E 1 program and press F2 Edit Prog 5 SYSdev51 will be invoked and th
77. le Appendix A RS 232 Pinouts Cables Appendix B Field Wiring Connector Pinouts Appendix C M4020 User s Manual SYSTEMS Electronics Group iv SECTION 1 GENERAL DESCRIPTION The M4020 is combination of the M4040 PLS module PLS section with the processor and 8 in 8 out digital I O of the M4010 PLC section The PLC section is a high performance programmable logic controller which incorporates a built in processor user program 24K bytes and data memory 2K bytes 10 30VDC digital inputs 10 30VDC digital outputs RS 232 programming port and a serial network interface port The PLS section 1 a high speed programmable limit or cam switch which accepts angular position information in the form of resolver format signals and converts these to digital The module contains 16 timing channels which can be programmed and off at user defined position set points The scale factor of the M4020 is programmable from 2 to 512 divisions per revolution while the offset is programmable from 0 to one minus the scale factor High speed operation is attained with a resolver tracking rate greater than 6 000 RPM and a timing channel output update uncertainty of less than one microsecond to a change in angular position 1 1 PROGRAMMING Programming of the PLC section is implemented using SYSdev an IBM PC or compatible software package which allows the user to create document and compile the user application program as well as directly i
78. le the reference input and two stator inputs are used to determine the absolute position of the resolver The direction of rotation is determined by the connection S1 and S3 Swapping S1 and S3 will reverse the direction of rotation for the M4000 module Figure 12 8 shows two M4000 modules wired to one resolver with module 2 slaved to module 1 reference for resolver supplied by module 1 In this case the reference output RO of module 1 is connected to the resolver and tied to the reference inputs RI of both modules while the reference output of module 2 is not used Up to 8 modules can be slaved off one resolver this way In all cases a shielded twisted pair cable should be used to wire the resolver to the M4020 making sure the cable is routed free of other high voltage wiring The shield connection SH should be tied to either the resolver reference ground R2 or to earth ground 12 8 2 RESOLVER REFERENCE VOLTAGE SELECTION The resolver reference voltage of the M4020 module can be selected for either 1 45 VRMS or 3 70VRMS depending on the requirements of the resolver For Autotech and Gemco resolvers the reference should be set for 1 45 VRMS For C amp A resolvers the reference should be set for 3 70VRMS For other resolvers refer to the manufactures specifications to determine which reference should be selected The reference 1 selected via dip switches accessible through an access hole on the lower left side of the module To
79. master receive stack W086 CETEROS WicEQr slave send stack M4020 User s Manual SYSTEMS Electronics Group 10 APPENDIX PROGRAMMING EXAMPLE W120 re mI Slave receive stack M4020 User s Manual SYSTEMS Electronics Group A 11 APPENDIX PROGRAMMING EXAMPLE This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group APPENDIX RS 232 PINOUTS CABLES NOT USED RXD RECEIVE DATA IN TXD TRANSMIT DATA OUT NOT USED 56 SIGNAL GROUND NOT USED NOT USED NOT USED NOT USED PROG CHAN Port Pin Out OON OONDOAWNH 089 FEMALE DB9 FEMALE COMPUTER INTERFACE PROG PORT 2 RXD 3 TXD 5 sc RXD TXD sc RTS CTS DSR DTR POON OWN DB9 com1 to PROG Port Cable DB25 MALE 089 FEMALE COMPUTER INTERFACE PROG PORT TXD 2 2 RXD RXD 3 3 TXD sc 7 5 sc RTS 4 CTS 5 DSR 6 20 DB25 com1 to PROG Port Cable M4020 User s Manual SYSTEMS Electronics Group B 1 APPENDIX RS 232 PINOUTS CABLES This Page Intentionally Left Blank M4020 User s Manual SYSTEMS Electronics Group APPENDIX C FIELD WIRING CONNECTOR PIN OUTS
80. mber as shown in the following table Digit Binary Equivalent Number 8 s 4 s 2 s 1 s 0 0 0 0 0 1 0 0 0 1 2 0 0 1 0 3 0 0 1 1 4 0 1 0 0 5 O 1 0 1 6 0 1 1 0 7 0 1 1 1 8 9 1 0 0 1 blank Ae d ue x When interfacing with a PLC the blank digit digit data equal to all 1 s should be converted to zero by the PLC logic M4020 User s Manual SYSTEMS Electronics Group 56 SECTION 9 RPM POSITION OUTPUT CONNECTOR 9 2 REMOTE RPM POSITION DISPLAY INTERFACE Figure 9 2 shows a Cincinnati Electro Systems 4161 4 24 BCD display wired to the M4020 RPM POSITION connector This would be a typical remote display application Note The REMOTE ENABLE is tied high and that a switch located at the remote display is wired to the RPM SELECT input This switch allows the remote selection of either RPM or POSITION to be displayed In this example the strobe time could be set as low as 2 5msec or the required strobe time of the display REMOTE M4020 40 41 DISPLAY US e 1 2 S 2 NER 4 S 4 B S 8 STRB STROBE 1 S STRB DGT1 STRB DGT2 LI a STRB DGT3 i B RPM SEL l p REM EN 4 424406 I 24VDC STROBE 10 S REMOTE rie SWITCH 7 2 POSITION RPM B00 24VDC STROBE 100 S 1000 2000 MET 4000 8000 t
81. mber entered between 1 and 255 1s a preset for a timer with a 2 5msec time base and represents the time the strobe output is See section 9 for more details on the remote display output 7 3 4 BRAKE WEAR COMPENSATION If the brake wear compensation algorithm available is to be used it must be enabled in the PLS configuration If enabled the following additional parameters must be set DESIRED STOPPING LOCATION This is the desired stopping location in degrees of the press when a normal top dead center or back dead center stop is performed ALLOWED STOPPING ERROR This is the amount of deviation in degrees from the desired stopping location that is allowed before the brake wear compensation algorithm modifies the timing CH00 TIMING SIGNAL WIDTH This is the width in degrees that the compensation algorithm will program set point when it is modified COMPENSATION ENABLE WINDOW This is the window in which the brake wear algorithm will be allowed to move set point for brake wear compensation See section 8 for more details on the brake wear compensation algorithm and the use of the above parameters If the brake wear compensation is disabled CH00 will function as a standard timing channel and the brake wear parameters above will be ignored M4020 User s Manual SYSTEMS Electronics Group 46 SECTION 7 PLS PROGRAMMING 7 3 5 CH17
82. mmed with up to 50 arbitrary on off set points or with a pulse train of fixed and off divisions throughout the entire channel All timing channels are mapped to 10 30VDC sourcing 100milliamp outputs which can be wired to PLC inputs for machine control timing The status of these channels can also be read internally by the PLC section The status of each timing channel output is indicated with an individual LED The timing channel outputs contain short circuit protection such that the detection of a short circuit disables the outputs with a fault code displayed on the RPM POSITION display Once the short circuit condition is removed the fault code can be reset by toggling the RPM POSITION toggle switch on the front of the M4020 The outputs will then resume normal operation 1 7 INTERFACE PORTS The M4020 contains three interface ports the serial network comm port the PROGramming port and the CHAN port SERIAL NETWORK The serial network port conforms to the S3000 N1 network This network is a high speed up to 344KBPS twisted pair serial network configured in a master slave topology Up to 32 M4000 modules and or S3000 processors nodes can be connected on one network Communications between the nodes on the network is controlled via commands sfunc13 in the user application program resident in the node acting as the master PROG PORT The PROG port is an RS 232 port dedicated for on line monitoring and program d
83. n mode These parameters are all set through SYSdev when the program is developed See the SYSdev Programming Manual for more details 3 1 TARGET BOARD This is used to select the module that the program will be loaded into This should be set to the M4020 Selecting this enables the complier to generate the appropriate I O reads and writes corresponding to the available I O of the M4020 3 2 NETWORK BAUD RATE Three serial network baud rates are available 344KBPS bits per second 229KBPS or 106KBPS Note the modules connected on the network must be set to the same baud rate otherwise communications error will occur For the most part the baud rate is set as a function of the total network distance The longer the total network the slower the baud rate As a general rule the baud rate can be set as follows 344KBPS for network distance of 1000 feet or less 229KBPS for 2000 feet or less and 106KBPS for 4000 feet or less 3 3 INPUTO INTERRUPT ENABLE If the InputO interrupt is to be used it must be enabled in the system configuration The inputO interrupt calls ufunc00 when activated thus the user must create ufunc00 The ufunc00 file is created and executed just like any other user function file with the exception that it is called when the inputO interrupt input makes an off to transition instead of being called from the main user program If the inputO interrupt is disabled interrupt inputO can be us
84. nc07 and sfunc08 see Sections 5 2 2 and 5 2 3 M4020 User s Manual SYSTEMS Electronics Group 17 SECTION 4 PLC VARIABLE TYPES MEMORY MAP 4 2 1 VOLATILE DATA MEMORY The memory map for the M4020 volatile data memory is shown below Address Valid Variable References 0032 F000 F007 B032 W032 0033 008 2015 B033 0034 F016 F023 B034 W034 0035 F024 F031 B035 thru thru thru thru 0043 F088 F095 B043 0044 F096 F 103 B044 RESERVED 0045 RESERVED RESERVED RESERVED 0046 RESERVED RESERVED RESERVED thru thru thru thru 0062 RESERVED RESERVED RESERVED 0063 RESERVED RESERVED RESERVED 0064 B064 W064 0065 B065 0066 B066 W066 thru thru thru thru 0230 B230 W230 0231 B231 These memory locations B032 thru B231 are not battery backed and will not retain data at power down At power up or reset these addresses are cleared Note Flags F000 thru F103 are mapped into bytes B032 thru B044 Bytes B032 thru B231 are also mapped into W032 thru W230 These addresses can be referenced as any or all three of these variable types The flags are mapped into the bytes as shown as follows F000 B032 0 F001 B032 1 F002 B032 2 F003 B032 3 F004 B032 4 F005 B032 5 F006 B032 6 F007 B032 7 F008 B033 0 F009 B033 1 etc M4020 User s Manual SYSTEMS Electronics Group 18 SECTION 4 PLC VARIABLE TYPES MEMORY The bytes are mapped into the words wit
85. ng 100 milliamps The fault output is on true low sinking current when the module is executing the user program properly If a fault condition is detected the fault output is turned off high Figure 12 4 shows the fault output wired to a 24VDC relay This relay could be interlocked with the digital outputs power to remove power from the outputs if the module was to fault out M4000 OUTPUT TO OTHER CIRCUITS INPUT ROWER 24VDC m _ CLOSED WITH NO FAULT FLT 24VDC RELAY TO OTHER CIRCUITS TO OTHER CIRCUITS C INPUT POWER RETURN Figure 12 4 Typical Fault Interlock Wirin 12 7 SERIAL NETWORK INSTALLATION The serial network installation consists of wiring the network and setting each M4000 module on the network with a unique network address Up to 32 M4000 modules can be installed on one network M4020 User s Manual SYSTEMS Electronics Group 77 SECTION 12 INSTALLATION 12 7 1 WIRING THE SERIAL NETWORK Refer to figure 12 5 for a typical schematic of the network and for the pin outs of the network interface connectors When wiring the network the following rules must be followed 1 Wire the network using Belden 9182 single shielded twisted pair cable or an equivalent data communications cable meeting the following spec Wire gauge 22AWG Nom impedance 150 ohms ft Nom attenuation at 1MHZ 0 004 db ft Twisted pair single shielded 2 The
86. nt 1 250 B or indirect B dest The address where the first byte received will be stored A consecutive number of bytes rcve is received thru the USER PORT and stored in a stack starting with this address Variable types B or indirect B Return Values 0 NOT BUSY READY 1 BUSY 2 DONE receive successful 3 TIME OUT bytes not received Type simultaneous Valid Files Initialization and Main Program only 5 2 7 sfunc11 USER PORT transmit System function 11 transmits a consecutive number of bytes out the USER PORT PROG port used as USER PORT F104 set to 1 See Section 6 2 2 for a detailed description of the use of sfuncll General form sfunc1 1 sent srce Parameters sent The number of bytes to transmit out the USER PORT Variable types constant 1 250 B or indirect B srce The address where the first byte transmitted is stored A consecutive number of bytes sent is transmitted out the USER PORT starting with this address Variable types B or indirect B Return Values 0 NOT BUSY READY 1 BUSY 2 DONE transmit successful Type simultaneous Valid Files Initialization and Main Program only M4020 User s Manual SYSTEMS Electronics Group 29 SECTION 5 PLC PROGRAMMING REFERENCE 5 2 8 sfunc13 serial network communications System function 13 is used to communicate to other 30125 S3014s or other M4000 nodes on the serial communication network See sect
87. nterface to the M4020 for program download and on line monitoring The program is developed off line compiled and then downloaded to the module SYSdev allows the M4020 to be programmed in a combination of languages Ladder High level subset of C and Assembly MCS 51 Typical program scan times are on the order of 0 6 milliseconds per K of user program with scan times as low as 80 microseconds for short programs Two additional 10 30VDC interrupt inputs allow through puts even less than 80 microseconds When using the SYSdev shell SYSdev is invoked when M4020 PLC is selected as the target board see the SYSdev Program Development manual M4020 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION Configuration and timing channel programming of the PLS section is performed with PLSdev a DOS based programming software package which runs on any IBM PC or compatible PLSdev allows the user to perform the following o Configuration of the M4020 including gt Scale factor gt Offset gt Brake wear compensation enable parameter programming gt Motion output enable parameter programming o Onand Off line timing channel programming including arbitrary set point programming pulse train channel programming timing channel fine tune o Channel set points download to M4020 o Channel set points upload from M4020 o Configuration and Channel set point print outs M4020 Hardware Confidence test When using the SY
88. ogramming This invokes the channel edit menu and loads the existing channel set points from the channel data file on disk See section 7 2 2 for a description of the channel edit menu and set point programming commands When editing is complete press ESC to return to the main development menu The modified channel set points will then be saved in the channel data file on disk for the selected program 2 Online Channel Setpoint Programming This selection is used to edit the channel set points in an M4020 module directly To initiate the on line programming mode connect the COMI port on the PC running PLSdev to the port on the M4020 to be programmed Select 2 Online Channel Setpoint Programming The channel edit menu will be invoked and the existing channel set points in the M4020 will be uploaded and displayed in the menu See section 7 2 2 for a description of the channel edit menu and set point programming commands M4020 User s Manual SYSTEMS Electronics Group 37 SECTION 7 PLS PROGRAMMING Note Any changes to the channel set points made are updated immediately to the 4020 module This allows set point editing during machine operation if desired When editing is complete press ESC to return to the main development menu The modified channel set points will also be saved in the channel data file on disk for the selected program when exiting the on line mode 3 Edit PLS Configuration This activates
89. ogramming commands M4020 User s Manual SYSTEMS Electronics Group 42 SECTION 7 PLS PROGRAMMING If the channel is not programmed as a pulse train a large block cursor is placed in the ON field of the currently selected set point to be edited This cursor can be moved to any set point number using the cursor arrow left right up and down keys Whichever set point the block cursor is located at is the set point that the various set point programming commands will operate on If the channel is programmed as a pulse train the cursor will not be display at all The only commands which are valid once a channel is programmed as a pulse train are the F5 Pulse Train and F8 Clear Chan commands Thus the cursor is not used to select set points since the commands that operate on individual set points are not valid 29 If no set point is programmed at a given set point number the field is displayed as Otherwise as an example the set point will be displayed as 020 040 where 020 is the the channel turns and 040 is where the channel turns off for the given set point SCALE FACTOR This is the scale factor as entered in the PLS configuration Note The scale factor cannot be changed from the channel edit menu but is displayed only for reference MESSAGE This is field which displays various status messages informing the user of invalid commands i e invalid set point operations in
90. ownload of the PLC section when the M4020 is connected to an IBM PC or compatible running SYSdev CHAN PORT The CHAN port is an RS 232 port dedicated to configuration and channel programming of the PLS section using PLSdev 1 8 RPM POSITION DISPLAY OUTPUT CONNECTOR A 4 digit RPM POSITION display is built into the M4020 In addition an RPM POSITION output connector is also built in for remote displays or for interfacing to PLCs If no remote display is used a switch located on the front of the M4020 is used to select either RPM or POSITION If a remote display is used an input on the RPM POSITION output connector is used to select either RPM or POSITION See section 9 for complete details on the use of the RPM POSITION connector M4020 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 9 BRAKE WEAR COMPENSATION The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm of the M4020 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear The brake wear algorithm is implemented in and can be enabled or di
91. pdated inputs read outputs written at the beginning of each main program scan These updates are stored in the X and Y I O image bytes of the module see section 4 1 When the timed interrupt is enabled the X input variables are updated at the beginning of the main program as normal however the Y output variables are updated at the beginning of the timed interrupt execution instead of the beginning of the main scan In addition to these I O updates the inputs are read at the beginning of the timed interrupt and stored at special function variables B62 B64 see Section 4 4 2 This in effect constitutes an immediate I O for the timed interrupt M4020 User s Manual SYSTEMS Electronics Group SECTION 2 PLC PROGRAM STRUCTURE Note output variables cannot be used as coils in the main program if the timed interrupt is enabled Any outputs that are to be activated by the main program file must be passed to the timed interrupt file as a flag F variable and then mapped to the output in the timed interrupt See the SYSdev Program Development Manual for more details on the typical program structure M4020 User s Manual SYSTEMS Electronics Group SECTION 3 PLC SYSTEM CONFIGURATION The system configuration defines the configuration of the PLC section of the M4020 This includes defining the serial network baud rate enabling or disabling the inputO and inputl interrupts and enabling or disabling the fixed sca
92. r n 1 09 34 34 ASCII code for 5 2 3 sfunc07 general external address read System function 07 is used to read the battery backed data memory which is not referenced as W variables These are memory locations 1900H thru 1fefH This system function reads one byte from the address specified General form sfunc07 ext address dest Parameters ext address The 16 bit external RAM address 1900H thru 1fefH to be read Variable Return value Type Valid files Example M4020 User s Manual types W or constant 1900H thru 1fefH dest The variable where the value read will be stored Variable types B or indirect B sfunc07 returns with the value read from the external address suspended Initialization Main Program and User functions sfunc07 1900H B100 The above reads the non volatile data byte address 1900H and stores the value read in B100 SYSTEMS Electronics Group OTs SECTION 5 PLC PROGRAMMING REFERENCE 5 2 4 sfunc08 general external address write System function 08 is used to write data to the battery backed data memory which is not referenced as or W variables These are memory locations 1900H thru 1fefH This system function writes one byte to the address specified General form sfuncO8 ext address srce Parameters ext address The 16 bit external RAM address 1900H thru 1fefH to be written to Valid variables W or
93. red 1 IBM PC or compatible with PLSdev installed 2 RS 232 interface cable to connect COM1 on the PC to CHAN port on the M4020 3 24VDC power supply to power the M4020 4 M4020 to be tested 11 4 2 EXECUTING THE PLS TEST To execute the test perform the following steps 1 Power up the M4020 to be tested 2 Power up PC and enter PLSdev if using the SYSdev shell select M4020 PLS to invoke PLSdev Enter any user program name to proceed to the PLSdev Main Development Menu 3 Connect Interface cable to COM1 on PC and CHAN port on M4020 4 Select PLS Hardware Confidence Test A prompt will be displayed verifying to proceed with the test Note Proceeding with the test will clear all set points and configuration data from the M4020 The user channel program will have to be re downloaded to the M4020 once the test is complete Press ESC to abort the test any other key to proceed 5 Select Perform Test from the Test Functions Menu to start the test Once the test is initiated all tests enabled will be executed repeatedly starting with test 1 thru the last enabled test until any key is depressed M4020 User s Manual SYSTEMS Electronics Group 70 SECTION 11 HARDWARE CONFIDENCE TEST If no faults are detected the tests will continue to execute repeatedly displaying Test Passed messages after the successful completion of each test If a fault does occur the t
94. rifies replace the M4020 module and try again If the problem still persists verify the COMT1 port for proper operation see manual from PC manufacture M4020 User s Manual SYSTEMS Electronics Group 62 SECTION 10 FAULT DETECTION 10 3 3 INVALID PROGRAM FAULTS 5CH and 5DH The Program invalid 5CH fault occurs when the module does not contain a valid user program This typically occurs when a new module is installed which has never had a user program downloaded to it or after the hardware confidence test is performed which erases the program memory The Program dump timeout 5DH fault occurs when program download to the M4020 module is interrupted while program download is in progress Trouble shooting 1 Dump the user program to the M4020 module These faults will clear once the module is loaded with a valid user program 2 Ifre loading the module with the user program does not clear the fault replace the M4020 module and try again 10 3 4 USER PROGRAM sfunc09 SYSTEM FAULT CALL 45H This fault code is set when the user program performs an sfunc09 system function fault call See the user program for the purpose of the system fault call See section 5 2 5 for details on sfunc09 10 3 5 INTERNAL M4020 FAULTS 43H 44H 59H 5BH The remainder of the fault codes detected by the M4020 module represent an internal failure of the module These can range from the RAM battery low to invalid interrupt requests
95. rmed in an M4020 module installed in a user s control system Unpredictable output states may result while the test is being performed 11 3 1 EQUIPMENT REQUIRED In order to perform the hardware confidence test the following is required 1 IBM PC or compatible with SYSdev installed 2 RS 232 interface cable to connect COM1 on the PC to PROG port on the M4000 module 3 24VDC power supply to power module 4 M4020 module to be tested M4020 User s Manual SYSTEMS Electronics Group 68 SECTION 11 HARDWARE CONFIDENCE TEST 11 3 2 EXECUTING THE PLC TEST To execute the test perform the following steps Power up the M4020 module to be tested Power up PC and enter SYSdev If using the SYSdev shell select M4020 PLC to invoke SYSdev Enter any user program name to proceed to the SYSdev Main Development Menu Connect Interface cable to COM1 on PC and PROG port on module Select Target Board Interface from the Main Development Menu then select Target Board Hardware Confidence Test from the Target Board Interface menu Select M4000 Confidence test from the confidence test menu A prompt will be displayed verifying to proceed with the test Note Proceeding with the test will clear the program and data memory in the module The user application program will have to be re downloaded to the module once the test is complete Press ESC to abort the test any other key to proceed
96. rue high outputs capable of sourcing 100milliamps of current The outputs were designed to drive PLC inputs or other low current devices and are not capable of driving solenoids The timing channel outputs contain short circuit protection such that if the output current exceeds 500milliamps all outputs within the eight channel group are disabled protecting the output Power for the timing channel outputs is wired to power and common or return terminals on the Timing channel output connector Be sure to observe the proper polarity of the power and wiring otherwise damage to the module may occur Note The timing channels are optically isolated thus the 10 30VDC power applied to the timing channel outputs does not have to be commoned with the 24VDC input power described above Figure 12 9 shows the typical timing channel output wiring M4020 User s Manual SYSTEMS Electronics Group 83 SECTION 12 INSTALLATION 12 11 WIRING THE 128PPR AND 1KPPR OUTPUTS The 128 and pulse per revolution outputs are implemented with an MM88C30 differential line driver These outputs provide fixed pulse train signals that can be used to drive digital tachometers etc The devices these outputs drive must incorporate differential inputs do not ground either output See figure 12 10 for a typical example of the 128PPR and IKPPR output wiring M4020 40 41 CHANNEL OUTPUT TO OTHER CIRCUITS C m 410 3
97. s 5 words W090 thru W098 to the master storing this data at W110 thru W118 The transmission of the data was done concurrently with the program executions of both the master and the slave The return value of the sfunc13 is stored in BO70 Once the sfunc13 is initiated the return value of the sfunc13 is BUSY B070 1 until the transmission is complete At that time the return value is DONE B070 2 or an error code 070 ERROR CODE if an error occurred in transmission M4020 User s Manual SYSTEMS Electronics Group 4332 SECTION 6 SERIAL NETWORK COMMUNICATIONS 6 2 USER PORT PROG PORT COMMUNICATIONS The PROG port can be used as a USER PORT by setting F104 to a 1 See Section 4 4 1 The PROG port will then function in the same manner as other 53000 boards equipped with a separate USER PORT such as the 3012 and 3016 While F104 1 set to a 1 the PROG port will be referred to as the USER PORT As a USER PORT the PROG port is a general purpose RS 232 port available for connection to any RS 232 user device Typical applications include M4020 connection to operator workstations connection to IBM PC or compatibles for system data acquisition etc Communications through the USER PORT is achieved using sfunc10 USER PORT read and sfunc11 USER PORT write These sfuncs allow any ASCII codes from 0 to 255 to be read from or written to the port The baud rate of the USER PORT is preset at 9600 with 8 data bits 1 stop
98. s is Xaab c where 15 the I O address b is the byte at the slot and c is the bit or input point Examples X010 X000 X010 5 X000 7 etc 4 1 6 Outputs Y Output variables are bytes which contain the data that is written to M4020 outputs at the beginning of the main program I O update One variable is allocated for each output byte thus the M4020 module has one variable allocated for it for outputs 10 thru 17 The format for the variable is Yaab where aa is the two digit I O address 00 02 and b is the byte at the slot 0 or 1 Note The must be a capital letter and that the I O address must be two digits add leading zero Also variables can only be referenced for outputs that are actually available in the module Any reference to output variables that do not correspond to existing outputs will result in a compiler error variables can only be assigned used as coils in the main program file but can be referenced used as contacts in any file M4020 User s Manual SYSTEMS Electronics Group 16 SECTION 4 PLC VARIABLE TYPES MEMORY As with byte variables individual bits within the variable can be referenced These bits correspond to the respective I O point on the output board The form of this is Yaab c where is the I O address b is the byte at the slot and c is the bit or output point Examples Y011 Y011 5 Y011 7 etc
99. s three fault states These are invalid scale factor code 07 invalid offset code 08 and timing channel output short circuit code 09 When the M4020 detects any one of these faults the respective fault code is displayed on the RPM POSITION display of the module in the form 88XX where XX is the fault code The individual faults are discussed below 10 5 1 8807 INVALID SCALE FACTOR This fault is displayed when the scale factor is greater than 512 or less than 2 To reset the fault download the user channel program through PLSdev This downloads the configuration file which contains the scale factor as specified by the user 10 5 2 8808 INVALID OFFSET This fault is displayed any time the offset is greater than or equal to the scale factor To reset the fault set the offset to less than the scale factor by downloading the user channel program or by setting the offset in the on line mode of PLSdev 10 5 3 8809 TIMING CHANNEL OUTPUT SHORT CIRCUIT This fault is displayed anytime any one of the timing channel outputs detects a short circuit current greater than SOOmAMP even if only momentarily Once the short circuit condition is removed the fault can be reset by toggling the RPM POSITION toggle switch on the front of the M4020 M4020 User s Manual SYSTEMS Electronics Group 66 SECTION 11 HARDWARE CONFIDENCE TEST The hardware confidence test allows the entire M4000 module hardware to be verified for proper operat
100. sabled by the user When disabled functions as a standard timing channel When enabled the brake wear compensation algorithm is automatically performed for TDC stops See section 8 for complete details on this feature 1 10 MOTION SPEED OUTPUT The motion output is a user enabled feature which uses the CH17 output Two user programmable parameters are used in conjunction with the motion output low speed threshold and high speed threshold When enabled as a motion output CH17 is when the speed RPM is between the low and high speed thresholds When the speed is below the low speed threshold or above the high speed threshold CH17 is off When disabled CH17 functions as a standard timing channel 1 11 DIAGNOSTICS FAULT DETECTION The M4020 contains comprehensive fault detection routines which verify the proper operation of the module at all times Each detected fault has a corresponding fault code which can be viewed using SYSdev providing a description of the fault and recommended corrective action The M4020 contains a fault interlock 24VDC 100mAMP sinking output which can be interlocked to the control system for system shut down or annunciation when a fault is detected In addition to the fault code detection a hardware confidence test 1s resident in the module to provide a complete test of the module hardware This test is initiated through SYSdev and can be used to verify the M4020 for proper operation
101. sem Ist which is the assembly list file complete with program addresses This file can be viewed with any text editor or with the MS DOS type command The numbers in the second column from the left are the program addresses Locate the address in this file which was displayed in the PC xxxxH field The assembly instructions for each block are headed with the block number they are in From this it is possible to find what block the program was at when the timeout occurred Remove the assembly block created above to re compile the program without error 4 Ifthe problem persists try another M4020 module to verify if a hardware problem exists 10 3 2 IBM PC TO M4000 COMMUNICATIONS FAILURE 42H If an attempt to read the fault codes from the M4020 module results in an error code of 42H Cannot communicate with target board the PC cannot communicate with the module This is not an internal M4020 fault but instead a fault detected by SYSdev The cause of this fault ranges from catastrophic failure of the module to a misconnection of the PC to the module Trouble shooting 1 Verify the PWR LED on the module is on If not verify that 24VDC power is applied to the module 2 Verify that the RS 232 cable is connected to COM1 on the PC and port on the module 3 Verify that the RS 232 cable connecting the PC to the module is wired correctly See appendix B for the pin out of the cable 4 Ifthe above ve
102. st be unique See section 12 7 2 3 Ifthe problem persists replace the slave M4000 module where the problem is occurring Next replace the 4000 master module 10 4 3 SERIAL NETWORK INTEGRITY ERROR 03H 06H 0EH 10H The serial network integrity errors occur when corruption of the transmitted frame is detected The sources of these errors range from multiple masters attempting communications on the network to excessive induced EMI on the network Trouble shooting 1 Verify that only one master is communicating on the network The master is defined as the node which is executing the sfunc13 system functions If two nodes are executing sfunc13s simultaneously a network collision will occur with the corresponding corruption of data 2 Verify that the network wiring is isolated from other high voltage wiring which could induce EMI into the network The network should be routed in a conduit separate from other wiring 3 Replace the slave M4000 module with which the error occurred If the problem persists replace the M4000 module at the master node 10 4 4 ADDRESS OUTSIDE RANGE 0FH This error occurs when an attempt to write to memory outside the data memory range occurs in either the master or slave Verify the corresponding sfunc13 call specifies the proper data range M4020 User s Manual SYSTEMS Electronics Group 65 SECTION 9 RPM POSITION OUTPUT CONNECTOR 10 5 PLS SECTION FAULT CODES The PLS section detect
103. t Target board Network Address 4 SYSdev will read the current network address of the M4000 module and display it in the network display If the network address is to be changed follow the directions displayed and enter the new address The above steps must be done for all 4000 modules on the network This is true when the network is first installed and when a new module is added or replaced that module must have the network address set it 1n 12 8 RESOLVER INTERFACE The M4020 module can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc dip switch accessible through an access hole on the left side of the module selects the desired resolver reference voltage either 1 45 VRMS or 3 70VRMS Separate resolver reference input and output connections are provided on the resolver interface connector This allows the M4020 module to be slaved to other 4000 PLS modules or to other manufactures programmable limit switches off one resolver M4020 User s Manual SYSTEMS Electronics Group 80 SECTION 12 INSTALLATION 12 8 1 RESOLVER WIRING Figure 12 7 shows the typical wiring to a generic resolver for stand alone operation M4000 PLS provides reference voltage for resolver Note The reference output RO is tied to the reference input RI The reference output excites the resolver whi
104. t l3 off 4 5 else if B102 gt 4 amp amp B102 lt 7 counter accum between 4 and 7 6 7 X114 2 09 yes set output 12 off and 8 X11 3 1 output 13 on oi 10 else 11 if counter accum is less than 4 T2 2 03 set output 12 off and 13 11 3 0 output 13 ofr 14 T5 B102 Fma counter accum 011 2 I O output 12 3 I O output 13 M4020 User s Manual SYSTEMS Electronics Group A 9 APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN block 6 High level The following block is an example of communications between a master M4000 module the module this program is running in and a slave module on the serial network address 2 The slave module has no program code pertaining to this communications it responds automatically to this communications request The communications is implemented as follows 1 In this example communications is enabled when B67 is set to any value other than 0 B67 can be written to using the Assign Value selection of the on line monitoring menu If B67 is zero no communications on the network is performed if B67 is any value other than zero network communications is performed continuously Onc nabled the
105. the shift done in the rungs I O output 14 Y011 4 T j I O output 1 5 YOTI S block continued on next page M4020 User s Manual A 4 SYSTEMS Electronics Group APPENDIX PROGRAMMING EXAMPLE block originated on prev page shift I O reg output bit 6 16 B090 6 Y011 6 Sid Teil shift 1 0 reg output bit 7 17 B090 7 YOTXl 7 6 4 11 M4020 User s Manual SYSTEMS Electronics Group A 5 APPENDIX PROGRAMMING EXAMPLE SYS51 Main Program M4020E1 LMN block 3 Ladder The following example shows 14 contacts ored together This shows that even though the ladder block is 7 rows by 9 columns large or statements can still be entered up to 22 contacts ored together Also note the coils ored together out the output of the rung Up to 7 coils can be ored in one block M4020 User s Manual A 6 I O I O output inputl TI X010 1 Y011 1 4 t shift internl I O I O reg flag input2 input7 bit 8 010 X010 2 X010 7 B091 1 F010 t t t shift internl I O output reg flag input3 14 bit 9 011 X010 3 Y011 4 B091 2 F011 ELI xm np po y I O shift 1 0 output reg input4 15 bit 10 X010 4 XOTLli5 B091 3 ches gp eS peat t
106. utomatic and require no interaction once the test is initiated Each test performs a complete check of the respective hardware area of the module If a fault 1s detected the test is stopped and a test fault code is displayed to indicate the nature of the hardware failure Note The actual input and output points hardware is not checked with these tests This can be done using the on line monitoring mode of SYSdev to view the states of the inputs and set the states of the outputs M4020 User s Manual SYSTEMS Electronics Group 67 SECTION 11 HARDWARE CONFIDENCE TEST 11 2 TESTS PERFORMED PLS SECTION The following is a list of the tests performed in the PLS section by the hardware confidence test Micro controller RAM test Channel 00 07 PLS memory test Channel 10 17 PLS memory test Channel 20 27 PLS memory test Channel 30 37 PLS memory test PLS Memory address access test RS 232 Chan port test Tests 1 through 6 are not optional and are always performed Test 7 is optional and may be disabled if desired tests are automatic and require no interaction once the test is initiated Each test performs a complete check of the respective hardware area of the M4020 If a fault is detected the test is stopped and test fault code is displayed to indicate the nature of the hardware failure 11 3 PERFORMING THE PLC HARDWARE CONFIDENCE TEST WARNING The hardware confidence test should not be perfo
107. ve network address to communicate to 2 Number of words to be sent to slave 3 Starting address of stack in master of words which will be sent to slave 4 Starting address of stack in slave where the words are to be stored 5 Number of words to be received from slave 6 Starting address of stack in slave where the words will be sent from 7 Starting address of stack in master where the words from the slave will be stored See section 5 2 5 for a complete description of the above parameters the general form of sfunc13 and the return values possible with sfunc13 Note sfunc13 is used only in the master the slaves respond to network communications completely transparently No commands are added to the slave programs in order to implement the serial network Thus only one program the master s in the entire network has any commands pertaining to network communications M4020 User s Manual SYSTEMS Electronics Group 31 SECTION 6 SERIAL NETWORK COMMUNICATIONS System function 13 is a simultaneous function such that once it is initiated program execution continues without waiting for the sfunc to complete Subsequent calls of sfunc13 result in a return value of BUSY until the sfunc completes return DONE or detects an error return ERROR CODE See section 10 4 1 for a description of the serial network error codes Since sfunc13 is a simultaneous function the impact on the user application program s
108. w X 9 column matrix The following ladder instructions are available 1 Contacts 3 Timers Normally open 0 01 second time base Normally closed 0 10 second time base 1 00 second time base 2 Coils Standard 4 Counters Latch Unlatch 5 Shift Registers Inverted Valid variables for contacts and coils are flags F or bits out of bytes B Valid variables for timer counter presets and accumulators are bytes B The maximum preset is 255 Valid variables for shift registers are also bytes B The number of shifts per variable is 7 M4020 User s Manual SYSTEMS Electronics Group 2203 SECTION 5 PLC PROGRAMMING REFERENCE 5 1 2 HIGH LEVEL The High level language is a subset of the programming language High level is used for all arithmetic comparisons conditional program execution program looping calling user functions subroutines and calling system functions High level blocks are implemented as a 57 row X 80 column text array The High level language incorporates the following 1 Operators add increment subtract decrement multiply equate divide gt greater than remainder gt greater than or equal lt lt left shift lt less than gt gt right shift lt less than or equal amp bitwise AND l not equal bitwise OR complement bitwise EX OR indirection unary amp amp logical AND amp address operator
109. working directory where your program will be stored name your user program name without any extension M4020 User s Manual SYSTEMS Electronics Group 36 SECTION 7 PLS PROGRAMMING Note For the user program name two user program files are actually created by PLSdev one that contains the PLS configuration data for the program another which contains the channel set point data for the program These are the files that are used to edit download and upload to and from the M4020 module Thus when referencing the program through PLSdev no extension should ever be typed in If no program name is entered when PLSdev is invoked the program name will be prompted for by PLSdev before the program proceeds to the main menu Enter the program name as outlined above to proceed 7 2 MENUS The following sections are a description of the various PLSdev menus In general the PgUp PgDn Home End and cursor left right up and down keys all function as defined 7 2 1 Main Development Menu 1 Offline Channel Setpoint Programming This selection is used to edit the channel set points off line while not connected to an M4020 module changes made to the channel set points are saved in the channel data file for the selected program The channel set points can then be downloaded to an M4020 module using the Download Channels to PLS selection To initiate the off line programming mode select 1 Offline Channel Setpoint Pr
110. ypes The typical M4020 user program consists of the following files 1 Initialization file optional executed once at power up POWER UP 2 Main Program file required scanned continuously TIMED 3 Timed Interrupt file optional executed once every 0 5 INTERRUPT 1 0 or 10 0 milliseconds as set by the user 4 User Function files optional up to 100 user defined subroutines which can be called from any of the above files 5 Input Interrupts optional the two input interrupts can be enabled or disabled InputO interrupt calls ufunc00 when activated off to transition of inputO while input1 interrupt calls 01 Note 00 must be created by the user if the inputO interrupt is enabled and ufunc01 if the input1 interrupt is enabled Each file is executed sequentially from beginning to end The main program file is executed scanned continuously unless interrupted by the timed interrupt or an input interrupt is activated When this occurs main program execution is suspended while the interrupt file is executed At the completion of the interrupt program execution resumes at the point in the main program where the interrupt occurred Each file is implemented as a series of consecutive blocks Each block is defined as one of the three programming languages Ladder High level or Assembly Blocks of the different languages can be intermixed as necessary within the file M4020 I O is u

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